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FOREWORD

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's Manual.
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.

Manual Name Pub. No.

S1-LXJE12A
Chassis Workshop Manual
S1-LXJE12A EWD
J05E Engine Workshop Manual S5-LJ05E15A
S7-LXJE12A 2/5
S7-LXJE12A 3/5
Trouble shooting Workshop Manual
S7-LXJE12A 4/5
S7-LXJE12A 5/5
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL
Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL No. S7-LXJE12A 1/5 (U.S.A.), S7-LXJE13A 1/5 (CANADA)
MODELS HINO 155, 155h, 195, 195h
CHAPTER
XFC710, XFC720, XFC730, XFC740,
Production Code
XJC700, XJC710, XJC720, XJC730, XJC740

GENERAL INTRODUCTION 1-001

ENGINE 2-001 (J05E)

 INDEX: TROUBLE SHOOTING GROUP 1/2

GENERAL INTRODUCTION

ENGINE

HYBRID

WORKSHOP TRANSMISSION

MANUAL CLUTCH

PROPELLER SHAFT

AXLE

DIFFERENTIAL

BRAKE

STEERING

SUSPENSION

FRAME AND FRAME ACCESSORY

CAB MOUNTING AND CAB SUSPENSION

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-
out the written consent of Hino Motors, Ltd. HEATER AND AIR CONDITIONER
INDEX: TROUBLE SHOOTING GROUP 2/2

ELECTRICAL

CONTROL SYSTEM
 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 .................................. 1-5
WARNING ....................................................................1-5
GENERAL PRECAUTIONS ....................................1-5
IDENTIFICATION INFORMATION ........................ 1-10
SAFETY INSTRUCTIONS FOR WORK..................... 1-13
PRECAUTIONS .................................................... 1-13
INTRODUCTION TO WORKSHOP MANUAL............ 1-17
GENERAL ............................................................. 1-17
INTRODUCTION TO DESCRIPTIONS................. 1-18
DEFINITION OF TERM.........................................1-21

TROUBLE SHOOTING .................................. 1-22

TROUBLESHOOTING WITH DIAGNOSIS
MONITOR ................................................................... 1-22
TROUBLESHOOTING PROCEDURE .................. 1-22
APPARATUS FOR TROUBLE SHOOTING........... 1-24
TROUBLE DIAGNOSIS USING THE COMPUTER
(HINO DX Ⅱ ) ............................................................. 1-25
STEP OF TROUBLE DIAGNOSIS ........................ 1-25
APPARATUS FOR TROUBLE DIAGNOSIS .......... 1-26

GLOSSARY ................................................... 1-27

DEFINITION OF ABBREVIATION ............................. 1-27
LIST OF ABBREVIATION ..................................... 1-27
GLOSSARY OF SAE AND HINO TERMS ............ 1-30
1–2 GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE

HOW TO IDENTIFY VEHICLE TYPE

VEHICLE TYPE
EN01H01ZZZ010102001001

ձ ղ ճ մ յ ն շ ո չ պ ջ ռ ս վ տ
X J C 7 0 0 L ࣮ H K T Q L A 3
REPORTED MODEL CLASSIFICATION

ձ ղ㸸ENGINE MODEL ճ㸸VEHICLE MODEL պ㸸DECK HEIGHT

X F J05E-UG (HV) C HEAVY DUTY TRUCK K HIGH FLOOR CAB
X J J05E-TP (Diesel)

մ յ㸸CAB WIDTH, DRIVE, FRAME FORM, WHEEL BASE ջ㸸TRANSMISSION

CAB WIDTH DRIVE FRAME WHEEL BASE T 6AT
FORM FRAME ASSEMBLY WIDTH
840 mm {33 in.}
7 0 WIDE 2WD OPEN MEDIUM 2,900 mm {114 in.}
7 1 WIDE 2WD OPEN LONG 3,500 mm {138 in.} ռ㸸LOADING CAPACITY, GVW, REAR TIRES
7 2 WIDE 2WD OPEN SUPER LONG 3,800 mm {150 in.} Q 6.58 t {14,500 lbs} REAR DOUBLE
7 3 WIDE 2WD OPEN SUPER LONG 4,100 mm {161 in.} 8.14 t {17,950 lbs},
T REAR DOUBLE
7 4 WIDE 2WD OPEN SUPER LONG 4,400 mm {173 in.} 8.85 t {19,500 lbs}

ն㸸TYPE OF SUSPENSION ս㸸ENGINE HORSEPOWER, FUEL

0 FRONT RIGID, REAR RIGID FUEL HORSEPOWER EXHAUST

M DIESEL OIL VERY HIGH US13 (13OBD)

ո㸸STEERING WHEEL POSITION վ㸸DESTINATION

L LEFT HAND DRIVE
DESTINATION
չ㸸CAB FORM, BRAKE TYPE
CAB FORM BRAKE TYPE A U.S., CANADA
H SINGLE CAB VACUUM
Q CREW CAB VACUUM
տ㸸DECK FORM
C SINGLE CAB HYDRAULIC
3 CHASSIS WITH CAB
D CREW CAB HYDRAULIC
K SINGLE CAB VACUUM
L CREW CAB HYDRAULIC

SHTS01ZZZ0100001
 WMI VDS CD VIS
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17)
J H H K D L 2 H X C K 0 0 1 0 0 1

MANUFACTURER ,TYPE SERIES CHECK DIGIT ASSEMBLY PLANT

SEQUENTIAL NUMBER
MODEL, CAB TYPE, ENGINE MODEL MAKE MODEL YEAR
WHEEL BASE,
BRAKE SYSTEM

CODE MANUFACTURER TYPE CODE YEAR CODE YEAR

JHN HINO MOTORS, LTD. INCOMPLETE VEHICLE E 2014 K 2019
HINO MOTORS F 2015 L 2020
2AY INCOMPLETE VEHICLE
CANADA, LTD.
G 2016 M 2021
PRODUCTION BRAKE H 2017 N 2022
CODE CLASS MODEL CAB TYPE WHEEL BASE
CODE SYSTEM
J 2018 P 2023
HINO 195h XFC730 COE
G 5 4100mm{161 in.} HYDRAULIC
HINO 195 XJC730 SINGLE CAB For USA
HINO 195h XFC710 COE CODE ASSEMBLY PLANT
H 5 3500mm{138 in.} HYDRAULIC
HINO 195 XJC710 SINGLE CAB CODE MAKE
HINO MOTORS, LTD.
K Hamura Plant in Japan
COE
K 5 HINO 195 XJC700 2900mm{114 in.} HYDRAULIC H HINO
SINGLE CAB
HINO 155h XFC720 For Canada
COE
L 4 3800mm{150 in.} VACUUM CODE ASSEMBLY PLANT
HINO 155 XJC720 CREW CAB
HINO 155h XFC740 COE CODE SERIES GVWR
P 4 4400mm{173 in.} VACUUM 1 Canada Plant (COE)
HINO 155 XJC740 CREW CAB 6,580 kg
1
HINO 195h XFC720 COE {14,500 lbs.} HINO MOTORS, LTD.
R 5 3800mm{150 in.} HYDRAULIC K Hamura Plant in Japan
HINO 195 XJC720 SINGLE CAB 8,140 - 8,850 kg
2
HINO 195h XFC740 COE {17,950 - 19,500 lbs.}
S 5 4400mm{173 in.} HYDRAULIC
HINO 195 XJC740 SINGLE CAB
COE
VEHICLE IDENTIFICATION NUMBER (VIN) STRUCTURE

T 4 HINO 155 XJC700 2900mm{114 in.} VACUUM

SINGLE CAB
HINO 155h XFC710 COE
U 4 3500mm{138 in.} VACUUM
HINO 155 XJC710 SINGLE CAB
GENERAL INTRODUCTION/HOW TO IDENTIFY VEHICLE TYPE

HINO 195h XFC720 COE CODE ENGINE MODEL APPLICATION

V 5 3800mm{150 in.} HYDRAULIC
HINO 195 XJC720 CREW CAB
PM J05E-UG Hybrid
HINO 195h XFC740 COE
W 5 4400mm{173 in.} HYDRAULIC
HINO 195 XJC740 CREW CAB DM J05E-TP Diesel
HINO 155h XFC740 COE
X 4 4400mm{173 in.} VACUUM
HINO 155 XJC740 SINGLE CAB
HINO 155h XFC720 COE
Y 4 3800mm{150 in.} VACUUM
HINO 155 XJC720 SINGLE CAB

SHTS01ZZZ0100002
EN01H01ZZZ010102001002
1–3
1–4 GENERAL INTRODUCTION/APPEARANCE OF VEHICLE

APPEARANCE OF VEHICLE

APPEARANCE

APPEARANCE OF VEHICLE
EN01H01ZZZ020101003001

SHTS01ZZZ0200001
 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. If you have any question about per-
forming maintenance, please consult your Hino dealer.

WARNING

When working on your vehicle, observe the following general precautions to prevent death, personal injury and/
or property damage in addition to the particular DANGERS, WARNINGS, CAUTIONS and NOTICES in each chap-
ter.
• Always wear safety glasses or goggles to protect your eyes.
• Remove rings, watches, ties, loose hanging jewelry and loose clothing before starting work on the vehicle.
• Bind long hair securely behind the head.
• When working on the vehicle, apply the parking brake firmly, place the gear shift lever in "Neutral" or "N" and
block the wheels.
• Always turn off the starter switch to stop the engine, unless the operation requires the engine running.
Removing the key from the switch is recommended.
• To avoid serious burns, keep yourself away from hot metal parts such as the engine, exhaust manifold, radia-
tor, muffler, exhaust pipe and tail pipe.
• Do not smoke while working on the vehicle since fuel, and gas from battery are flammable.
• Take utmost care when working on the battery. It contains corrosive sulfuric acid.
• Large electric current flows through the battery cable and starter cable. Be careful not to cause a short which
can result in personal injury and/or property damage.
• Read carefully and observe the instructions specified on the jack before using it.
• Use safety stands to support the vehicle whenever you need to work under it. It is dangerous to work under a
vehicle supported only by a jack.
• If it is necessary to run the engine after the hood is raised (tilted), make sure that the parking brake is firmly
applied, the wheels are blocked, and the gear shift lever is positioned in "Neutral" before staring the engine.
• Run the engine only in a well-ventilated area to avoid inhalation of carbon monoxide.
• Keep yourself, your clothing and your tools away from moving parts such as the cooling fan and V-belts when
the engine is running.
• Be careful not to damage lines and hoses by stepping or holding your feet on them.
• Be careful not to leave any tool in the engine compartment. The tool may be hit by moving parts, which can
cause personal injury.
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.
• Park the vehicle on a level place and ensure ample space around the cab before tilting the cab.
• Apply the parking brake firmly and place the gearshift lever in “N” position (“P” position if your vehicle is
equipped with automatic transmission).
• Stop the engine and block the wheels.
• Remove any articles in or over the cab and close the doors firmly.
• Make sure there is no one in or around the cab and there are no obstacles in front of the vehicle or above the
cab.
• The catch (E), stopper (F), stay (G) and other parts such as the engine, radiator, and exhaust pipe can be very
hot while your vehicle is operated. Be sure to confirm they have been cooled down before you start working
under the cab.
• Never raise or lower the cab only by yourself if your cab is equipped with heavy component such as a roof rack.
• Never put your body under the cab while raising or lowering the cab.
• Make sure the cab stopper stay is securely locked by the catch (E) and raise the stopper (F) to lock the catch (E)
completely after raising the cab.
• Before lowering the cab, make sure that any object such as hand tools, gloves or cloth are not left under the
cab.
• Make sure the handle (B) is caught by the catch after lowering the cab.
Read the Owner’s manual for details.

B E
G

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 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.

Indicates a hazardous situation if proper procedures are not followed and could result
in serious injury or damage to parts/equipment.

Indicates the need to follow proper procedures and to pay attention to precautions so
that efficient service is provided.

Provides additional information to help you to perform the repair efficiently.

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. 1 cross member when attaching the towing chain. Never lift or tow the vehicle if the chain is in direct contact with
the bumper.

1. Towing procedures
(1) Make sure that the propeller shaft of the vehicle to be towed is removed. When the differential gear or rear axle
shaft is defective, remove both right and left rear axle shafts, then cover the hub opening to prevent loss of axle
lubricant and entry of dirt or foreign matter.
(2) Use a heavy duty cable or rope when towing the vehicle. Fasten the cable securely to the towing hook on the
frame.
(3) The angle of pulling direction of the cable fastened to the towing hook must not exceed 15° in horizontal and ver-
tical directions from the straight ahead, level direction. Avoid using the hook in a way that subjects it to jerk, as in
towing a vehicle trapped in a gutter.
(4) Keep the gear shift lever in Neutral.
(5) Make sure that the starter switch is kept in the "ON" position, if the engine is not running.
(6) Make sure that the engine of the towed vehicle is kept running. If the engine is off, no compressed air/ no vac-
uum will be available for the brake. This is dangerous, as the brake system does not function if the engine is not
running.
In addition, the power steering system will not function. The steering wheel, therefore, will become unusually
hard to turn, making it impossible to control the vehicle.
(7) Note that the engine brake and exhaust brake cannot be applied, if the propeller shaft is removed.
(8) Make a slow start to minimize shock. Towing speed should be less than 30 km/h {18 mile/h}.

2. If the engine of the towed vehicle is defective, make sure that the vehicle is towed only by a tow truck
designed for that purpose.
(1) Front end towing (with front wheels raised off the ground)
When towing from the front end with the front wheels raised off the ground, remove the rear axle shafts to protect
the transmission and differential gears from being damaged. The hub openings should be covered to prevent the
loss of axle lubricant or the entry of dirt or foreign matter. The above-mentioned precautions should be observed
for vehicles equipped with either manual or automatic transmission, and for even short distance towing. After
being towed, check and refill the rear axle housing with lubricant if necessary.
(2) Rear end towing
When being towed with the rear wheels raised off the ground, fasten and secure the steering wheel in a straight-
ahead position.
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–9

CLEAN AIR ACT

1. 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. Any deviation from the provisions contained in this section is a prohibited act under section 203(a) (3) of
the Clean Air Act (42 U.S.C. 7522(a) (3)).
(1) When rebuilding an engine, portions of an engine, or an engine system, there must be a reasonable technical
basis for knowing that the resultant engine is equivalent, from an emissions standpoint, to a certified configura-
tion (i.e., tolerances, calibrations, specifications) and the model year(s) of the resulting engine configuration must
be identified. A reasonable basis would exist if:
a. Parts installed, whether the parts are new, used, or rebuilt, are such that a person familiar with the design and
function of motor vehicle engines would reasonably believe that the parts perform the same function with
respect to emissions control as the original parts; and
b. Any parameter adjustment or design element change is made only:
• In accordance with the original engine manufacturer's instructions; or
• Where data or other reasonable technical basis exists that such parameter adjustment or design element
change, when performed on the engine or similar engines, is not expected to adversely affect in-use emis-
sions.
(2) When an engine is being rebuilt and remains installed or is reinstalled in the same vehicle, it must be rebuilt to a
configuration of the same or later model year as the original engine. When an engine is being replaced, the
replacement engine must be an engine of (or rebuilt to) a configuration of the same or later model year as the
original engine.
(3) At time of rebuild, emissions-related codes or signals from on-board monitoring systems may not be erased or
reset without diagnosing and responding appropriately to the diagnostic codes, regardless of whether the sys-
tems are installed to satisfy requirements in § 86.004-25 or for other reasons and regardless of form or interface.
Diagnostic systems must be free of all such codes when the rebuilt engine is returned to service. Such signals
may not be rendered inoperative during the rebuilding process.
(4) When conducting a rebuild without removing the engine from the vehicle, or during the installation of a rebuilt
engine, all critical emissions-related components listed in § 86.004-25(2) not otherwise addressed by para-
graphs (1) through (3) of this section must be checked and cleaned, adjusted, repaired, or replaced as neces-
sary, following manufacturer recommended practices.
(5) Records shall be kept by parties conducting activities included in paragraphs (1) through (4) of this section. The
records shall include at minimum the mileage and/or hours at time of rebuild, a listing of work performed on the
engine and emissions-related control components including a listing of parts and components used, engine
parameter adjustments, emissions-related codes or signals responded to and reset, and work performed under
paragraph (4) of this section.
a. Parties may keep records in whatever format or system they choose as long as the records are understand-
able to an EPA enforcement officer or can be otherwise provided to an EPA enforcement officer in an under-
standable format when requested.
b. Parties are not required to keep records of information that is not reasonably available through normal busi-
ness practices including information on activities not conducted by themselves or information that they cannot
reasonably access.
c. Parties may keep records of their rebuilding practices for an engine family rather than on each individual
engine rebuilt in cases where those rebuild practices are followed routinely.
d. Records must be kept for a minimum of two years after the engine is rebuilt.

2. Maintenance instructions.
§ 86.010-38
(1) For each new diesel-fueled engine subject to the standards prescribed in § 86.007-11, as applicable, the manu-
facturer shall furnish or cause to be furnished to the ultimate purchaser a statement that
"This engine must be operated only with ultra low-sulfur diesel fuel (meeting EPA specifications for
highway diesel fuel, including a 15 ppm sulfur cap)."
1–10 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

IDENTIFICATION INFORMATION
EN01H01ZZZ030101001002

1. VEHICLE IDENTIFICATION NUMBER

(1) 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
(2) VIN
See VEHICLE IDENTIFICATION NUMBER (VIN) STRUC-
TURE on the following page.
A

SHTS01ZZZ0300007

(3) PRODUCTION CODE AND VEHICLE COMPONENTS

MODEL (CLASS) HINO 155h (4) HINO 155 (4) HINO 195h (5) HINO 195 (5)

XJC700
XJC700 XFC710
XFC710 XJC710
XJC710 XFC720
PRODUCTION CODE XFC720 XJC720
XJC720 XFC730
XFC740 XJC730
XJC740 XFC740
XJC740

TRANSMISSION SERIES A465

1st 3.742

2nd 2.003

3rd 1.343
TRANSMISSION RATIO
4th 1.000

5th 0.773

6th 0.634

REAR AXLE SERIES SH13

SERVICE BRAKE Vacuum Hydraulic

PARKING BRAKE ACTING ON DIFFERENTIAL OUTPUT SHAFT

SUSPENSION LEAF
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–11

2. VEHICLE NOISE EMISSION CONTROL INFORMATION

• The Vehicle Noise Emission Control Information is affixed to the
FOR ALL MODELS left pillar of the cab. The name of manufacturer, production year
and month, and noise emission applicable to medium and heavy
trucks in conformity with U.S. EPA Regulations are displayed.

SHTS01ZZZ0300008

3. ENGINE SERIAL NUMBER

(1) The engine serial number is stamped on the cylinder block,
as shown in the illustration.
A: J05E

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4. TRANSMISSION SERIAL NUMBER

(1) The transmission serial number is stamped on the transmis-
A sion, as shown in the illustration.
A: A465

SHTS01ZZZ0300010

5. CLEAN IDLE CERTIFIED LABEL FOR U.S.

• Make sure that the following clean engine idling certified label is
affixed to the outside of the left door. By the CARB below, the
label must be affixed there to prove that the new vehicle with
diesel engine manufactured from Jan., 2008 conforms to this
low.

CARB § 1956.8. Exhaust Emission Standard and Test

Procedure (a) (b) Heavy-Duty Diesel Engine Idling
Requirements

SHTS01ZZZ0300011
1–12 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

6. 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. EPA Regulations are displayed.

Vehicle emission
control information

SHTS01ZZZ0300012

SHTS01ZZZ0300013
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–13

SAFETY INSTRUCTIONS FOR WORK

PRECAUTIONS
EN01H01ZZZ030101004001

1. SAFETY INSTRUCTIONS FOR HANDLING ELECTRICAL SYSTEMS

(1) 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" position. Otherwise, the vehicle data will
not be recorded on ECU properly and DCU will not complete working properly, which may result in the malfunc-
tion of DPR system and DEF-SCR system.
• The MIL (malfunction indicator light) may come on when the starter key is turned to "ON" position again, even if
you wait for at least ten minutes before disconnecting the battery terminals from the battery after the starter key
is turned to "LOCK" position. In this case, use HINO DXⅡ to clear the DTC (P204F and P068A), to turn off the MIL
and to conduct DPR regeneration manually.
a. Before electrical system work, remove the cable from the minus terminal of the battery in order to avoid burn-
ing caused by short-circuiting.
b. To remove the battery cable, fully release the nut to avoid damage to the battery terminal. Never twist the ter-
minal.

Loosen

SHTS01ZZZ0300014
1–14 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

(2) Handling of electronic parts

a. Never give an impact to electronic parts of a computer or relay.
b. Keep electronic parts away from high temperatures and humidity.
c. Never splash water onto electronic parts in washing the vehicle.
d. Do not remove the harness connector, electric component box, and cover except for repair and inspection.
If removal is necessary, pay attention that water and foreign matters do not attach or enter to the connector,
terminals, electric component box, and cover.
In restoration, make sure there is no attachment or entry of water and foreign matters and mount them prop-
erly, because it causes degradation of waterproof function.

Incorrect

SHTS01ZZZ0300015

(3) Handling of wire harness

a. Perform marking on a clamp and a clip and secure then in original position so that the wire harness will not
interfere with the end and acute angle section of the body and a bolt.
b. To attach a part, take care not to bite the wire harness.

Incorrect Incorrect

Incorrect
SHTS01ZZZ0300016
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–15

(4) Handling of connectors

a. 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.
b. Pull off a lockable connector after unlocking.
c. When connecting a lockable connector, make sure to insert a lockable connector until it makes a click sound.
d. When inserting a test lead, insert it from the back of a connector.
e. If it is difficult to insert a test lead from the back of a connector, make and use an inspection harness.

Incorrect
Incorrect

Correct

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(5) Installation of battery disconnect switch

! WARNING
• Installation of the battery disconnect switch on the power supply circuit for the dosing control unit of DEF-SCR
(DCU) may damage or result in the malfunction of DEF-SCR system.
• Be sure to read and follow the procedures and instructions on the service bulletin before the installation of the
battery disconnect switch.
(6) Handling of battery disconnect switch
! WARNING
• Wait for at least ten minute before using the battery disconnect switch after the starter key is turned to "LOCK"
position.
Otherwise, the vehicle data will not be recorded on ECU properly, which may result in the malfunction of DPR
system.
1–16 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

2. 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. Consequently, the following precautions are always to be taken during welding.
(1) Disconnect the earth terminal of the battery at the frame fitment and earth the welding equipment securely to the
frame itself. (Do not fit the welding equipment earth to such things as the tire rims, brake pipes or fuel pipes and
leaf spring, etc.)
a. Turn the starter switch off.
b. Disconnect the battery’s negative terminal of the battery.
c. Earth welding equipment securely, near to the area to be welded.
d. Put back battery negative ground as original condition.
e. Finally check the functioning of all instruments.

Computer

Alternator
Battery
etc

Disconnect the ground terminal for

battery at the connecting point on the
frame and disconnect the ground for
computer as well.

Chassis frame
Chassis frame

Connect the ground of the ARC welding

machine near the place on the frame to be
ARC welding welded but not connect it to plated parts such
machine as fuel pipes, brake pipes and leaf spring.

SHTS01ZZZ0300018

(2) In order to prevent damage to ancillary equipment components from sparks during welding, take steps such as
putting fire-resistant covers over things like the engine, meters, steering wheel, hoses, leaf spring and tires.
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–17

GENERAL INFORMATION

INTRODUCTION TO WORKSHOP MANUAL

GENERAL
EN01H01ZZZ030102002001

1. SCOPE OF REPAIR DESCRIPTIONS

(1) There are three major processes in repair work: i.e. "trouble shooting", "removal/installation, replacement, over-
haul, assembly, inspection and adjustment" and "final inspection".
(2) 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).
(3) The element tasks listed below are omitted from this document but must be done in actual repair work.
a. Jacking and lifting
b. Cleaning and washing of removed parts as required
c. Visual check

2. STANDARD VALUE
(1) Standard values, limits, required actions and tightening torques are tabulated in this document.

3. REQUIRED ITEMS
(1) Special tools, tools, instruments, oil and grease and other items to be prepared before starting work are listed in
the section titled "REQUIRED ITEMS". Note that general tools, jacks, rigid racks and other required items sup-
posedly available at a general service shop are omitted from the list.

4. REPRESENTATION OF SECTION AND TITLE

(1) Under a title containing a system name such as "ENGINE CONTROL SYSTEM", the descriptions cover
"INSPECTION", "ADJUSTMENT", "REPLACEMENT" and "OVERHAUL" of components.
(2) Under a title containing a part name such as "AIR COMPRESSOR ASSEMBLY", the descriptions cover
"REPLACEMENT" and "OVERHAUL".
1–18 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

INTRODUCTION TO DESCRIPTIONS
EN01H01ZZZ030102002002

1. TROUBLE SHOOTING FOR EACH TROUBLE SYMPTOM WITH REFERENCE TO THE CHART

A possible cause and remedy/prevention are indicated for

every item, respectively.

SHTS01ZZZ0300019
 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK 1–19

2. INTRODUCTION TO TROUBLE SHOOTING

(1) 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-
"Step 2"
(3) Reproducing technique tom. If a symptom check does not gain enough
reproducibility, use a reproducing technique.

(4) Trouble shooting for each

Sort the inspection results obtained from the step 2 and con-
diagnosis code
"Step 3" duct an systematized inspection in accordance with the pro-
(5) Trouble shooting for each
cedures for trouble shooting for each trouble symptom.
trouble symptom

Verify that the same trouble will not occur after trouble shoot-
ing. If a trouble is not reproducible enough, conduct a verifi-
(6) Verification test "Step 4"
cation test under the reproduced conditions and
environment.

(2) Prior check

• Take the following prior check steps.

Diagnosis inspectiondiagnosis deletiontrouble symptom verification (use a reproducing
technique if not reproducible.)diagnosis recheck
• Prior to a reproduction test, identify a system suspected to have a trouble, attach a tester and
other apparatuses and then conduct both a symptom check and an examination on a sus-
pected trouble. For a suspected cause of a trouble symptom, the trouble shooting chart.
Prior check
• Instantaneous occurrence of a trouble symptom will also trigger a failure code. If no troubles
are observed, use a reproducing technique in performing each trouble shooting activity.
• Trouble symptom verification
If not reproducible, take the steps 2, 3 and 4.
If not reproducible, use a reproducing technique (e.g. adjust external conditions and inspect
each wire harness and connector part).
1–20 GENERAL INTRODUCTION/SAFETY INSTRUCTIONS AND READINESS TO WORK

3. INTRODUCTION TO TROUBLE SHOOTING FOR EACH DIAGNOSIS MONITOR CODE

(1) 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.

2–466 ENGINE (COMMON ITEMS)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0606

1 Reading DTC [HINO DX ൖ ]

1. Turn the starter key to the "LOCK" position.

2. Connect the diagnostic tester (HINO DX ൖ ) to the vehicle.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, select [VCS] and check that no

vehicle speed signal-related DTC, P0501 or P0503, is detected.

SHTS029990300431

Is DTC P0501 or P0503 detected?

YES NO

Perform troubleshooting for related DTC. Go to step 2.

2 Inspecting the CAN communication line

1. Inspect the CAN communication line.

Is any defect found?

YES NO

Repair or replace the CAN communication Replace the vehicle control ECU.
line.

SHTS01ZZZ0300020
 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

1. CHASSIS RELATED
(1) Longitudinal direction
a. The forward direction and the reverse direction of a vehicle are respectively defined as front and rear in the
installed position in a vehicle.
(2) Rotational direction
a. The clockwise direction and the counterclockwise direction viewed from the rear side of a vehicle are defined
as right-handed and left-handed respectively.
(3) Vertical direction
a. The upward direction and the downward direction in the installed position in a vehicle are defined as an upper
side and a lower side respectively.
(4) Lateral direction
a. The leftward direction and the rightward direction viewed from the back of a vehicle are respectively defined as
a left side and a right side in the installed position in a vehicle.

2. INDIVIDUAL DEVICES
(1) Longitudinal direction
a. The input side and the output side of motive power are defined as a front side and a rear side respectively.
(2) Rotational direction
a. The clockwise direction and the counterclockwise direction viewed from the back side are defined as right-
handed and left-handed respectively.
(3) Vertical direction
a. The upward direction and the downward direction of a device in its installed position in a vehicle (chassis) are
defined as an upper side and a lower side respectively.
(4) Lateral direction
a. The leftward direction and the rightward direction as viewed from the back side are defined as a left side and a
right side respectively.

STANDARD VALUE
Represents a basic dimension (excluding a tolerance), and a clearance arising from tolerances when two parts are assem-
bled.

REPAIR LIMIT
Represents a numerical value indicating need of correction. A symbol "+" or "-" indicated next to a repair limit represents
an increase or a decrease from a standard value.

SERVICE LIMIT
Represents a numerical value indicating need of replacement. A symbol "+" or "-" indicated next to a repair limit represents
an increase or a decrease from a standard value.
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.

1. CONNECTION OF DIAGNOSIS CHECK WIRE

DLC3 (1) Turn the starter key to the "LOCK" position.
TC TS (2) Use a SST to short circuit DLC3 12(TS) or 13(TC)  4(CG)
terminals.
SST: 09843-18040
Diagnosis check wire
HINT
The terminals to be shorted vary depending on the device to be
diagnosed.

CG ! CAUTION
SHTS01ZZZ0400001
• Never fail to connect connectors to correct locations. Other
wise failure may occur.
• Use the dedicated diagnosis check wire.

2. INDICATION OF DIAGNOSIS MONITOR CODE

(1) 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. For the first code, the number
"3" in the ten's place of the first code will be represented by
three 0.5-second flashings, followed by an interval of 1.5 sec-
onds. Then, the light will flash twice. For the next code, after
an interval of 4.3 seconds, two flashings will be followed by
one flashing in the similar fashion to the first code. This flash-
ing pattern will be repeated. If no system malfunctions are
detected, the light will repeat a 0.3-second flashing pattern.
NOTICE
As individual systems have different diagnosis monitor code out-
putting patterns, follow the descriptions provided for each sys-
tem.
HINT
• This figure indicates a typical indication of diagnosis monitor
codes. For details, refer to the descriptions provided for individ-
ual systems.
• If no malfunctions are detected, the "diagnosis monitor code 1"
will be indicated.
• Malfunction codes will be repeatedly output in the ascending
order regardless of present or past malfunction codes.
 GENERAL INTRODUCTION/TROUBLE SHOOTING 1–23

Indication of diagnosis monitor code (example)

When codes 32 and 21 are indicated:
0.5 second 0.5 second

Light ON

Light OFF
4.3 second

1.5 second Code 21

Code 32 The operation is repeated

When the system is normal

0.3 second

Light ON

Light OFF

SHTS01ZZZ0400002

HINT
• If no code is indicated (light not flashing), it is suspected that
the TC or TS terminal line is broken or the computer is faulty.
• If the check engine warning light is always on, it is suspected
that the wire harness is shorted (for example, jammed) or the
computer is faulty.
• If any meaningless code is out, the computer is suspected of
being faulty.
• 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.
(2) Release DLC3 12(TS) or 13(TS)  14(CG) terminals.
1–24 GENERAL INTRODUCTION/TROUBLE SHOOTING

APPARATUS FOR TROUBLE SHOOTING

EN01H01ZZZ040301002002

1. TAG CODE AND SYSTEM NAME LIST FOR DEDICATED HARNESS

No. Tag name Name of system to be diagnosed

1 STD: ENG Common rail

3 STD: AIR BAG Not used

5 STD: ABS/ASR ABS

7 STD: ES START Not used

10 STD: VSC Not used

11 STD: TIRE Not used

2 OPT: RTD/4WD Not used

4 OPT: SHAKAN Not used

6 OPT: AIR SUS Not used

8 OPT: IDL STOP Not used

9 OPT: ATM Not used

12 OPT: PRO SHIFT Not used

Dedicated harness (S0963-02300) 2 1

4 3

10 6 5

8 7

12 11 9

SHTS01ZZZ0400003
 GENERAL INTRODUCTION/TROUBLE SHOOTING 1–25

TROUBLE DIAGNOSIS USING THE COMPUTER (HINO DX Ⅱ )

STEP OF TROUBLE DIAGNOSIS

EN01H01ZZZ040301003001

1. PREPARATION FOR CONNECTING HINO DX Ⅱ

(1) 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" and the dedi-
cated cable will be required.

SPECIAL TOOL: Computer interface

Part name Part No.

DENSO DST-i Set Without Bluetooth 95171-01021

(Without LCD) With Bluetooth 95171-01041
SHTS01ZZZ0400004

DENSO DST-i Set Without Bluetooth 95171-01031

(With LCD) With Bluetooth 95171-01051

HINT
Install the "Hino Diagnostic eXplorer Ⅱ " (HINO DX Ⅱ ) software in a
computer. For detailed installation procedures, refer to the HINO
DX Ⅱ OPERATION MANUAL supplied on the Global Service Portal
Site (Hino-GSPS).

2. CONNECTION OF HINO DX Ⅱ
(1) Connect the DST-i to the trouble diagnosis connector located
in the electrical component box in the instrument panel or
located in the electrical component box behind the rearmost
seat.
(2) Connect the computer in which the HINO DX Ⅱ is installed, to
the DST-i.
(3) Turn the starter key to "ON".
(4) Turn on the power switch of the computer to start the HINO
DX Ⅱ .
Trouble diagnosis connector
SHTS01ZZZ0400005
1–26 GENERAL INTRODUCTION/TROUBLE SHOOTING

APPARATUS FOR TROUBLE DIAGNOSIS

EN01H01ZZZ040301003002

1. APPARATUS FOR TROUBLE DIAGNOSIS

Part name Part No. Illustration of appearance Outline/function

Laptop computer*1 The following specifications are nec-

essary for operation of HINO DX Ⅱ .
• Operating system (OS): Windows7
Professional 32 bit.
• Browser: Microsoft Internet Explorer
— 8.0, 9.0
• CPU: 32 bit processors more than
1GHz.
• Memory: More than 1Gbyte.
• HDD: More than 100Gbyte.
DENSO DST-i Set Computer interface
(without LCD) Without Bluetooth These parts are supplied by DENSO Dis-
95171-01021 tributor.
With Bluetooth
95171-01041

DENSO DST-i Set

(with LCD) Without Bluetooth
95171-01031
With Bluetooth
95171-01051

Signal check har- Inserting this harness between the ECU

ness and the harness of the vehicle, you can
diagnose the ECU using tester rods with-
out cutting off the power.

09843-E4090
(For engine ECU)

09843-E9030
—
(For DCU)

(*1): Complete function of HINO DX Ⅱ is confirmed on "Panasonic CF-D1".

 GENERAL INTRODUCTION/GLOSSARY 1–27

GLOSSARY

DEFINITION OF ABBREVIATION

LIST OF ABBREVIATION
EN01H01ZZZ060102001001

Abbreviations Meaning, or Official Name

A/C Air Conditioner

ABS Anti-lock Brake System

ACC Accessory

ACU Auto Clutch Unit

AMT Automated Manual Transmission

ATC After Turbo Catalyst

ATF Automatic Transmission Fluid

CA Crank Angle

CAN Controller Area Network

CD-ROM Compact Disc Read Only Memory

CPU Central Processing Unit

dB Decibel

DC Direct Current

D-CAT Diesel-Clean Advanced Technology System

DC motor Direct Current Motor

DCU Dosing Control Unit

DEF Diesel Exhaust Fluid

DPR Diesel Particulate active Reduction system

DSS Driving Support System

ECU Electronic Control Unit

EEPROM Electronically Erasable and Programmable Read Only Memory

EGR Exhaust Gas Recirculation

ELR Emergency Locking Retractor

ENG Engine

EOP Electric Oil Pump

ES START Easy and Smooth start system

F/A Front Axle

FCCB Fuel Control Cylinder Balance

FCV Fuel Cutoff Valve

1–28 GENERAL INTRODUCTION/GLOSSARY

Abbreviations Meaning, or Official Name

FF shift Feather touch & Finger shift

FL Fusible link

Fr Front

FRP Fiber Reinforced Plastic

FUP Front Underrun Protector

GCU Glow Control Unit

GND Ground

GVW Gross Vehicle Weight

Hi High

HINO DX Hino Diagnostic eXplorer

HV Hybrid Vehicle

HVAC Heating, Ventilating and Air-Conditioning unit

I.S.C. Idle Speed Control

IC Integrated Circuits

ID Identification

IPD Intelligent Power Device

ISO International Organization for Standardization

JIS Japanese Industrial Standards

LED Light Emitting Diode

LEV Low Emission Vehicle

LH Left Hand

LLC Long Life Coolant

Lo Low

MAX Maximum

MIN Minimum

MS evaporator Multi-tank and Super slim structure evaporator

MT Manual Transmission

No. Number

NOx Nitrogen Oxide

NMR No load Maximum Revolution

OHC Over Head Camshaft

PAB Power Assist Brake

PC Personal Computer

PCD Pitch Circle Diameter

PCS Pre-Crash Safety

 GENERAL INTRODUCTION/GLOSSARY 1–29

Abbreviations Meaning, or Official Name

PCV Pump Control Valve

PCV valve Positive Crankcase Ventilation valve

PM Particulate Matter

PPG Glass-fiber-reinforced Polypropylene

ppm Parts Per Million

PS Power Steering

PTO Power Take-Off

PVD Physical Vapor Deposit

PWR Power

QR code Quick Response Code

R/A Rear Axle

RH Right Hand

S&S HINO STOP&START SYSTEM

SCR Selective Catalytic Reduction

SCV Suction Control Valve

SST Special Service Tool

SW Switch

SVS Service Vehicle Soon

T/M Transmission

VCS Vehicle Control System

VNT Variable Nozzle Turbine

VSS Vehicle Speed control System

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

A/T AUTOMATIC TRANSMISSION Automatic transmission

AAT AMBIENT AIR TEMPERATURE Ambient Air Temperature

ACL AIR CLEANER Air cleaner

ACL Element ACL (Air Cleaner) Element Air Cleaner element

ACL Element AIR CLEANER Element Air Cleaner element

ACL Housing AIR CLEANER Housing Air cleaner body assembly

ACL Housing Cover AIR CLEANER Housing Cover Air Cleaner Housing Cover

AFTER TREATMENT DIESEL EXHAUST

AFTDEF DEF
FLUID

AFTER TREATMENT DIESEL EXHAUST

AFTDEFDU DCU
FLUID DOSING UNIT

AFTER TREATMENT DIESEL OXIDATION

AFTDOC DOC (Diesel Oxidation Catalyst)
CATALYST

AFTDOS AFTER TREATMENT DOSER AFTDOS Dosing

AFTER TREATMENT DIESEL PARTICU-

AFTDPF DPR filter
LATE FILTER

AFTER TREATMENT DIESEL PARTICU-

AFTDPFDP DPR differential pressure
LATE FILTER DIFFERENTIAL PRESSURE

AFTER TREATMENT EXHAUST GAS TEM-

AFTEGT Exhaust gas temperature
PERATURE

AP ACCELERATOR PEDAL Accelerator pedal

AP Sensor ACCELERATOR PEDAL Sensor Accelerator Pedal Position Sensor

APP ACCELERATOR PEDAL POSITION Accelerator Pedal Position

CAC CHARGE AIR COOLER Intercooler

CPP Switch CLUTCH PEDAL POSITION Switch Clutch Switch

DCC DIAGNOSTIC CONNECTOR, Cab Diagnosis connector

DCU DIAGNOSTIC CONNECTOR, Under-hood Diagnosis connector

DRIVER DRIVER Driver

DTC DIAGNOSTIC TROUBLE CODE Diagnosis Trouble Code

DTM Switch DIAGNOSTIC TEST MODE Switch Diagnosis switch

EBP EXHAUST BACK PRESSURE Back pressure

EBP EXHAUST BACK PRESSURE Exhaust back pressure

EBP Sensor EXHAUST BACK PRESSURE Sensor Back Pressure Sensor

EXHAUST BACK PRESSURE REGULATOR

EBPR Valve Exhaust control valve
Valve
 GENERAL INTRODUCTION/GLOSSARY 1–31

SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS

EC ENGINE CONTROL Engine control

ECT ENGINE COOLANT TEMPERATURE Coolant Temperature

ECT ENGINE COOLANT TEMPERATURE Water Temperature

EFT ENGINE FUEL TEMPERATURE Fuel temperature

EFT Sensor ENGINE FUEL TEMPERATURE Sensor Fuel temperature sensor

EGR EXHAUST GAS RECIRCULATION EGR

EGR Valve EXHAUST GAS RECIRCULATION Valve EGR valve

EXHAUST GAS RECIRCULATION TEM-

EGRT EGR temperature
PERATURE

EXHAUST GAS RECIRCULATION TEM-

EGRT Sensor EGR exit temperature sensor
PERATURE Sensor

EGT EXHAUST GAS TEMPERATURE Exhaust gas temperature

EI ELECTRONIC IGNITION Ignition coil

EOP ENGINE OIL PRESSURE Oil Pressure

EOT ENGINE OIL TEMPERATURE Oil Temperature

FP FUEL PUMP Fuel pump

FUEL PRESSURE
FUEL PRESSURE Sensor Fuel Pressure sensor
Sensor

GLOW PLUG GLOW PLUG Glow plug

GND GROUND GROUND

IA INTAKE AIR Air Intake

IA System INTAKE AIR System Air Intake System

IAT INTAKE AIR TEMPERATURE Intake temperature

IAT Sensor INTAKE AIR TEMPERATURE Sensor Intake temperature sensor

IDLE IDLE Idle

IMAT INTAKE MANIFOLD AIR TEMPERATURE Intake manifold Air temperature sensor

IMAT INTAKE MANIFOLD TEMPERATURE Intake manifold temperature sensor

INJ INJECTOR Injector

MAF Sensor MASS AIR FLOW Sensor Air flow sensor

MIL MALFUNCTION INDICATOR LAMP Check engine

OSS Sensor OUTPUT SHAFT SPEED Sensor Output Speed Sensor

OSS Sensor OUTPUT SHAFT SPEED Sensor Speed Sensor

PC Solenoid Valve PRESSURE CONTROL Solenoid Valve Solenoid control valves

PCV POS CRANKCASE VENTILATION PCV (Positive Crankcase Vent)

PCV Valve POS CRANKCASE VENTILATION Valve PCV (Positive Crankcase Vent) Valve

PCV Valve POS CRANKCASE VENTILATION Valve PCV Valve

1–32 GENERAL INTRODUCTION/GLOSSARY

SAE ABBREVIATIONS SAE TERMS HINO TERMS( )--ABBREVIATIONS

PCV Valve POSITIVE CRANKCASE VENT Valve PCV Valve

PNP PARK/NEUTRAL POSITION Neutral position

PNP Switch PARK/NEUTRAL POSITION Switch Neutral switch

RFP RAIL FUEL PRESSURE Common rail Pressure

RFP Sensor RAIL FUEL PRESSURE Sensor Common rail pressure sensor

SPARK PLUG SPARK PLUG Spark plug

SRI SERVICE REMINDER INDICATOR Check engine

ST SCAN TOOL Diagnostic tool

TC TURBOCHARGER Turbocharger

TCC TORQUE CONVERTER CLUTCH Torque Converter

TP Sensor THROTTLE POSITION Sensor Throttle Sensor

TSS Sensor TURBINE SHAFT SPEED Sensor Turbine Speed Sensor

VAF Sensor VOLUME AIR FLOW Sensor Air flow sensor

VLS VEHICLE LIMITING SPEED Speed Limiter Upper Limit

VSS VEHICLE SPEED SENSOR Vehicle Speed sensor

 ENGINE (J05E) 2–1

ENGINE (J05E)
2-001

TROUBLESHOOTING ..................................... 2-4 DTC: P0045 ........................................................2-133

DTC: P0047 ........................................................2-137
ENGINE ECU (J05E)....................................................2-4
DTC: P0048 ........................................................2-141
PRECAUTIONS FOR DIAGNOSIS .........................2-4
DTC: P006E ........................................................2-145
ELECTRICAL ..........................................................2-6
DTC: P006F ........................................................2-149
PRECAUTIONS ......................................................2-7
DTC: P007B ........................................................2-153
COMPUTER (ECU) PIN ASSIGNMENT............... 2-11
DTC: P007C and P007D.....................................2-167
ENGINE ECU CONNECTOR................................ 2-17
DTC: P0088 ........................................................2-175
INSPECTION ........................................................ 2-21
DTC: P0096 ........................................................2-183
TROUBLE DIAGNOSIS USING THE COMPUTER
DTC: P0097 and P0098 ......................................2-194
(HINO DX Ⅱ ) ....................................................... 2-22
DTC: P00AF........................................................2-203
DIAGNOSTIC TROUBLE CODE (DTC) TABLE.... 2-23
DTC: P0101 ........................................................2-207
GROUP SHARING THE SENSOR SUPPLY
DTC: P0104 ........................................................2-216
TERMINAL ............................................................ 2-50
DTC: P0106 ........................................................2-223
GROUP SHARING THE SENSOR GND
DTC: P0107 ........................................................2-229
TERMINAL ............................................................ 2-51
DTC: P0108 ........................................................2-235
MALFUNCTION CODES IN CASE OF DISRUPTION
DTC: P0111 ........................................................2-241
OF CAN COMMUNICATION................................. 2-52
DTC: P0112 and P0113 ......................................2-247
PRE-INSPECTION FOR ENGINE CAN
DTC: P0115 ........................................................2-255
COMMUNICATION LINE (250 k) .......................... 2-55
DTC: P0117 and P0118 ......................................2-264
DISCONNECTION INSPECTION FOR ENGINE
DTC: P011A ........................................................2-272
CAN_H COMMUNICATION L LINE (250 k)
DTC: P0122 and P0123 ......................................2-281
[DIESEL] ............................................................... 2-60
DTC: P0126 ........................................................2-291
DISCONNECTION INSPECTION FOR ENGINE
DTC: P0128 ........................................................2-295
CAN_H COMMUNICATION L LINE (250 k)
DTC: P0148 ........................................................2-301
[HYBRID]............................................................... 2-70
DTC: P016E and P016F .....................................2-313
PRE-INSPECTION FOR ENGINE CAN
DTC: P0182 and P0183 ......................................2-323
COMMUNICATION LINE (500 k) [DIESEL] .......... 2-81
DTC: P0191 ........................................................2-331
PRE-INSPECTION FOR ENGINE CAN
DTC: P0192 and P0193 ......................................2-340
COMMUNICATION LINE (500 k) [HYBRID].......... 2-86
DTC: P01A5 ........................................................2-350
DISCONNECTION INSPECTION FOR ENGINE
DTC: P01A6 ........................................................2-357
CAN_H COMMUNICATION L LINE (500 k)
DTC: P0200 ........................................................2-364
[DIESEL] ............................................................... 2-92
DTC: P0201, P0202, P0203 and P0204 .............2-367
DISCONNECTION INSPECTION FOR ENGINE
DTC: P0217 ........................................................2-372
CAN_H COMMUNICATION L LINE (500 k)
DTC: P0219 ........................................................2-377
[HYBRID]............................................................... 2-97
DTC: P0222 and P0223 ......................................2-385
MALFUNCTION CODES FOR FAULTY
DTC: P0234 ........................................................2-395
ACTUATOR POWER RELAY ..............................2-102
DTC: P0263, P0266, P0269 and P0272 .............2-401
ENG BASIC INSPECTION SHEET
DTC: P026C and P026D.....................................2-412
(ENGINE INSPECTION CHECK SHEET) ..........2-103
DTC: P0299 ........................................................2-425
NO DTC ..............................................................2-107
DTC: P0300 ........................................................2-431
DTC: P0005 ........................................................2-111
DTC: P0301, P0302, P0303 and P0304 .............2-439
DTC: P0006 and P0007 ......................................2-115
DTC: P0335 ........................................................2-448
DTC: P0016 ........................................................2-120
DTC: P0336 ........................................................2-455
DTC: P0027 ........................................................2-123
DTC: P0340 ........................................................2-462
DTC: P003A ........................................................2-128
DTC: P0341 ........................................................2-466
2–2 ENGINE (J05E)

DTC: P0381.........................................................2-474 DTC: P0AC4........................................................2-770

DTC: P0401.........................................................2-480 DTC: P0CA1........................................................2-772
DTC: P0402.........................................................2-496 DTC: P1133.........................................................2-774
DTC: P0404.........................................................2-507 DTC: P119F ........................................................2-781
DTC: P0405 and P0406 ......................................2-512 DTC: P1426.........................................................2-787
DTC: P041B ........................................................2-518 DTC: P1427.........................................................2-794
DTC: P041C and P041D .....................................2-531 DTC: P1428.........................................................2-801
DTC: P0420.........................................................2-539 DTC: P1458.........................................................2-809
DTC: P0421.........................................................2-541 DTC: P1459.........................................................2-814
DTC: P0422.........................................................2-554 DTC: P14B0 ........................................................2-819
DTC: P0489 and P0490 ......................................2-557 DTC: P14B2 ........................................................2-823
DTC: P049D ........................................................2-563 DTC: P14B3 and P14B4 .....................................2-827
DTC: P04D5 and P04D6 .....................................2-568 DTC: P14B7 and P14B8 .....................................2-833
DTC: P04DA........................................................2-576 DTC: P14BC and P14BD ....................................2-839
DTC: P04DB........................................................2-586 DTC: P14BF ........................................................2-845
DTC: P0500 and P0501 ......................................2-594 DTC: P1515.........................................................2-850
DTC: P0504.........................................................2-601 DTC: P1530.........................................................2-855
DTC: P0506.........................................................2-606 DTC: P2002.........................................................2-859
DTC: P0507.........................................................2-610 DTC: P200C ........................................................2-880
DTC: P0521.........................................................2-614 DTC: P2032 and P2033 ......................................2-889
DTC: P0524.........................................................2-618 DTC: P203F ........................................................2-897
DTC: P0545 and P0546 ......................................2-623 DTC: P204F ........................................................2-901
DTC: P054E ........................................................2-631 DTC: P206B ........................................................2-904
DTC: P054F ........................................................2-635 DTC: P207F ........................................................2-929
DTC: P0562 and P0563 ......................................2-639 DTC: P2080.........................................................2-937
DTC: P0603.........................................................2-644 DTC: P2084.........................................................2-945
DTC: P0605.........................................................2-648 DTC: P20CD .......................................................2-953
DTC: P0606.........................................................2-650 DTC: P20CE........................................................2-957
DTC: P0607.........................................................2-652 DTC: P20CF ........................................................2-960
DTC: P0610.........................................................2-654 DTC: P20D8 ........................................................2-966
DTC: P0611.........................................................2-657 DTC: P20DE........................................................2-972
DTC: P0617.........................................................2-659 DTC: P20DF ........................................................2-976
DTC: P0628 and P0629 ......................................2-663 DTC: P20E0 ........................................................2-982
DTC: P062F ........................................................2-671 DTC: P20EE ........................................................2-988
DTC: P0630.........................................................2-675 DTC: P20EF ........................................................2-996
DTC: P0642.........................................................2-679 DTC: P2100.........................................................2-998
DTC: P0643.........................................................2-684 DTC: P2101.......................................................2-1004
DTC: P064C ........................................................2-690 DTC: P2103.......................................................2-1011
DTC: P0652.........................................................2-695 DTC: P2120.......................................................2-1016
DTC: P0653.........................................................2-701 DTC: P2122 and P2123 ....................................2-1020
DTC: P0671 and P0672 ......................................2-708 DTC: P2127 and P2128 ....................................2-1030
DTC: P0673 and P0674 ......................................2-714 DTC: P2135.......................................................2-1039
DTC: P0683.........................................................2-720 DTC: P2138.......................................................2-1044
DTC: P0686.........................................................2-726 DTC: P2146.......................................................2-1049
DTC: P0698.........................................................2-731 DTC: P2147 and P2148 ....................................2-1056
DTC: P0699.........................................................2-734 DTC: P2149.......................................................2-1064
DTC: P06A4 ........................................................2-737 DTC: P2150 and P2151 ....................................2-1071
DTC: P06A5 ........................................................2-740 DTC: P2184 and P2185 ....................................2-1079
DTC: P06D3 and P06D4 .....................................2-743 DTC: P2201.......................................................2-1087
DTC: P0700.........................................................2-752 DTC: P2227.......................................................2-1133
DTC: P073D ........................................................2-754 DTC: P2228 and P2229 ....................................2-1137
DTC: P081A ........................................................2-758 DTC: P2269.......................................................2-1142
DTC: P081B ........................................................2-764 DTC: P226C ......................................................2-1146
DTC: P0A7B........................................................2-768 DTC: P229F ......................................................2-1152
 ENGINE (J05E) 2–3

DTC: P22D3...................................................... 2-1199 DTC: U110A......................................................2-1500

DTC: P240F ...................................................... 2-1203
DTC: P2428 ...................................................... 2-1213
DTC: P242B ...................................................... 2-1217
DTC: P242C and P242D................................... 2-1225
DTC: P244A ...................................................... 2-1233
DTC: P244B ...................................................... 2-1253
DTC: P2457 ...................................................... 2-1270
DTC: P2458 ...................................................... 2-1285
DTC: P2459 ...................................................... 2-1296
DTC: P2463 ...................................................... 2-1299
DTC: P246F ...................................................... 2-1307
DTC: P2470 and P2471 .................................... 2-1315
DTC: P2481 and P2482 .................................... 2-1323
DTC: P2483 ...................................................... 2-1331
DTC: P24A0 ...................................................... 2-1339
DTC: P24A1 ...................................................... 2-1342
DTC: P24A2 ...................................................... 2-1344
DTC: P24A3 (2 digit diagnosis code: 01) .......... 2-1354
DTC: P24AE (2 digit diagnosis code: 04, 05,
06, 14, 25, 26, 27, 28) ....................................... 2-1358
DTC: P24AF (2 digit diagnosis code: 23).......... 2-1360
DTC: P24B0 (2 digit diagnosis code: 19, 20,
21) ..................................................................... 2-1363
DTC: P24B1 (2 digit diagnosis code: 18) .......... 2-1365
DTC: P24B4 (2 digit diagnosis code: 10, 11,
15, 17) ............................................................... 2-1367
DTC: P24B7 (2 digit diagnosis code: 08) .......... 2-1369
DTC: P24C7 (2 digit diagnosis code: 09).......... 2-1372
DTC: P24D0 (2 digit diagnosis code: 02).......... 2-1376
DTC: P24D1 (2 digit diagnosis code: 12).......... 2-1380
DTC: P24DA (2 digit diagnosis code: 07).......... 2-1382
DTC: P2562 ...................................................... 2-1386
DTC: P259E ...................................................... 2-1390
DTC: P259F ...................................................... 2-1396
DTC: P2635 ...................................................... 2-1401
DTC: P268A and P2696.................................... 2-1410
DTC: P26C8...................................................... 2-1416
DTC: P2A00 ...................................................... 2-1418
DTC: P2A01 ...................................................... 2-1422
DTC: P2BA9...................................................... 2-1426
DTC: U0073 ...................................................... 2-1431
DTC: U010A...................................................... 2-1434
DTC: U010C...................................................... 2-1440
DTC: U010E...................................................... 2-1446
DTC: U0293 ...................................................... 2-1452
DTC: U029D (DIESEL) ..................................... 2-1457
DTC: U029D (HYBRID)..................................... 2-1463
DTC: U029E (DIESEL)...................................... 2-1469
DTC: U029E (HYBRID)..................................... 2-1475
DTC: U02A2...................................................... 2-1481
DTC: U02A3...................................................... 2-1487
DTC: U0301 ...................................................... 2-1490
DTC: U1001 ...................................................... 2-1493
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.
• Replace the part or the component that have a failure or trouble. Do not fix and reuse it.
• Delete the past malfunction code after recording. Then conduct a diagnosis again to check for present failures.
• Delete the past failure memory after completion of a diagnostic analysis.
 ENGINE (J05E)/TROUBLESHOOTING 2–5

1. 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
CONNECTOR CONNECTOR

NUMBERING OF CONNECTOR TERMINALS

3 2 1 1 2 3 The terminals are symmetrically numbered (symmetrically
6 5 4 4 5 6 reversed numbering) as viewed on the connecting faces of a
pair of connectors.
The terminal #1 is located at the top right corner of a male
connector and at the top left corner of a female connector
MALE FEMALE respectively in this document.
CONNECTOR CONNECTOR

PRECAUTIONS FOR TERMINAL MEASUREMENT

Unless otherwise specified in this document, the illustration
INCORRECT of a connector represents an image of a connector as viewed
from the connecting face. A test probe must access the back
CORRECT face of a connector.
However, some types of connector do not allow a test probe
to contact with the back face such as a waterproof connector.
In such case, a test probe may be allowed to access the front
face of a connector but a special care must be used to avoid
a risk of damage in terminals.
CORRECT
As to a connector that is designed to use the signal check
harness for terminal measurement, do not place a test probe
INCORRECT directly onto the front or back face. Use a contact box of the
connected signal check harness to take measurement on
terminals.
WATERPROOF CONNECTOR

ILLUSTRATION OF CONNECTOR AND

MEASUREMENT SURFACE
A The illustration of a connector contained in this document
1 2
4 3 represents an image of a connector as viewed from the
5 6 connecting face. For example, the terminal #1 of a female
VIEW A connector is located at the top left corner of a connector as
viewed from the connecting face.
3 2
6 1 In actual measurement on the terminal #1 of a female
5 4 connector, a test probe must be placed onto the top right
corner on the back face of a connector.
VIEW B
B

SHTS021270300001
2–6 ENGINE (J05E)/TROUBLESHOOTING

ELECTRICAL
EN01H02127030602016002

ACTUATOR RELAY
FUSE
POWER SOURCE
KEY SWITCH FUSE

- +
STARTER SWITCH
MAIN RELAY
ACCELERATOR PEDAL BATTERY
POSITION SENSOR 1, 2

PTO ACCELERATOR SENSOR CAN COMMUNICATION (VARIABLE NOZZLE TURBO CHARGER, EGR VALVE DEF DOSING SYSTEM)

VEHICLE SPEED SENSOR OTHERS CAN COMMUNICATION (DIAGNOSIS,VEHICLE CONTROL ECU)

VEHICLE CONTROL ECU
ENGINE STOP SWITCH
Troubleshooting tool
NEUTRAL SWITCH

PTO SWITCH 1

PTO SWITCH 2 STARTER CUT RELAY

DIAGNOSIS SWITCH INPUT DPR INDICATOR LIGHT

DPR REGENERATION SWITCH GLOW LAMP (WAIT-TO-START LIGHT) PC Troubleshooting

MALFUNCTION INDICATOR LIGHT (MIL)
PTO CUT RELAY
SVS LIGHT
STOP LIGHT SWITCH
INJECTOR DRIVE SIGNAL
WATER LEVEL WARNING OUT PUT INJECTOR
SWITCH
AFTERTREATMENT FUEL INJECTOR DRIVE SIGNAL
OIL PRESSURE SWITCH
AFTERTREATMENT FUEL CUTOFF VALVE DRIVE SIGNAL
AFTERTREATMENT FUEL CUTOFF VALVE

EXHAUST TEMPERATURE SENSOR No.4 EXHAUST BRAKE DRIVE SIGNAL

EXHAUST BRAKE MAGNETIC VALVE
DPF DIFFERENTIAL PRESSURE SENSOR
DC MOTOR (FOR DIESEL THROTTLE VALVE) DRIVE SIGNAL
EXHAUST TEMPERATURE SENSOR No.3
EXHAUST TEMPERATURE SENSOR No.2 GLOW PLUG DRIVE SIGNAL
EXHAUST TEMPERATURE SENSOR No.0 SUPPLY PUMP
BARMETRIC
EXHAUST TEMPERATURE SENSOR No.1 PRESSURE SENSOR SUCTION CONTROL VALVE FOR FUEL SUPPLY PUMP DRIVE SIGNAL
EGR TEMPERATURE SENSOR (ECU BUILT-IN)
SUCTION CONTROL VALVE FOR FUEL SUPPLY PUMP DRIVE POWER S/P
INTERCOOLER OUT TEMPERATURE SENSOR
INTAKE MANIFOLD TEMPERATURE SENSOR
FUEL TEMPERATURE SENSOR
COOLANT TEMPERATURE SENSOR 1 T
COOLANT TEMPERATURE SENSOR 2
GLOW STATUS SIGNAL GCU
CRANK POSITION SENSOR
CAMSHAFT POSITION SENSOR
BOOST PRESSURE SENSOR
AFTERTREATMENT FUEL PRESSURE
INTAKE AIR TEMPERATURE SENSOR

AFTERTREATMENT FUEL PRESSURE SENSOR

(AIR FLOW METER BUILT-IN)

DIESEL THROTTLE VALVE POSITION SENSOR 1 DIESEL

A
COMMON RAIL PRESSURE

DC
COMMON RAIL PRESSURE

DIESEL THROTTLE VALVE POSITION SENSOR 2 THROTTLE

A VALVE MOTOR
(FREQUENCY TYPE )
AIR FLOW METER

SENSOR (MAIN)

SENSOR (SUB)

T P
AFTER TREATMENT
FREQUENCY TYPE COMMON FUEL INJECTOR
P RAIL
AFS
G
ATC DOC DPR DEF-SCR
ENGINE
N
T T
EGR EGR T T P T
T T T T TURBO-
COOLER VALVE
CHARGER
T DC MOTOR
DC MOTOR
EGR VALVE VARIABLE NOZZLE
CONTROLLER AND TURBOCHARGE (VNT)
ACTUATOR CONTROLLER AND ACTUATOR
EXHAUST TEMPERATURE SENSOR No.1
EXHAUST TEMPERATURE SENSOR No.0
DCU
EXHAUST TEMPERATURE SENSOR No.2
EXHAUST TEMPERATURE SENSOR No.3 PM SENSOR
DPF DIFFERENTIAL PRESSURE SENSOR NOx SENSOR No.1
EXHAUST TEMPERATURE SENSOR No.4 NOx SENSOR No.2

SHTS021270300002
 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.

1. BE CAREFUL NOT TO LET DIRT OR DUST GET INSIDE THE

ACTUATOR OR MAGNETIC VALVES.

2. HARNESS WIRE CONNECTOR.

(1) Multi-contact connectors suitable for the small electrical sig-
nals of electronic circuitry are used for wiring connections to
the sensors, actuator and control unit. Be very careful when
handling them.
• Before disconnecting any connectors, make sure that the
starter key is in the "LOCK" position.
• When disconnecting connectors, try to pull them out in a
straight line, disengaging the lock and holding onto the
housing.
• Do not try to disconnect connectors by gripping the wires
or twisting them, as this could bend the contacts.
• Do not disconnect connectors unnecessarily.
• When using a circuit tester, apply the tester probe to the
harness wire side only. Never stick the tester probe into the
holes on the connector terminal side, as this could cause
poor contacts when the connector is reconnected.

Correct Correct

Incorrect
Incorrect

How to use tester probe

SHTS021270300003

• Do not let water, oil or dust get on the connector when it is

disconnected, as this could cause poor contacts when the
connector is reconnected.
• Do not open the control unit cover. It could malfunction if
dust or water gets inside.
• Take care to ensure that water, oil or dust do not get on or
inside parts.
• When connecting in connectors, push them in all the way
and make sure that the lock engages.

3. ERASING THE MALFUNCTION MEMORY STORED IN THE

PAST, CHECK THE CURRENT MALFUNCTION BY PERFORM-
ING A DIAGNOSIS OF THE PRESENT MALFUNCTION AGAIN.
2–8 ENGINE (J05E)/TROUBLESHOOTING

4. AFTER COMPLETING THE MALFUNCTION ANALYSIS, ERASE

THE MALFUNCTION MEMORY STORED IN THE PAST. OTHER-
WISE, THE MALFUNCTION LIGHT IN THE DISPLAY WILL
REMAIN LIT.

5. CONNECTOR DRAWING, ALL OF WHICH HAS A VIEW TO BE

SEEN FROM THE CONNECTION SIDE, INSERT THE TESTING
LEAD FROM THE BACKSIDE.

6. USING A CIRCUIT TESTER

• Use a circuit tester with an internal resistance of 100 k or
greater in the voltage measuring range.

7. USING A SIGNAL CHECK HARNESS

• To prevent breakage of the ECU connector, connect the signal
check harness and perform measuring by bringing the test lead
into contact with the signal check harness side (contact box).
NOTICE
The terminal numbers in the text and in the illustrations corre-
spond to the table on the next page (computer pin assignment) as
shown below.

Computer (ECU) terminal signal

Computer (ECU) terminal No.
A
Main/
Exhaust brake Glow
Power supply 1 Starter cut relay Actuator power PTO cut relay -
relay (Indic
relay 1
V1 VF V2 STCR V3 MREL V4 EXB V5 PTOC V6 - V7

Vehicle speed CAN CA

Neutral switch Starter signal Starter switch 1 - communication commun
pulse converter
line lin
V11 NSW V12 STA V13 IGSW V14 SP1 V15 - V16 CANL V17

Main/
Power supply 2 - Actuator power Glow relay - - Diagnos
relay 2
V21 VF2 V22 - V23 MRL2 V24 SREL V25 - V26 - V27

Engine stop CAN CA

PTO switch 1 Starter switch 2 TACHO Pulse - communication commun
switch
line lin
V31 PTO V32 ESTP V33 IG V34 TAC V35 - V36 CANH V37

Example: V23 terminal

A
A (1 to 40)
Signal check
harness
(contact box) 1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
V23

SHTS021270300004
 ENGINE (J05E)/TROUBLESHOOTING 2–9

8. CONNECT THE SIGNAL CHECK HARNESS.

(1) Set the starter key to the "LOCK" position and disconnect the
connectors from the engine ECU.
(2) Connect a signal check harness to the engine sub harness
and the engine ECU.
SST: 09843-E4090
Signal check harness

Computer (Engine ECU)

Engine sub harness
(Engine side) Engine side
connector

Blue (80 pin)

Middle side
Blue (56 pin) connector

Gray (80 pin)

Vehicle side
connector
Engine sub harness
(Chassis side)

Blue Light Green Yellow Red Pink

blue green

A B C D E F

Test lead

Signal check connector

09843-E4090

SHTS021270300005
2–10 ENGINE (J05E)/TROUBLESHOOTING

9. 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. AIR CONDITIONER INSTALLATION

• Be careful not to scratch or damage the engine, chassis or the
harness inside the cab when installing an air conditioner. Also,
make sure to reattach afterward any connectors that were dis-
connected during the installation process.

12. PERFORMING ELECTRIC WELDING

• Disconnect the negative terminal of the battery before perform-
ing any electric welding.

13. OTHER
• Make sure to check the other connectors before connecting
them in to prevent incorrect connections.
• Be careful not to allow the connectors to become soiled with
dust, water, fuel or oil when performing inspections or removing
and replacing parts.
 A
Main/ Glow plug Check engine
Power supply 1 Starter cut relay Actuator power - PTO cut relay - DPR refresh light warning light -
(Indicator)
relay 1
V1 VF V2 STCR V3 MREL V4 - V5 PTOC V6 - V7 GIND V8 W2 V9 W V10 -

CAN Power supply 1

Vehicle speed Glow plug 1 Back up power
Neutral switch Starter signal Starter switch 1 communication - (+B) -
pulse converter (Signal) supply
COMPUTER (ECU) PIN ASSIGNMENT

line
V11 NSW V12 STA V13 IGSW V14 SP1 V15 ST V16 CANL V17 - V18 +B V19 BATT V20 -

Main/
Power supply 2 - Actuator power - - - Diagnosis light - - Diagnosis switch
relay 2
V21 VF2 V22 - V23 MRL2 V24 - V25 - V26 - V27 DG V28 - V29 - V30 TC
ENGINE (J05E)/TROUBLESHOOTING

Glow plug 2 CAN

Engine stop Power supply 2
PTO switch 1 Starter switch 2 TACHO Pulse communication - Power ground 1 Signal ground 1
switch (Signal) (+B)
line
V31 PTO V32 ESTP V33 IG V34 TAC V35 DI V36 CANH V37 - V38 +B1 V39 E1 V40 E11

SHTS021270300006
2–11

EN01H02127030602016004
 2–12

B
After treatment Exhaust
Accelerator Sensor power
- WIF signal - - Sensor ground 7 Sensor ground 9 fuel pressure temperature sensor
sensor 1 supply 3
sensor No.2 (DOC inlet)

V41 - V42 WSW V43 - V44 - V45 E01 V46 E03 V47 VPA V48 FPR V49 THO2 V50 VC

Exhaust
Sensor power DPR refresh temperature sensor
Power supply 3
- - - - Power ground 2 Signal ground 2
supply 4 switch No.4 (DPR outlet) (+B)

V51 VC2 V52 - V53 - V54 - V55 - V56 RGSW V57 THCO V58 +B2 V59 E2 V60 E12

PTO Exhaust
Accelerator DPR differential
- PTO switch 2 - - Sensor ground 8 - accelerator temperature sensor
sensor 2 pressure sensor
sensor No.3 (DOC outlet)

V61 - V62 PTO2 V63 - V64 - V65 E02 V66 - V67 VPA2 V68 VPA1 V69 THCI V70 PEX
ENGINE (J05E)/TROUBLESHOOTING

Sensor power Power supply 4

- - - Stop light switch - - Power ground 3 Power ground 4
supply 5 (+B)

V71 VCPE V72 - V73 - V74 - V75 ST1- V76 - V77 - V78 +BM V79 E3 V80 E4

SHTS021270300007
 C
Intake throttle Exhaust brake After treatment Suction control Suction control
valve motor (+) - - - - -
magnetic valve fuel injector valve (Main) valve (Main)

E1 M+ E2 - E3 EXB E4 - E5 FIV E6 - E7 - E8 - E9 PCV+ E10 PCV-

Air flow sensor Sensor power No.1 Fuel injector No.1 Fuel injector No.4 Fuel injector No.2 Fuel injector No.3 Fuel injector No.2 Fuel injector
- -
(Power) supply 1 (Main) (Main) (Main) (Main) (Main) (Main)

E11 - E12 VAF E13 VCP1 E14 IJ1+ E15 #1 E16 #3 E17 - E18 I2+S E19 #2 E20 #4

Intake throttle Suction control Suction control

valve motor (-) - - - - - - -
valve (Sub) valve (Sub)

E21 M- E22 - E23 - E24 - E25 - E26 - E27 - E28 - E29 PV+S E30 PV-S
ENGINE (J05E)/TROUBLESHOOTING

After treatment Sensor power No.4 Fuel injector No.1 Fuel injector No.4 Fuel injector No.3 Fuel injector No.3 Fuel injector No.2 Fuel injector
- -
fuel cutoff valve supply 2 (Sub) (Sub) (Sub) (Sub) (Sub) (Sub)

E31 FCV E32 - E33 VCP2 E34 I1+S E35 #10 E36 #30 E37 - E38 IJ2+ E39 #20 E40 #40

SHTS021270300008
2–13
 2–14

D
Exhaust Intake air EGR cooler outlet Intake throttle Intake air
Engine oil temperature sensor Fuel temperature Fuel rail pressure
- temperature sensor temperature sensor temperature valve position -
pressure switch No.0 (ATC outlet) (Intercooler outlet) (Air flow sensor sensor 1 (Main)
sensor sensor 2
sensor built-in)
E41 OSW E42 - E43 THO1 E44 THAO E45 THG E46 VTA2 E47 THA E48 THF E49 PCR1 E50 -

CAN
G sensor G sensor
- NE sensor (+) - Sensor ground 1 - Sensor ground 5 communication -
(Supply) (ground)
line
E51 - E52 NE+ E53 VCG E54 G- E55 - E56 EP1 E57 - E58 ETHW E59 CAN+ E60 -

Intake throttle Intakemanifold Coolant Boost pressure Fuel rail pressure Engine coolant
Fuel rail pressure Fuel rail pressure
- valve position temperature temperature temperature -
sensor 2 (Main) sensor 2 (Sub) sensor sensor 1 (Sub)
sensor 1 sensor sensor sensor 2
E61 - E62 VTA1 E63 THIA E64 PCR2 E65 PC2S E66 THW E67 PIM E68 PC1S E69 THWO E70 -
ENGINE (J05E)/TROUBLESHOOTING

CAN
- NE sensor (-) G sensor Air flow sensor NE sensor (SLD) Sensor ground 2 Sensor ground 4 Sensor ground 6 communication -
line
E71 - E72 NE- E73 G+ E74 VG E75 SNE E76 EP2 E77 EPA E78 EVG E79 CAN- E80 -

SHTS021270300009
 E

- - - - - - - - - -

M1 - M2 - M3 - M4 - M5 - M6 - M7 - M8 - M9 - M10 -

- - - - - - - - - -

M11 - M12 - M13 - M14 - M15 - M16 - M17 - M18 - M19 - M20 -

Sensor power
- - Sensor ground 3 - - - - - -
supply 3

M21 - M22 - M23 E05 M24 - M25 VCPR M26 - M27 - M28 - M29 - M30 -
ENGINE (J05E)/TROUBLESHOOTING

- - - - - - - - - -

M31 - M32 - M33 - M34 - M35 - M36 - M37 - M38 - M39 - M40 -

SHTS021270300010
2–15
 2–16

F
Exhaust
- - - - - - - - - temperature sensor
No.1 (ATC inlet)

M41 - M42 - M43 - M44 - M45 - M46 - M47 - M48 - M49 - M50 THO

Sensor power Sensor power

supply 5 - Sensor ground 7 - Sensor ground 8 - - - -
supply 4

M51 VCPA M52 VCTA M53 - M54 ETHA M55 - M56 E07 M57 - M58 - M59 - M60 -

- - - - - - - - - -

M61 - M62 - M63 - M64 - M65 - M66 - M67 - M68 - M69 - M70 -
ENGINE (J05E)/TROUBLESHOOTING

- - - - - - - - - -

M71 - M72 - M73 - M74 - M75 - M76 - M77 - M78 - M79 - M80 -

SHTS021270300011
 ENGINE (J05E)/TROUBLESHOOTING 2–17

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.)

1. CLEANING THE ENGINE ECU CONNECTOR

(1) Check that the engine ECU connector is completely con-
nected to the engine ECU.
(2) Directly spray water around the engine ECU connector by
using a small spray bottle.
NOTICE
Do not remove the connector while at work.
HINT
If it is much dirty, squirt water at the connector sliding portion and
connector surface.
(3) Blow air around the engine ECU connector and engine ECU
surface to remove dirt and foreign matter.
NOTICE
• Do not remove the connector while at work.
• Blow off water with air as much as possible for drying.
(4) Using a small brush, carefully remove dirt and foreign matter
remaining at the sliding portion.
NOTICE
Do not remove the connector while at work.
(5) Using a waste cloth, wipe off around the engine ECU con-
nector and engine ECU surface.
NOTICE
Up
• Do not remove the connector while at work.
Sliding portion • Wipe up water thoroughly.
Rr Lever
(6) If you feel the movement of the lever un-smooth, repeat steps
SHTS021270300012 (1), (2), (3), (4) and (5).
(7) Disconnect the engine ECU connector and check it for depo-
sition of dirt and foreign matter.
a. Set the hook of the connector in the direction of the arrow
to release the lock.

Up

Hook
Rr

SHTS021270300013
2–18 ENGINE (J05E)/TROUBLESHOOTING

b. 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.

Up

Primary latch
Rr Lever

SHTS021270300014

c. Pull out the connector straight.

NOTICE
• Do not insert and remove the connector more than necessary.
• Do not give shocks to the engine ECU.
• Never detach the harness by holding and pulling or prying as it
may result in wire or terminal deformation.
• Never insert a test lead from the rear of the connector.
Up
• Do not paint or apply grease or oil to the connector to maintain
its function and durability.
Rr
HINT
SHTS021270300015 If it cannot be pulled out with a light force, check if the lever is
fully open.
(8) If the side of the harness side connector is found dirty, wipe it
off with a moistened waste cloth while being careful not
allowing dirt and foreign matter to drop.
Wipe off NOTICE
Do not
wipe • Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
• Do not directly spray water.
Harness side
connector

SHTS021270300016

(9) If the engine ECU side connector is found dirty, wipe off its
Do not wipe off side with a moistened waste cloth.
Portions to be the terminal. NOTICE
wipe clean
• Use a thoroughly wrung waste cloth.
• Do not wipe off the terminal opening.
• Do not directly spray water.

Engine ECU (10) Blow air on the terminal part inside the engine ECU side con-
Up
side nector to remove dirt and foreign matter.
connector
Rr
SHTS021270300017
 ENGINE (J05E)/TROUBLESHOOTING 2–19

MOUNTING THE ENGINE ECU CONNECTOR

1. ATTACHING THE ENGINE ECU CONNECTOR

(1) 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

Up

Rr

SHTS021270300018

HINT
Check that it is inserted along the wrong fitting prevention key-
way.

Wrong fitting
prevention keyway
SHTS021270300019

(2) Press the upper part of the harness side connector and
insert the connector uniformly.

Lever

Up

Rr

SHTS021270300020
2–20 ENGINE (J05E)/TROUBLESHOOTING

(3) 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.

Up

Sliding portion
Rr Lever

SHTS021270300021

(4) Move the hook in the direction of the arrow as shown in the
figure until a "click" is heard in order to lock the connector.

Up

Hook
Rr

SHTS021270300022
 ENGINE (J05E)/TROUBLESHOOTING 2–21

INSPECTION
EN01H02127030602016006

1. PRIOR CHECK
(1) 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.
MIL
HINT
• If the MIL (Malfunction Indicator Light) is lit, perform a system
check to see if the malfunction is of the past or present.
SVS Light • In the case of the past malfunction, this light will turn off if a sta-
tus is judged to be normal in 3 times of driving.
• DTC must be cleared on the HINO DX Ⅱ , after MIL comes off.
.

SHTS021270300023
(DEFINITION OF 1 TIME OF DRIVING)
a. Begins with engine start and ends with engine shut off.
b. Begins with engine start and ends after four hours of continu-
ous engine-on operation.
c. Begins at end of the previous four hours of continuous
engine-on operation and ends after four hours of continuous
engine-on operation.
d. Begins at the end of the previous four hours of continuous
engine-on operation and ends with engine shut off.
• Since the normal judgement method and time differ accord-
ing to the malfunction code, a proper definition will be
selected from the above 4 definitions.
• If the malfunction indicator light does not go out, the system is
abnormal. Check the system according to diagnosis on the fol-
lowing page.

MALFUNCTION INDICATOR LIGHT ILLUMINATION

PATTERN

Start
Starter ON
switch
Lock

Running
Engine
Stop

Malfunction ON
indicator
light OFF

TIME
SHTS021270300024
2–22 ENGINE (J05E)/TROUBLESHOOTING

TROUBLE DIAGNOSIS USING THE COM-

PUTER (HINO DX Ⅱ )
EN01H02127030602016007

1. PREPARATION FOR CONNECTING HINO DX Ⅱ

(1) 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" and the dedi-
cated cable will be required.

SPECIAL TOOL: Computer interface

Part name Part No.

DENSO DST-i Set Without Bluetooth 95171-01021

(Without LCD) With Bluetooth 95171-01041
SHTS021270300025

DENSO DST-i Set Without Bluetooth 95171-01031

(With LCD) With Bluetooth 95171-01051

HINT
Install the "Hino Diagnostic eXplorer Ⅱ " (HINO DX Ⅱ ) software in a
computer. For detailed installation procedures, refer to the HINO
DX Ⅱ OPERATION MANUAL supplied on the Global Service Portal
Site (Hino-GSPS).

2. CONNECTION OF HINO DX Ⅱ
(1) Connect the DST-i to the trouble diagnosis connector located
in the electrical component box in the instrument panel or
located in the electrical component box behind the rearmost
seat.
(2) Connect the computer in which the HINO DX Ⅱ is installed, to
the DST-i.
(3) Turn the starter key to "ON".
(4) Turn on the power switch of the computer to start the HINO
DX Ⅱ .
Trouble diagnosis connector
SHTS021270300026
 ENGINE (J05E)/TROUBLESHOOTING 2–23

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

EN01H02127030602016008

NOTICE
A: Torque limit

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

No
Light P0005 — Fuel Cut Valve stuck closed • Fuel cut valve —
Light

• Fuel cut valve

No Malfunction of fuel cutoff
Light P0006 — • Wire harness —
Light valve - low
• ECU (ECU connector)
• Fuel cut valve
No Malfunction of fuel cutoff
Light P0007 — • Wire harness —
Light valve - high
• ECU (ECU connector)
• Camshaft gear
• Flywheel
Crankshaft position sensor
No
Light P0016 — and Camshaft position sen- • Engine speed main sensor —
Light (crankshaft position sensor)
sor - rationality
• Engine speed sub sensor
(camshaft position sensor)

No Exhaust Brake Perfor-

Light P0027 — • Exhaust brake valve —
Light mance

Initialization failure
No
Light P003A — (VNT actuator initialize • VNT controller A
Light
error)

DC motor open circuit • VNT actuator

No
Light P0045 — (VNT actuator motor open A
Light • VNT controller
circuit)

DC motor terminal short cir-

cuit, DC motor short circuit • VNT actuator
No
Light P0047 — (Short to Battery) A
Light • VNT controller
(VNT actuator motor short
to BATT)

DC motor terminal short cir-

cuit, DC motor short circuit • VNT actuator
No
Light P0048 — (Short to GND) A
Light • VNT controller
(VNT actuator motor short
to GND)

Power supply failure (Out of

No
Light P006E — range low) (VNT actuator • VNT controller A
Light
power supply too low)

Power supply failure (Out of

No
Light P006F — range high) (VNT actuator • VNT controller A
Light
power supply too high)
2–24 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Intercooler outlet temperature

sensor
Intake air temperature sen- • ECU (ECU connector)
No sor • Intake air temperature sensor
Light P007B — —
Light (intercooler outlet) - ratio- • Boost pressure sensor
nality • Intake manifold temperature
sensor
• Wire harness
• Intercooler outlet temperature
Intake air temperature sen- sensor
No
Light P007C — sor (intercooler outlet) - out —
Light • ECU (ECU connector)
of range (Out of range low)
• Wire harness
• Intercooler outlet temperature
Intake air temperature sen- sensor
No
Light P007D — sor (intercooler outlet) - out —
Light • ECU (ECU connector)
of range (Out of range high)
• Wire harness
• Engine
• Supply pump
• SCV
• Engine ECU
• Pre fuel filter
• Fuel pipe
• Breather hose
No No Excessive common-rail • Fuel tank feed pipe
P0088 — —
Light Light pressure • Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Fuel filter
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Intake manifold temperature
sensor
• ECU (ECU connector)
Intake air temperature sen- • Intake air temperature sensor
No
Light P0096 — sor (intake manifold) - ratio- (air flow meter built-in) —
Light
nality • Intercooler outlet temperature
sensor
• Boost pressure sensor
• Wire harness
• Intake manifold temperature
Intake air temperature sen- sensor
No
Light P0097 — sor (intake manifold) - out of —
Light • ECU (ECU connector)
range (Out of range low)
• Wire harness
 ENGINE (J05E)/TROUBLESHOOTING 2–25

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Intake manifold temperature

Intake air temperature sen- sensor
No
Light P0098 — sor (intake manifold) - out of —
Light • ECU (ECU connector)
range (Out of range high)
• Wire harness
No Controller error (VNT actu-
Light P00AF — • VNT controller A
Light ator CPU malfunction)

• Air cleaner element

• Intake system
• Air flow meter
• ECU (ECU connector)
No
Light P0101 — Air flow meter - rationality • Wire harness —
Light
• EGR valve
• Diesel throttle valve (intake
throttle valve)
• Intercooler
• Air flow meter
No
Light P0104 — Air flow meter - out of range • ECU (ECU connector) A
Light
• Wire harness
• Boost pressure sensor
No Boost pressure sensor -
Light P0106 — • ECU (ECU connector) —
Light rationality
• Wire harness
• Boost pressure sensor
No Boost pressure sensor - out
Light P0107 — • ECU (ECU connector) A
Light of range (Out of range low)
• Wire harness

Boost pressure sensor - out • Boost pressure sensor

No
Light P0108 — of range • ECU (ECU connector) A
Light
(Out of range high) • Wire harness
Intake air temperature sen- • Intake air temperature sensor
No sor
Light P0111 — • ECU (ECU connector) —
Light (air flow meter built-in) -
rationality • Wire harness

Intake air temperature sen-

sor • Intake air temperature sensor
No
Light P0112 — (air flow meter built-in) - out • ECU (ECU connector) —
Light
of range • Wire harness
(Out of range low)

Intake air temperature sen-

sor • Intake air temperature sensor
No
Light P0113 — (air flow meter built-in) - out • ECU (ECU connector) —
Light
of range • Wire harness
(Out of range high)
2–26 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Coolant temperature sender

No.1
Malfunction of coolant tem- • Coolant temperature sender
No
Light P0115 — perature sensor and intake No.2 A
Light
air temperature sensor
• ECU (ECU connector)
• Wire harness
• Engine coolant temperature
Coolant temperature sensor
No
Light P0117 — sender No.1 - out of range —
Light • ECU (ECU connector)
(Out of range low)
• Wire harness
• Engine coolant temperature
Coolant temperature sensor
No
Light P0118 — sender No.1 - out of range —
Light • ECU (ECU connector)
(Out of range high)
• Wire harness
• Coolant temperature sender
No.1
No Engine coolant temperature • Coolant temperature sender
Light P011A — No.2 —
Light sensor - rationality
• ECU (ECU connector)
• Wire harness
• Diesel throttle (intake throttle
Intake throttle valve position valve) position sensor 1
No
Light P0122 — sensor 1 - out of range (Out —
Light • ECU (ECU connector)
of range low)
• Wire harness
• Diesel throttle (intake throttle
Intake throttle valve position valve) position sensor 1
No
Light P0123 — sensor 1 - out of range (Out —
Light • ECU (ECU connector)
of range high)
• Wire harness
Abnormally in thermostat
No
Light P0126 — (Fixing the thermostat after • Thermostat —
Light
warm-up)

Thermostat - The coolant • Engine coolant temperature

No
Light P0128 — temperature does not reach sensor —
Light
a warmed-up temperature • Thermostat
• Fuel line
• Pre fuel filter
No
Light P0148 — Post injection failure • Injector —
Light
• Engine speed main sensor
(Crankshaft position sensor)
 ENGINE (J05E)/TROUBLESHOOTING 2–27

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Engine
• Supply pump
• SCV
• Engine ECU
• Pre fuel filter
• Fuel pipe
• Breather hose
No Fuel system pressure con- • Fuel tank feed pipe
Light P016E — —
Light trol - high • Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Fuel filter
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Engine
• Supply pump
• SCV
• Engine ECU
• Pre fuel filter
• Fuel pipe
• Breather hose
No Fuel system pressure con- • Fuel tank feed pipe
Light P016F — A
Light trol - low • Fuel tank
• Supply pump gauze filter
• Fuel high-pressure pipe
• Fuel filter
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Fuel temperature sensor
No Fuel temperature sensor
Light P0182 — • ECU (ECU connector) —
Light Low
• Wire harness
• Fuel temperature sensor
No Fuel temperature sensor
Light P0183 — • ECU (ECU connector) —
Light High
• Wire harness
2–28 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Engine
• Supply pump
• SCV
• Engine ECU
• Pre fuel filter
• Fuel pipe
• Breather hose
Fuel rail pressure sensor
No • Fuel tank feed pipe
Light P0191 — (main and sub) - out of —
Light • Fuel tank
range
• Supply pump gauze filter
• Fuel high-pressure pipe
• Fuel filter
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose

Fuel rail pressure sensor • Common rail pressure sensor

No
Light P0192 — (main) - out of range (Out of • Wire harness —
Light
range low) • ECU (ECU connector)

Fuel rail pressure sensor • Common rail pressure sensor

No
Light P0193 — (main) - out of range (Out of • Wire harness —
Light
range high) • ECU (ECU connector)
Fuel rail pressure sensor • Common rail pressure sensor
No (sub)
Light P01A5 — • Wire harness —
Light - out of range (Out of range
low) • ECU (ECU connector)

Fuel rail pressure sensor • Common rail pressure sensor

No (sub)
Light P01A6 — • Wire harness —
Light - out of range (Out of range
high) • ECU (ECU connector)

Fuel injector driver charge

No
Light P0200 — circuit • Engine ECU A
Light
(circuit high)

• ECU (ECU connector)

No Fuel injector - disconnec- • Injector
Light P0201 — —
Light tion (#1cyl) • Engine ECU
• Injector harness

• ECU (ECU connector)

No Fuel injector - disconnec- • Injector
Light P0202 — —
Light tion (#2cyl) • Engine ECU
• Injector harness
 ENGINE (J05E)/TROUBLESHOOTING 2–29

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• ECU (ECU connector)

No Fuel injector - disconnec- • Injector
Light P0203 — —
Light tion (#3cyl) • Engine ECU
• Injector harness

• ECU (ECU connector)

No Fuel injector - disconnec- • Injector
Light P0204 — —
Light tion (#4cyl) • Engine ECU
• Injector harness

• Engine
• Cooling fan
No Engine coolant over tem-
Light P0217 — • Fan clutch —
Light perature condition
• Engine coolant temperature
sensor

• Engine oil level

• Engine speed main sensor
No No
P0219 — Engine overspeed condition (Crankshaft position sensor) —
Light Light
• ECU (ECU connector)
• Wire harness
• Diesel throttle (intake throttle
Intake throttle valve position valve) position sensor 2
No
Light P0222 — sensor 2 - out of range (Out —
Light • ECU (ECU connector)
of range low)
• Wire harness
• Diesel throttle (intake throttle
Intake throttle valve position valve) position sensor 2
No
Light P0223 — sensor 2 - out of range (Out —
Light • ECU (ECU connector)
of range high)
• Wire harness
• Boost pressure sensor
No
Light P0234 — Overboost • VNT controller —
Light
• EGR valve
• Fuel line
• Pre fuel filter
No #1 Injection quantity and
Light P0263 — • Injector —
Light timing
• Engine speed main sensor
(Crankshaft position sensor)

• Fuel line
• Pre fuel filter
No #2 Injection quantity and
Light P0266 — • Injector —
Light timing
• Engine speed main sensor
(Crankshaft position sensor)
2–30 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Fuel line
• Pre fuel filter
No #3 Injection quantity and
Light P0269 — • Injector —
Light timing
• Engine speed main sensor
(Crankshaft position sensor)

• Fuel line
• Pre fuel filter
No All injector (#1 – #4) Injec-
Light P026C — • Injector —
Light tion quantity and timing
• Engine speed main sensor
(Crankshaft position sensor)

• Fuel line
• Pre fuel filter
No All injector (#1 – #4) Injec-
Light P026D — • Injector —
Light tion quantity and timing
• Engine speed main sensor
(Crankshaft position sensor)

• Fuel line
• Pre fuel filter
No #4 Injection quantity and
Light P0272 — • Injector —
Light timing
• Engine speed main sensor
(Crankshaft position sensor)

• Boost pressure sensor

No • Wire harness
Light P0299 — Underboost —
Light • VNT controller
• EGR valve

No • Fuel pipe
Light P0300 — All injector (#1 – #4) Misfire —
Light • Injector

No • Fuel injection pipe

Light P0301 — #1 Misfire —
Light • Injector

No • Fuel injection pipe

Light P0302 — #2 Misfire —
Light • Injector

No • Fuel injection pipe

Light P0303 — #3 Misfire —
Light • Injector

No • Fuel injection pipe

Light P0304 — #4 Misfire —
Light • Injector
• Engine speed main sensor
Crankshaft position sensor (crankshaft position sensor)
Light Light P0335 — A
- disconnection • ECU (ECU connector)
• Wire harness
• Engine speed main sensor
No Crankshaft position sensor (crankshaft position sensor)
Light P0336 — —
Light - rationality • ECU (ECU connector)
• Wire harness
 ENGINE (J05E)/TROUBLESHOOTING 2–31

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Engine speed sub sensor

No Camshaft position sensor (camshaft position sensor)
Light P0340 — —
Light - disconnection • ECU (ECU connector)
• Wire harness
• Engine speed sub sensor
No Camshaft position sensor - (camshaft position sensor)
Light P0341 — —
Light rationality • ECU (ECU connector)
• Wire harness

Glow lamp (wait-to-start • Combination meter

No
Light P0381 — lamp) • ECU (ECU connector) —
Light
- circuit • Wire harness
• Air cleaner element
• Air flow meter
• Boost pressure sensor
• Intake manifold temperature
No
Light P0401 — EGR low flow sensor A
Light
• EGR valve
• EGR cooler
• SCV
• Injector

• EGR valve
• VNT controller
• Air cleaner element
No • Air flow meter
Light P0402 — EGR high flow —
Light • Air intake system
• Boost pressure sensor
• Intake manifold temperature
sensor

Valve position control failure

No - DC motor out of range,
Light P0404 — • EGR valve A
Light functional (EGR valve stick
failure)

EGR valve controller posi-

No tion sensor signal too low
Light P0405 — • EGR valve A
Light (EGR actuator position sen-
sor signal too low)

Valve position sensor mag-

No
Light P0406 — net lost (EGR actuator posi- • EGR valve A
Light
tion sensor signal too high)
2–32 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• EGR cooler outlet temperature

sensor
• ECU (ECU connector)
EGR gas temperature sen- • Wire harness
No
Light P041B — sor • Intake manifold temperature —
Light
- rationality sensor
• Intercooler outlet temperature
sensor
• Boost pressure sensor

EGR gas temperature sen- • EGR cooler outlet temperature

No sor sensor
Light P041C — —
Light - out of range (Out of range • ECU (ECU connector)
low) • Wire harness

EGR gas temperature sen- • EGR cooler outlet temperature

No sor sensor
Light P041D — —
Light - out of range (Out of range • ECU (ECU connector)
high) • Wire harness
No No Tentative determination of
P0420 — — —
Light Light ATC deterioration

• Fuel
• Exhaust temperature sensor
No Determination of ATC dete-
Light P0421 — No.0 —
Light rioration
• Exhaust temperature sensor
No.1

• Fuel
No
Light P0422 — DOC deterioration • Exhaust temperature sensor —
Light
No.3

EGR valve controller motor

No
Light P0489 — (open circuit) (EGR actua- • EGR valve A
Light
tor motor open circuit)

EGR valve controller motor

No
Light P0490 — (short circuit) (EGR actua- • EGR valve A
Light
tor motor short circuit)

No Position failure • EGR valve

Light P049D — A
Light (EGR actuator wiping fault) • EGR controller
• Exhaust brake magnetic valve
No Exhaust brake - circuit (Cir-
Light P04D5 — • Wire harness —
Light cuit low)
• ECU (ECU connector)
• Exhaust brake magnetic valve
No Exhaust brake - circuit (Cir-
Light P04D6 — • Wire harness —
Light cuit high)
• ECU (ECU connector)
No
Light P04DA — EGR feedback failure — —
Light
 ENGINE (J05E)/TROUBLESHOOTING 2–33

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Air cleaner element

• Air intake system
• Air flow meter
Crankcase ventilation sys- • Wire harness
No tem - disconnection
Light P4DB — • ECU (ECU connector) —
Light between the CV valve and
the intake manifold • EGR valve
• Diesel throttle valve (intake
throttle valve)
• Intercooler
• Combination meter
No
Light P0500 — Vehicle speed sensor - low • Wire harness —
Light
• ECU (ECU connector)
• Combination meter
No
Light P0501 — Vehicle speed sensor - high • Wire harness —
Light
• ECU (ECU connector)
• Brake switch
No No
P0504 — Brake Switch Correlation • Wire harness —
Light Light
• ECU (ECU connector)
No Idle speed abnormality
Light P0506 — — —
Light (Low)

No Idle speed abnormality

Light P0507 — — —
Light (High)

• Engine oil
No Engine oil pressure ratio- • Oil pressure switch
Light P0521 — —
Light nality • Wire harness
• ECU (ECU connector)

• Engine oil
No Engine oil pressure Too • Oil pressure switch
Light P0524 — —
Light Low • Wire harness
• ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.1 No.1
Light P0545 — —
Light - out of range (Out of range • Wire harness
low) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.1 No.1
Light P0546 — —
Light - out of range (Out of range • Wire harness
high) • ECU (ECU connector)
No Abnormality of injection rate
Light P054E — — —
Light during idling (Low)

No Abnormality of injection rate

Light P054F — — —
Light during idling (High)
2–34 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Fuse
• Fusible link
Battery voltage - out of • Battery cable
No
Light P0562 — range —
Light • Alternator
(Out of range low)
• Wire harness
• ECU (ECU connector)

• Fuse
• Fusible link
Battery voltage - out of • Battery cable
No
Light P0563 — range —
Light • Alternator
(Out of range high)
• Wire harness
• ECU (ECU connector)

Controller store data error

No
Light P0603 — (Engine ECU EEPROM • Engine ECU —
Light
error)

No
Light P0605 — Flash ROM error — A
Light

No
Light P0606 — Control module processor — —
Light

No Control module perfor-

Light P0607 — — A
Light mance

No
Light P0610 — VIN data error — —
Light

No Fuel injector driver charge

Light P0611 — — A
Light circuit - circuit (circuit low)

• Starter key
No • Wire harness
Light P0617 — Starter key - rationality —
Light • ECU (ECU connector)
• Neutral start switch

Suction control valve for • SCV

No
Light P0628 — fuel supply pump - circuit • Wire harness —
Light
(Circuit low) • ECU (ECU connector)

Suction control valve for • SCV

No
Light P0629 — fuel supply pump - circuit • Wire harness A
Light
(Circuit high) • ECU (ECU connector)
Controller store data error
No
Light P062F — (VNT actuator EEPROM • VNT controller A
Light
error)

No VIN Not Programmed or

Light P0630 — • Vehicle control ECU. —
Light Mismatch
 ENGINE (J05E)/TROUBLESHOOTING 2–35

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

ECU sensor power supply 1 • Wire harness

No No
P0642 — failure —
Light Light • ECU (ECU connector)
(Out of range low)

• Common rail pressure sensor 1

• Accelerator sensor 2
• Wire harness
• Boost pressure sensor
ECU sensor power supply 1
No No • Diesel throttle (intake throttle
P0643 — failure —
Light Light valve) position sensor
(Out of range high)
• Engine speed sub sensor
(camshaft position sensor)
• Wire harness
• ECU (ECU connector)
• Fuse
Glow controller - Battery for • Fusible link
No glow plug open, GND short
Light P064C — • Glow control unit —
Light Glow controller - Over tem-
perature • Wire harness
• ECU (ECU connector)

ECU sensor power supply 2 • Wire harness

No No
P0652 — failure —
Light Light • ECU (ECU connector)
(Out of range low)

• Common rail pressure sensor 2

• Wire harness
• Accelerator sensor 1
• DPR differential pressure sen-
ECU sensor power supply 2 sor
No No
P0653 — failure —
Light Light • PTO accelerator sensor
(Out of range high)
• Aftertreatment fuel injection
line pressure sensor
• Wire harness
• ECU (ECU connector)

Glow plug (Circuit low) • Fusible link

No (#1cyl), • Glow control unit
Light P0671 — —
Light Glow plug (Circuit high) • Wire harness
(#1cyl) • Glow plug

Glow plug (Circuit low) • Fusible link

No (#2cyl), • Glow control unit
Light P0672 — —
Light Glow plug (Circuit high) • Wire harness
(#2cyl) • Glow plug

Glow plug (Circuit low) • Glow control unit

No (#3cyl),
Light P0673 — • Wire harness —
Light Glow plug (Circuit high)
(#3cyl) • Glow plug
2–36 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Glow plug (Circuit low) • Glow control unit

No (#4cyl),
Light P0674 — • Wire harness —
Light Glow plug (Circuit high)
(#4cyl) • Glow plug

Glow controller - Battery for

glow controller open, GND • Glow control unit
No
Light P0683 — short Glow controller - Glow • Wire harness —
Light
control signal Glow control- • ECU (ECU connector)
ler - Diagnosis signal

• Main relay
No ECM/PCM Power Relay
Light P0686 — • Wire harness —
Light Control Circuit high
• ECU (ECU connector)

No No ECU sensor power supply 3 • Wire harness

P0698 — —
Light Light failure (Out of range low) • ECU (ECU connector)
No No ECU sensor power supply 3
P0699 — • Boost pressure sensor —
Light Light failure (Out of range high)

No No ECU sensor power supply 4 • Wire harness

P06A4 — —
Light Light failure (Out of range low) • ECU (ECU connector)
No No ECU sensor power supply 4 • Diesel throttle (intake throttle
P06A5 — —
Light Light failure (Out of range high) valve) position sensor

• Air flow meter

No No Air flow meter power supply
P06D3 — • Wire harness —
Light Light failure Short to GND
• ECU (ECU connector)
• Air flow meter
No No Air flow meter power supply
P06D4 — • Wire harness —
Light Light failure (High)
• ECU (ECU connector)
No
Light P0700 — HV clutch system failure — —
Light

Transmission information
No
Light P073D — (automatic transmission) - • Neutral switch —
Light
rationality

• Starter cut relay

No No
P081A — Starter Disable Circuit Low • Wire harness —
Light Light
• ECU (ECU connector)

No No • Wire harness
P081B — Starter Disable Circuit High —
Light Light • ECU (ECU connector)
No
Light P0A7B — HV BATTELY system failure — —
Light

No
Light P0AC4 — HV system failure — —
Light

No
Light P0CA1 — HV MOTOR system failure — —
Light
 ENGINE (J05E)/TROUBLESHOOTING 2–37

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• PTO accelerator sensor

No No PTO accelerator sensor
P1133 — • Wire harness —
Light Light (Hi)
• ECU (ECU connector)
• Common rail pressure sensor
No Fuel rail pressure sensor -
Light P119F — • Wire harness —
Light rationality
• ECU (ECU connector)
• Differential pressure hose and
pipe
No Differential pressure sen- • Differential pressure sensor
Light P1426 — —
Light sor - rationality
• Wire harness
• ECU (ECU connector)

Differential pressure sensor • Differential pressure sensor

No
Light P1427 — - out of range (Out of range • Wire harness —
Light
low) • ECU (ECU connector)

Differential pressure sensor • Differential pressure sensor

No
Light P1428 — - out of range (Out of range • Wire harness —
Light
high) • ECU (ECU connector)
Valve position control failure
- DC motor out of range,
No No
P1458 — functional • EGR valve A
Light Light
(EGR actuator over temp
warning level)

Controller high temperature

No
Light P1459 — (EGR actuator over temp • EGR valve A
Light
severe level)

Controller store data error

No
Light P14B0 — (EGR actuator abnormal • EGR valve A
Light
information reading)

EGR controller power sup-

No ply open circuit (EGR actu-
Light P14B2 — • EGR valve A
Light ator power supply open
circuit)

Battery voltage (high)

No
Light P14B3 — (EGR actuator power sup- • EGR valve A
Light
ply too high)

Battery voltage (low) (EGR

No
Light P14B4 — actuator power supply too • EGR valve A
Light
low)

EGR valve controller tem-

perature sensor 1 (Signal
No
Light P14B7 — too low) (EGR actuator • EGR valve A
Light
temp. sensor 1 signal too
low)
2–38 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

EGR valve controller tem-

perature sensor 1 (Signal
No
Light P14B8 — too high) (EGR actuator • EGR valve A
Light
temp. sensor 1 signal too
high)

EGR valve controller tem-

perature sensor 2 (Signal
No
Light P14BC — too low) (EGR actuator • EGR valve A
Light
temp. sensor 2 signal too
low)

EGR valve controller tem-

perature sensor 2 (Signal
No
Light P14BD — too high) (EGR actuator • EGR valve A
Light
temp. sensor 2 signal too
high)

EGR valve controller tem-

perature sensor 1, 2 - ratio-
No
Light P14BF — nality (EGR actuator temp. • EGR valve A
Light
sensor 1 performance
invalid)

• Radiator curtain
• Air cleaner element
• Radiator fan
No
Light P1515 — Charge air undercooling • Fan clutch —
Light
• Intercooler
• Intercooler tube
• Radiator

• Engine stop switch

No No Engine stop switch mal-
P1530 — • Wire harness —
Light Light function
• ECU (ECU connector)
• PM sensor
• DPF filter
• Boost pressure sensor
• Engine coolant temperature
sensor
• Intake air temperature sensor
No Filtering performance
Light P2002 — • DEF SCR temperature sensor —
Light (missing substate)
(SCR inlet)
• EGR valve
• VNT controller
• SCV
• Injector
• Engine ECU
 ENGINE (J05E)/TROUBLESHOOTING 2–39

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Exhaust pipe
• Injector
• Engine
No
Light P200C — DPF over temperature • Exhaust temperature sensor —
Light
No.3
• Exhaust temperature sensor
No.4

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.0 No.0
Light P2032 — —
Light - out of range (Out of range • Wire harness
low) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.0 No.0
Light P2033 — —
Light - out of range (Out of range • Wire harness
high) • ECU (ECU connector)

No No • DEF tank
P203F — Empty reductant tank A
Light Light • DEF tank level sensor
Light No
or Light Reductant System Perfor-
P204F — — —
No or mance
Light Light

No Reductant quality sensor -

Light P206B — • DEF sensor —
Light rationality

• DEF
• Engine
• Air flow meter
• DEF SCR temperature sensor
No
Light P207F — Improper reductant (SCR inlet) A
Light
• DEF pipe
• DEF injector
• NOx sensor
• SCR catalyst

• Exhaust temperature sensor

No Exhaust temperature sen- No.1
Light P2080 — —
Light sor No.1 - rationality • Wire harness
• ECU (ECU connector)
• Exhaust temperature sensor
No Exhaust temperature sen- No.0
Light P2084 — —
Light sor No.0 - rationality • Wire harness
• ECU (ECU connector)

Malfunction of fuel addition • Fuel dosing valve

No
Light P20CD — valve • Wire harness —
Light
[Short-circuit] • ECU (ECU connector)
2–40 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Malfunction of fuel addition

No
Light P20CE — valve • Fuel dosing valve —
Light
[+B short-circuit]

Malfunction of fuel addition

No
Light P20CF — valve [Leak] (Continuous — —
Light
injection)

No Exhaust Fuel Doser open/ • Fuel pipe (for aftertreatment)

Light P20D8 — —
Light close stuck • Fuel dosing valve

Aftertreatment Fuel Injec- • Aftertreatment fuel pressure

No
Light P20DE — tion Line Pressure Sensor sensor —
Light
Performance Invalid • Fuel pipe (for aftertreatment)
• Aftertreatment fuel injection
Aftertreatment Fuel Injec- line pressure sensor
No
Light P20DF — tion Line Pressure Sensor —
Light • Wire harness
Signal Too Low
• ECU (ECU connector)
• Aftertreatment fuel injection
Aftertreatment Fuel Injec- line pressure sensor
No
Light P20E0 — tion Line Pressure Sensor —
Light • Wire harness
Signal Too High
• ECU (ECU connector)
• DEF solution
• Engine
• Air flow meter
• DEF SCR temperature sensor
No NOx converting catalyst (SCR inlet)
Light P20EE — —
Light conversion efficiency • DEF pipe
• DEF injector
• Exhaust pipe
• NOx sensor
• SCR catalyst

Temporary determination of
No No purification drop/Tempo-
P20EF — — —
Light Light rary determination of water
quality concentration

DC motor for intake throttle • Diesel throttle (intake throttle)

No
Light P2100 — valve - circuit (Open circuit • Wire harness —
Light
(circuit low)) • ECU (ECU connector)
• Air cleaner element
• Air hose
No Intake throttle valve - func- • Air pipe
Light P2101 — —
Light tional • Exhaust muffler (exhaust pipe)
• Exhaust brake valve
• Diesel throttle (intake throttle)
 ENGINE (J05E)/TROUBLESHOOTING 2–41

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

DC motor for intake throttle • Diesel throttle (intake throttle)

No
Light P2103 — valve - circuit (Short circuit • Wire harness A
Light
(circuit high)) • ECU (ECU connector)
No No Throttle/Pedal Position Sen-
P2120 — — —
Light Light sor/Switch "D" Circuit

Accelerator pedal position • Accelerator sensor

No sensor 1
Light P2122 — • Wire harness —
Light - out of range (Out of range
low) • ECU (ECU connector)

Accelerator pedal position • Accelerator sensor

No sensor 1
Light P2123 — • Wire harness —
Light - out of range (Out of range
high) • ECU (ECU connector)

Accelerator pedal position • Accelerator sensor

No sensor 2
Light P2127 — • Wire harness —
Light - out of range (Out of range
low) • ECU (ECU connector)

Accelerator pedal position • Accelerator sensor

No sensor 2
Light P2128 — • Wire harness —
Light - out of range (Out of range
high) • ECU (ECU connector)

• Diesel throttle (intake throttle

Intake throttle valve position valve) position sensor
No
Light P2135 — sensor —
Light • Wire harness
- rationality
• ECU (ECU connector)

Accelerator pedal position • PTO accelerator sensor

No
Light P2138 — sensor • Accelerator sensor —
Light
- rationality • ECU (ECU connector)
• Injector
No Fuel injector driver circuit 1
Light P2146 — • Wire harness A
Light - circuit (circuit open)
• ECU (ECU connector)

No Fuel injector driver circuit 1 • Injector

Light P2147 — A
Light - circuit (circuit low) • Wire harness

No Fuel injector driver circuit 1 • Injector

Light P2148 — A
Light - circuit (circuit high) • Wire harness
• Injector
No Fuel injector driver circuit 2
Light P2149 — • Wire harness A
Light - circuit (circuit open)
• ECU (ECU connector)

No Fuel injector driver circuit 2 • Injector

Light P2150 — A
Light - circuit (circuit low) • Wire harness

No Fuel injector driver circuit 2 • Injector

Light P2151 — A
Light - circuit (circuit high) • Wire harness
2–42 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Coolant temperature sender

Coolant temperature No.2
No
Light P2184 — sender No.2 - out of range —
Light • Wire harness
(Out of range low)
• ECU (ECU connector)
• Coolant temperature sender
Coolant temperature No.2
No
Light P2185 — sender No.2 - out of range —
Light • Wire harness
(Out of range high)
• ECU (ECU connector)
• NOx sensor No.1 (SCR
upstream)
• NOx sensor No.2 (SCR down-
stream)
• Exhaust temperature sensor
No.3

• DEF SCR temperature sensor

(SCR inlet)
NOx sensor (SCR • EGR valve
No
Light P2201 — upstream) • Air flow meter —
Light
- Performance
• Boost pressure sensor
• Intake manifold temperature
sensor
• Coolant temperature sender
No.1
• Coolant temperature sender
No.2
• Wire harness
• Engine ECU
No Barometric pressure sensor
Light P2227 — • Boost pressure sensor —
Light - rationality

Barometric pressure sensor

No
Light P2228 — - out of range (out of range — A
Light
low)

Barometric pressure sensor

No
Light P2229 — - out of range (out of range — A
Light
high)

• Pre fuel filter

No No • Fuel filter water level sensor
P2269 — Water in Fuel Condition —
Light Light • Wire harness
• ECU (ECU connector)
 ENGINE (J05E)/TROUBLESHOOTING 2–43

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• VNT controller
• EGR valve
No Boost pressure slow • Air cleaner
Light P226C — —
Light response • Air intake system
• Boost pressure sensor
• VNT actuator

• NOx sensor No.1 (SCR

upstream)
• NOx sensor No.2 (SCR down-
stream)
• exhaust temperature sensor
No.3
• DEF SCR temperature sensor
(SCR inlet)
NOx sensor (SCR down- • EGR valve
No stream) • Air flow meter
Light P229F — —
Light - Performance and Monitor-
ing capability • Boost pressure sensor
• Intake manifold temperature
sensor
• Coolant temperature sender
No.1
• Coolant temperature sender
No.2
• Wire harness
• Engine ECU
No Nozzle stuck (VNT stick fail-
Light P22D3 — • VNT controller A
Light ure)

• EGR valve
• VNT controller
• Air cleaner element
• Air flow meter
No
Light P240F — EGR flow slow response • Intake system —
Light
• Boost pressure sensor
• Intake manifold temperature
sensor
• Injector
• Injector
• Pipe
No No
P2428 — Improper ATC temperature • Hose —
Light Light
• ATC
• DPR

• Exhaust temperature sensor

No Exhaust temperature sen- No.2
Light P242B — —
Light sor No.2 - rationality • Wire harness
• ECU (ECU connector)
2–44 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.2 No.2
Light P242C — —
Light - out of range (Out of range • Wire harness
low) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.2 No.2
Light P242D — —
Light - out of range (Out of range • Wire harness
high) • ECU (ECU connector)
• Exhaust temperature sensor
No.3
• Differential pressure sensor
• DPR filter
• Exhaust temperature sensor
No Filtering performance No.4
Light P244A — —
Light (missing substrate) • EGR valve
• VNT controller
• Diesel throttle valve (intake
throttle valve)
• SCV
• Injector
• DPR
• Differential pressure sensor
• Engine
• Exhaust temperature sensor
No.3
• Exhaust temperature sensor
No No.4
Light P244B — Incomplete regeneration • DPF indicator light A
Light
• DPR switch
• Neutral switch
• Accelerator switch
• PTO signal
• External accelerator signal
• Injector
• EGR cooler outlet gas tempera-
ture sensor
• EGR cooler
No • EGR valve
Light P2457 — EGR cooler performance —
Light • Diesel throttle valve (intake
throttle valve)
• SCV
• Injector
 ENGINE (J05E)/TROUBLESHOOTING 2–45

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• Exhaust pipe
• Exhaust brake valve
• Exhaust temperature sensor
No.3
No DPR manual regeneration
Light P2458 — • Exhaust temperature sensor —
Light failure
No.1
• DPR
• Coolant temperature sensor
• Engine
No
Light P2459 — Frequent regeneration — —
Light

• DPF indicator light

• DPR switch
No • Neutral switch
Light P2463 — DPF clogged A
Light • Accelerator switch
• PTO signal
• External accelerator signal

• Exhaust temperature sensor

No Exhaust temperature sen- No.3
Light P246F — —
Light sor No.3 - rationality • Wire harness
• ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.3 No.3
Light P2470 — —
Light - out of range (Out of range • Wire harness
low) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.3 No.3
Light P2471 — —
Light - out of range (Out of range • Wire harness
high) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.4 No.4
Light P2481 — —
Light - out of range (Out of range • Wire harness
low) • ECU (ECU connector)

Exhaust temperature sen- • Exhaust temperature sensor

No sor No.4 No.4
Light P2482 — —
Light - out of range (Out of range • Wire harness
high) • ECU (ECU connector)
• Exhaust temperature sensor
No Exhaust temperature sen- No.4
Light P2483 — —
Light sor No.4 - rationality • Wire harness
• ECU (ECU connector)
2–46 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Closed Loop DPF Regener-

No • Exhaust temperature sensor
Light P24A0 — ation Control At Limit —
Light No.3
- Temperature Too Low

Closed Loop DPF Regener-

No
Light P24A1 — ation Control At Limit — —
Light
- Temperature Too High

• Engine oil
• Exhaust pipe
• Injector
• Exhaust brake valve
No Excessive DPR fuel addi-
Light P24A2 — • EGR valve —
Light tion rate
• VNT controller
• Exhaust temperature sensor
No.3
• DPR
• PM sensor
No Abnormally in PM sensor
Light P24A3 01 • Battery —
Light power supply (high voltage)
• Wire harness
04, 05, 06,
No
Light P24AE 14, 25, 26, Abnormally in PM sensor • PM sensor —
Light
27, 28

No PM sensor circuit range/ • PM sensor

Light P24AF 23 —
Light Performance • DPR filter
No Malfunction of the PM sen-
Light P24B0 19, 20, 21 • PM sensor —
Light sor

No Malfunction of the PM sen-

Light P24B1 18 • PM sensor —
Light sor

No 10, 11, 15, Abnormal of PM sensor

Light P24B4 • PM sensor —
Light 17 heater

No PM sensor Heater Resis- • PM sensor

Light P24B7 08 —
Light tance • Battery
• PM sensor
No PM sensor temperature cir-
Light P24C7 09 • DEF SCR Temperature sensor —
Light cuit range/Performance
(SCR inlet)

• PM sensor
No Abnormally in PM sensor
Light P24D0 02 • Battery —
Light power supply (low voltage)
• Wire harness

No PM sensor regeneration • PM sensor

Light P24D1 12 —
Light incomplete • DPR filter

No PM sensor exhaust sample • PM sensor

Light P24DA 07 —
Light error • DPR filter
 ENGINE (J05E)/TROUBLESHOOTING 2–47

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Nozzle position sensor fail-

No ure range (High level) (VNT • VNT controller
Light P2562 — A
Light actuator position sensor • VNT actuator
performance invalid)

Nozzle operating range fail-

ure • VNT controller
No
Light P259E — - NARROW (VNT actuator A
Light • Turbocharger
wiping error (too narrow
range))

Nozzle operating range fail-

No ure
Light P259F — • VNT controller A
Light - WIDE (VNT actuator wip-
ing error (too wide range))

• Engine
• Supply pump
• Pre fuel filter
• Engine ECU
• Fuel hose
• Fuel tank breather
• Fuel tank feed pipe
No No Fuel Pump Low Flow/Per- • Supply pump gauze filter
P2635 — —
Light Light formance • Fuel high-pressure pipe
• Fuel filter
• SCV
• Common rail pressure sensor
• Engine speed main sensor
(crankshaft position sensor)
• Fuel return pipe and hose
• Fuel pipe
No Fuel injector adjustment
Light P268A — • Injector —
Light data error

No Fuel injector adjustment

Light P2696 — • Injector —
Light data error

No
Light P26C8 — Vehicle system failure — —
Light

• NOx sensor No.1 (upstream)

• Air flow meter
Characteristic abnormality
No • Engine speed main sensor
Light P2A00 — Abnormally in NOx sensor —
Light (crankshaft position sensor)
No.1 (upstream) (O2)
• Injector
• Wire harness
2–48 ENGINE (J05E)/TROUBLESHOOTING

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

• NOx sensor No.2 (downstream)

• Air flow meter
Characteristic abnormality
No • Engine speed main sensor
Light P2A01 — Abnormally in NOx sensor —
Light (crankshaft position sensor)
No.2 (downstream) (O2)
• Injector
• Wire harness
• DEF
No No
P2BA9 — Insufficient Reagent Quality • DEF tank A
Light Light
• DEF quality sensor
Engine ECU CAN commu-
No
Light U0073 — nication bus for Emission — A
Light
control system - bus off

Engine ECU CAN commu- • Connector

No
Light U010A — nication • Wire harness A
Light
(EGR valve control) • EGR controller
• Connector
No VNT actuator CAN commu-
Light U010C — • Wire harness A
Light nication error
• VNT controller

Engine ECU CAN commu- • Connector

No
Light U010E — nication • Wire harness —
Light
(DeNOx ECU) • DCU
• Connector
No CAN Bus-Line Open From
Light U0293 — • Wire harness —
Light HV
• HV system
Engine ECU CAN commu- • Connector
No nication
Light U029D — • NOx sensor No.1 —
Light (NOx sensor (SCR
upstream)) • Wire harness

Engine ECU CAN commu- • Connector

No nication
Light U029E — • NOx sensor No.2 —
Light (NOx sensor (SCR down-
stream)) • Wire harness

Engine ECU CAN commu- • Connector

No
Light U02A2 — nication • DEF sensor —
Light
(DEF tank sensor) • Wire harness

Engine ECU CAN commu- • Connector

No
Light U02A3 — nication • PM sensor —
Light
(PM sensor) • Wire harness
No No Software Incompatibility
U0301 — — —
Light Light With DeNOx ECU
 ENGINE (J05E)/TROUBLESHOOTING 2–49

DIAGNOSTIC TROUBLE CODE (DTC) TABLE

2 digit
SVS DTC
MIL diagnosis DIAGNOSIS ITEM INSPECTION ITEM SYMPTOM
Light No.
code

Engine ECU CAN commu- • Connector

No
Light U1001 — nication bus for Vehicle • Wire harness —
Light
control - bus off • Vehicle control ECU
Light • Connector
Engine ECU CAN commu-
or No
U110A — nication • Wire harness —
No Light
(Vehicle ECU) • Vehicle control ECU
Light

NOTICE
• It is necessary to reset the ECU default value using the diagnosis tool at the time of supply pump service
replacement. In addition, the ECU has a function enabling it to learn the performance of the supply pump at the
time of ECU service replacement, so ensure sufficient time (several minutes) is available.
• When an injector is newly installed in a vehicle, it is necessary to enter the ID codes in the engine ECU using
the Diagnostic tool.
2–50 ENGINE (J05E)/TROUBLESHOOTING

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 DTC

Boost pressure sensor P0107

E33 Diesel throttle (intake throttle valve) position sensor 1 P0122

Common rail pressure sensor (Main) P0193

PTO accelerator sensor —

V71
Differential pressure sensor P1428

• If P0642 or P0652 has also occurred, the sensor supply of the ECU may be in abnormal condition or the GND may be
shorted somewhere in the following sensor group.

Group Sensor DTC

Accelerator pedal position sensor 1 P2122

P01A5
Common rail pressure sensor (Sub)
P01A6
P0642
P1427
Differential pressure sensor
P1428

PTO accelerator sensor P1133

Boost pressure sensor P0107

P0192
Common rail pressure sensor (Main)
P0193
P0652
Diesel throttle (intake throttle valve) position sensor 1 P0122

Accelerator pedal position sensor 1 P2127

Camshaft position sensor P0016

 ENGINE (J05E)/TROUBLESHOOTING 2–51

GROUP SHARING THE SENSOR GND TERMINAL

EN01H02127030602016010

ECU terminal Sensor

E56 Common rail pressure sensor (Sub)

Exhaust temperature sensor No.0

Exhaust temperature sensor No.1

E58
Engine coolant temperature sensor

Intake air temperature sensor

Fuel temperature sensor

E76 Intake manifold temperature sensor

Common rail pressure sensor (Main)

Boost sensor
E77
Diesel throttle (intake throttle valve) position sensor 1

Accelerator sensor 1
V45
PTO accelerator sensor

Exhaust temperature sensor No.2

Exhaust temperature sensor No.3

V46
Exhaust temperature sensor No.4

Differential pressure sensor

V65 Accelerator sensor 2

2–52 ENGINE (J05E)/TROUBLESHOOTING

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

• The system itself is suspected of being faulty due to the broken harness or connector or supply circuit failure of the CAN
communication circuit for each actuator and controller.

ENGINE EQUIPMENT/EMISSION CONTROL DEVICE CAN LINE (250 k)

<Diesel>
Engine peripherals/ Diesel aftertreatment system CAN line

CAN - TMN2 DCU

(Terminator) J/C ENG J/C ENG J/C PM J/C CAN J/C DEF (Terminator)
8 9 CAN 10 DIESEL 11 12 13
CAN2 DIESEL SSR

1 2 3 4 5 6 7

VNT EGR PM NOx NOx DEF

Engine ECU
Controller Controller Sensor Sensor No.1 Sensor No.2 Sensor
<Hybrid>
Engine peripherals/ Diesel aftertreatment system CAN line

CAN - TMN2 DCU

(Terminator) J/C ENG J/C ENG 10 J/C HV2 11 J/C PM J/C DEF (Terminator)
8 9 12 J/C HV1 13 14
CAN2 CAN HV SSR

1 2 3 4 5 6 7

VNT EGR NOx PM NOx DEF

Engine ECU Sensor
Controller Controller Sensor No.2 Sensor Sensor No.1

SHTS021270300027
 ENGINE (J05E)/TROUBLESHOOTING 2–53

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE

(ENGINE ECU)

Malfunction Part Case

2 U010C

3 U010A

4 U02A3

5 U029D

6 U029E

7 U02A2

1, 8-14 U010A, U010C, U029D, U029E, U0073, U010E, U02A2, U02A3

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE

(DCU)

Malfunction Part Case

5 U029D

6 U029E

7 U02A2

1, 8-14 U029D, U029E, U0029, U0100, U02A2

2–54 ENGINE (J05E)/TROUBLESHOOTING

ENGINE CONTROL/DIAGNOSIS CAN LINE (500 k)

<Diesel>
Engine control/ Diagnosis CAN Line

CAN-TMN2 DCU
(Terminator) 4 J/C_CAN2 (22P) 5 J/C_CAN2 6 J/C_CAN1
J/C_CAN1 (10P)
(10P) 7 J/C_CAN5 8 (Terminator)

1 2 3

Engine
DLC AT ECU VCS ECU ABS ECU
ECU

<Hybrid>
Engine control/ Diagnosis CAN Line

HV PCU DCU
(Terminator) 4 J/C_CAN1 (10P) 5 J/C_CAN2 (22P) 6 J/C_CAN2 7 J/C_CAN5 8 (Terminator)

1 2 3

Engine
ABS ECU DLC AT ECU VCS ECU
ECU

SHTS021270300028

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE

(ENGINE ECU)

Malfunction Part Case

1, 3 Communication failure of the HINO DX Ⅱ

2 U1001, U110A Failure to communicate the VCU

4, 5, 6, 7, 8 U0293, U1001, U110A, Communication failure of the HINO DX Ⅱ

CAN COMMUNICATION LINE MALFUNCTION PART DETERMINATION TABLE

(DCU)

Malfunction Part Case

1 Communication failure of the HINO DX Ⅱ

4, 5, 6, 7, 8 U0038, Communication failure of the HINO DX Ⅱ

 ENGINE (J05E)/TROUBLESHOOTING 2–55

PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (250 k)

EN01H02127030602016012

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Check that the any DTC other than CAN communication system
DTC (U****) has been detected.

SHTS021270300029

Has a DTC other than CAN communication system DTC (U****) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2–56 ENGINE (J05E)/TROUBLESHOOTING

2 Check for +B/GND short-circuit in CAN H-line

1. Set the starter key to the "LOCK" position.

+B2
LEP
GND4
LEW
GND1
LET 2. Disconnect the following sensors and controllers connected to the
+B3
LEQ
GND5
LEX
GND2
LEU
Engine peripherals and after-treatment CAN line.
+B4
LER
+B1
LEN
GND3
LEV
• DCU(53P)
• EGR controller, VNT controller
CAH1
LF5
• NOx sensors 1 and 2, DEF sensor
CAL1
LF6 • CAN-TMN2 (terminating resistance)
TE1B
LF2

TE1A CAH0
LF1

TE2B
LEY

CAL0
3. Use the electrical tester to check the continuity between the follow-
LF4 LEZ

TE2A
LF3
ing terminals.
(1) Between the CAH0 terminal in the DCU (53P) vehicle side
connector and the 16th terminal in the DLC (16P).
ISGW
LES (2) Between the CAH0 terminal in the DCU (53P) vehicle side
connector and the 4th terminal in the DLC (16P).

Measurement Tester
Standard values
conditions connections
SHTS021270300030
DCU vehicle-side
connector –
Diagnostic con-
Starter key: LOCK No Continuity
nector
CAH0 – 16th
CAH0 – 4th

Do the measurements meet the standard value?

YES NO

Go to step 3. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k)" and check the CAN bus line.
 ENGINE (J05E)/TROUBLESHOOTING 2–57

3 Check for +B/GND short-circuit in CAN L-line

1. Use the electrical tester to check the continuity between the follow-
ing terminals.
+B2 GND4 GND1
LEP LEW LET
(1) Between the CAL0 terminal in the DCU (53P) vehicle side
+B3
LEQ
GND5
LEX
GND2
LEU
connector and the 16th terminal in the DLC(16P).
+B4
LER
+B1
LEN
GND3
LEV (2) Between the CAL0 terminal in the DCU (53P) vehicle side
connector and the 4th terminal in the DLC(16P).
CAH1
LF5
Measurement Tester
CAL1 Standard values
TE1B
LF6
conditions connections
LF2

TE1A CAH0
LF1

TE2B
LEY

CAL0
DCU vehicle-side
connector –
LF4 LEZ

TE2A
LF3

Diagnostic con-
Starter key: LOCK No Continuity
nector
ISGW
LES CAL0 – 16th
CAL0 – 4th

SHTS021270300031

Do the measurements meet the standard value?

YES NO

Go to step 4. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (250 k)" and check the CAN bus line.
2–58 ENGINE (J05E)/TROUBLESHOOTING

4 Check the terminating resistance

1. 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-
ISGW
LES
TMN2.

CAH0 Measurement Tester

Standard values
TE2A
LF3 conditions connections
TE2B CAH0
LF4 LEY

TE1A
LF1
CAL0
LEZ DCU (53P):
TE1B
CAH0 – CAL0
110 – 130 
LF2

CAL1 Starter key: LOCK

LF6
CAL0 CAN-TMN2:
CANP – CANN
CAH1
LF5

+B4 +B1 GND3

LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

CANP CANN

SHTS021270300032

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the faulty part.

After replacing the part, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–59

5 Check the resistance

1. Connect the DCU (53P) connector and CAN-TMN2 connector.

2. 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).
ISGW
LES

CAH0 Measurement Tester

Standard values
TE2A
LF3
conditions connections
TE2B CAH0

DCU (53P):
LF4 LEY

TE1A CAL0
Starter key: LOCK 45 – 75 
CAH0 – CAL0
LF1 LEZ

TE1B
LF2

CAL1
LF6

CAH1
CAL0
LF5

+B4 +B1 GND3

LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

SHTS021270300033

Do the measurements meet the standard value?

YES NO

Procedure completed. Refer to "DISCONNECTION INSPECTION

CAN bus line (main line and trunk lines) FOR ENGINE CAN_H COMMUNICATION L
between terminating resistances is normal. LINE (250 k)" and check the CAN bus line.
Go to the diagnostic procedure for the
detected DTC.
2–60 ENGINE (J05E)/TROUBLESHOOTING

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (250 k) [DIESEL]
EN01H02127030602016013

1 Inspecting the wire harness for disconnection: CAN bus line between the J/C_DEF_SSR and
DCU (malfunction area 13)

1. Turn the starter key to the "LOCK" position.

CANH
CANL 2. Disconnect the connectors of the following sensors and controllers
which are connected to the engine CAN line.
(Keep the DCU and CAN-TMN2 connected.)
• EGR controller, VNT controller, engine ECU
• NOx sensors 1 and 2, DEF sensor, PM sensor

3. Disconnect the J/C_DEF_SSR connector.

4. Using the electrical tester, measure the resistance between the

SHTS021270300034 DCU-side CAN H line and L line terminals when viewed from the J/
C_DEF_SSR.

Measurement Tester
Standard values
conditions connections

J/C_DEF_SSR
#4 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #9 (CANL)
terminal

the measured value within the standard range?

YES NO

Connect the J/C_DEF_SSR connector and Disconnection or continuity failure in the

then go to step 2. CAN bus line between the J/C_DEF_SSR and
DCU.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–61

2 Inspecting the wire harness for disconnection: CAN bus line between the J/C_CAN_Diesel
and J/C_DEF_SSR (malfunction area 12)

1. Disconnect the J/C_CAN_Diesel connector.

CANH CANL
2. Using the electrical tester, measure the resistance between the J/
C_DEF_SSR-side CAN H line and L line terminals when viewed
from the J/C_CAN_Diesel.

Measurement Tester
Standard values
conditions connections

J/C_CAN_Diesel
#5 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300035 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_CAN_Diesel connector and Disconnection or continuity failure in the

then go to step 3. CAN bus line between the J/C_CAN_Diesel
and J/C_DEF_SSR.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–62 ENGINE (J05E)/TROUBLESHOOTING

3 Inspecting the wire harness for disconnection: CAN bus line between the J/C_CAN_Diesel
and J/C_PM_Diesel (malfunction area 11)

1. Disconnect the J/C_PM_Diesel connector.

CANH CANL
2. Using the electrical tester, measure the resistance between the J/
C_CAN_Diesel-side CAN H line and L line terminals when viewed
from the J/C_PM_Diesel.

Measurement Tester
Standard values
conditions connections

J/C_PM_Diesel
#3 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300036 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_PM_Diesel connector and Disconnection or continuity failure in the

then go to step 4. CAN bus line between the J/C_PM_Diesel
and J/C_CAN_Diesel.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–63

4 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN and
J/C_PM_Diesel (malfunction area 10)

1. Disconnect the J/C_ENG_CAN connector.

CANH CANL
2. Using the electrical tester, measure the resistance between the J/
C_PM_Diesel-side CAN H line and L line terminals when viewed
from the J/C_ENG_CAN.

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN
#6 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300037 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_ENG_CAN connector and Disconnection or continuity failure in the

then go to step 5. CAN bus line between the J/C_ENG_CAN
and J/C_PM_Diesel.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–64 ENGINE (J05E)/TROUBLESHOOTING

5 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN2
and J/C_ENG_CAN (malfunction area 9)

1. Disconnect the J/C_ENG_CAN2 connector.

CANH CANL
2. Using the electrical tester, measure the resistance between the J/
C_ENG_CAN-side CAN H line and L line terminals when viewed
from the J/C_ENG_CAN2.

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN2
#5 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300038 terminal

Is the measured value within the standard range?

YES NO

Go to step 6. Disconnection or continuity failure in the

CAN bus line between the J/C_ENG_CAN2
and J/C_ENG_CAN.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–65

6 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN and
CAN-TMN2 (termination resistor) (malfunction area 8)

1. Using the electrical tester, measure the resistance between the

CANH CANL CAN TMN2-side CAN H line and L line terminals when viewed
from the J/C_ENG_CAN2

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN2
#6 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #7 (CANL)
terminal

SHTS021270300039

Is the measured value within the standard range?

YES NO

Connect the J/C_ENG_CAN2 connector and Disconnection or continuity failure in the

then go to step 7. CAN bus line between the J/C_ENG_CAN
and CAN-TMN2 (termination resistor).
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–66 ENGINE (J05E)/TROUBLESHOOTING

7 Inspecting the engine ECU [HINO DX Ⅱ ]

1. Turn the starter key to the "LOCK" position.

2. Connect the engine ECU connector.

3. Connect the diagnostic tester (HINO DX Ⅱ ) to the vehicle.

4. Turn the starter key to the "ON" position.

5. Delete the malfunction history and turn the starter key to the
"LOCK" position.

6. Turn the starter key to the "ON" position.

SHTS021270300040

7. On the diagnostic tester screen, check that no abnormality is

detected in Engine ECU communication (U0100 or U010E).

Did the abnormality in engine ECU communication (U0100 or U010E) disappear?

YES NO

Go to step 8. Replace the engine ECU.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

8 Inspecting the EGR controller [HINO DX Ⅱ ]

1. Delete the malfunction history and turn the starter key to the
"LOCK" position.

2. Connect the EGR controller connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in EGR controller communication (U010A).

SHTS021270300041

Did the abnormality in EGR controller communication (U010A) disappear?

YES NO

Go to step 9. Replace the EGR controller.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–67

9 Inspecting the VNT controller [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the VNT controller connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in VNT controller communication (U010C).

SHTS021270300042

Did the abnormality in VNT controller communication (U010C) disappear?

YES NO

Go to step 10. Replace the VNT controller.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

10 Inspecting the NOx sensor No.1 [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the NOx sensor No.1 connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in NOx sensor No.1 communication (U029D).

SHTS021270300043

Did the abnormality in NOx sensor No.1 communication (U029D) disappear?

YES NO

Go to step 11. Replace the NOx sensor No.1.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–68 ENGINE (J05E)/TROUBLESHOOTING

11 Inspecting the NOx sensor No.2 [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the NOx sensor No.2 connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in NOx sensor No.2 communication (U029E).

SHTS021270300044

Did the abnormality in NOx sensor No.2 communication (U029E) disappear?

YES NO

Go to step 12. Replace the NOx sensor No.2.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

12 Inspecting the DEF sensor [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the DEF sensor connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in DEF sensor communication (U02A2).

SHTS021270300045

Did the abnormality in DEF sensor communication (U02A2) disappear?

YES NO

Go to step 13. Replace the DEF sensor.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–69

13 Inspecting the PM sensor [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the PM sensor connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in PM sensor communication (U02A3).

SHTS021270300046

Did the abnormality in PM sensor communication (U02A3) disappear?

YES NO

Procedure completed. Replace the PM sensor.

If another CAN communication system DTC Perform After-inspection work. (Clear all past
is detected, go to the diagnostic procedure DTC. Check no DTC is stored after test
for the detected DTC. drive.)
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–70 ENGINE (J05E)/TROUBLESHOOTING

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (250 k) [HYBRID]
EN01H02127030602016014

1 Inspecting the wire harness for disconnection: CAN bus line between the J/C_DEF_SSR and
DCU (malfunction area 14)

1. Turn the starter key to the "LOCK" position.

CANH
CANL 2. Disconnect the connectors of the following sensors and controllers
which are connected to the engine CAN line.
(Keep the DCU and CAN-TMN2 connected.)
• EGR controller, VNT controller, engine ECU
• NOx sensors 1 and 2, DEF sensor, PM sensor

3. Disconnect the J/C_DEF_SSR connector.

4. Using the electrical tester, measure the resistance between the

SHTS021270300047 DCU-side CAN H line and L line terminals when viewed from the J/
C_DEF_SSR.

Measurement Tester
Standard values
conditions connections

J/C_DEF_SSR
#4 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #9 (CANL)
terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_DEF_SSR connector and Disconnection or continuity failure in the

then go to step 2. CAN bus line between the J/C_DEF_SSR and
DCU.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–71

2 Inspecting the wire harness for disconnection: CAN bus line between the J/C_HV1 and J/
C_DEF_SSR (malfunction area 13)

1. Disconnect the J/C_HV1 connector.

CANH
CANL 2. Using the electrical tester, measure the resistance between the J/
C_DEF_SSR-side CAN H line and L line terminals when viewed
from the J/C_HV1.

Measurement Tester
Standard values
conditions connections

J/C_HV1
#4 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #9 (CANL)
SHTS021270300048 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_HV1 connector and then go Disconnection or continuity failure in the
to step 3. CAN bus line between the J/C_HV1 and J/
C_DEF_SSR.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–72 ENGINE (J05E)/TROUBLESHOOTING

3 Inspecting the wire harness for disconnection: CAN bus line between the J/C_PM_HV and J/
C_HV1 (malfunction area 12)

1. Disconnect the J/C_PM_HV connector.

CANH
CANL
2. Using the electrical tester, measure the resistance between the J/
C_HV1-side CAN H line and L line terminals when viewed from the
J/C_PM_HV.

Measurement Tester
Standard values
conditions connections

J/C_PM_HV
#3 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300049 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_PM_HV connector and then Disconnection or continuity failure in the
go to step 4. CAN bus line between the J/C_PM_HV and J/
C_HV1.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–73

4 Inspecting the wire harness for disconnection: CAN bus line between the J/C_HV2 and J/
C_PM_HV (malfunction area 11)

1. Disconnect the J/C_HV2 connector.

CANH
CANL
2. Using the electrical tester, measure the resistance between the J/
C_PM_HV-side CAN H line and L line terminals when viewed from
the J/C_HV2.

Measurement Tester
Standard values
conditions connections

J/C_HV2
#3 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300050 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_HV2 connector and then go Disconnection or continuity failure in the
to step 5. CAN bus line between the J/C_HV2 and J/
C_PM_HV.
Repair or replace the wire harness.
2–74 ENGINE (J05E)/TROUBLESHOOTING

5 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN and
J/C_HV2 (malfunction area 10)

1. Disconnect the J/C_ENG_CAN connector.

CANH CANL
2. sing the electrical tester, measure the resistance between the J/
C_HV2-side CAN H line and L line terminals when viewed from the
J/C_ENG_CAN.

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN
#6 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300051 terminal

Is the measured value within the standard range?

YES NO

Connect the J/C_ENG_CAN connector and Disconnection or continuity failure in the

then go to step 6. CAN bus line between the J/C_ENG_CAN
and J/C_HV2.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–75

6 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN2
and J/C_ENG_CAN (malfunction area 9)

1. Disconnect the J/C_ENG_CAN2 connector.

CANH CANL
2. Using the electrical tester, measure the resistance between the J/
C_ENG_CAN-side CAN H line and L line terminals when viewed
from the J/C_ENG_CAN2.

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN2
#5 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #8 (CANL)
SHTS021270300052 terminal

Is the measured value within the standard range?

YES NO

Go to step 7. Disconnection or continuity failure in the

CAN bus line between the J/C_ENG_CAN2
and J/C_ENG_CAN.
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–76 ENGINE (J05E)/TROUBLESHOOTING

7 Inspecting the wire harness for disconnection: CAN bus line between the J/C_ENG_CAN2
and CAN-TMN2 (termination resistor) (malfunction area 8)

1. Using the electrical tester, measure the resistance between the

CANH CANL CAN-TMN2-side CAN H line and L line terminals when viewed
from the J/C_ENG_CAN2.

Measurement Tester
Standard values
conditions connections

J/C_ENG_CAN2
#6 (CANH) termi-
Starter key: LOCK 110 – 130 
nal – #7 (CANL)
terminal

SHTS021270300053

Is the measured value within the standard range?

YES NO

Connect the J/C_ENG_CAN2 connector and Disconnection or continuity failure in the

then go to step 8. CAN bus line between the J/C_ENG_CAN2
and CAN-TMN2 (termination resistor).
Repair or replace the wire harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–77

8 Inspecting the engine ECU [HINO DX Ⅱ ]

1. Turn the starter key to the "LOCK" position.

2. Connect the engine ECU connector.

3. Connect the diagnostic tester (HINO DX Ⅱ ) to the vehicle.

4. Turn the starter key to the "ON" position.

5. Delete the malfunction history and turn the starter key to the
"LOCK" position.

6. Turn the starter key to the "ON" position.

SHTS021270300054

7. On the diagnostic tester screen, check that no abnormality is

detected in Engine ECU communication (U0100 or U010E).

Did the abnormality in engine ECU communication (U0100 or U010E) disappear?

YES NO

Go to step 9. Replace the engine ECU.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

9 Inspecting the EGR controller [HINO DX Ⅱ ]

1. Delete the malfunction history and turn the starter key to the
"LOCK" position.

2. Connect the EGR controller connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in EGR controller communication (U010A).

SHTS021270300055

Did the abnormality in EGR controller communication (U010A) disappear?

YES NO

Go to step 10. Replace the EGR controller.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–78 ENGINE (J05E)/TROUBLESHOOTING

10 Inspecting the VNT controller [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the VNT controller connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in VNT controller communication (U010C).

SHTS021270300056

Did the abnormality in VNT controller communication (U010C) disappear?

YES NO

Go to step 11. Replace the VNT controller.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

11 Inspecting the NOx sensor No.1 [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the NOx sensor No.1 connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in NOx sensor No.1 communication (U029D).

SHTS021270300057

Did the abnormality in NOx sensor No.1 communication (U029D) disappear?

YES NO

Go to step 12. Replace the NOx sensor No.1.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–79

12 Inspecting the NOx sensor No.2 [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the NOx sensor No.2 connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in NOx sensor No.2 communication (U029E).

SHTS021270300058

Did the abnormality in NOx sensor No.2 communication (U029E) disappear?

YES NO

Go to step 13. Replace the NOx sensor No.2.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

13 Inspecting the DEF sensor [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the DEF sensor connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in DEF sensor communication (U02A2).

SHTS021270300059

Did the abnormality in DEF sensor communication (U02A2) disappear?

YES NO

Go to step 14. Replace the DEF sensor.

Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–80 ENGINE (J05E)/TROUBLESHOOTING

14 Inspecting the PM sensor [HINO DX Ⅱ ]

1. Delete the malfunction history on the diagnostic tester screen and

turn the starter key to the "LOCK" position.

2. Connect the PM sensor connector.

3. Turn the starter key to the "ON" position.

4. On the diagnostic tester screen, check that no abnormality is

detected in PM sensor communication (U02A3).

SHTS021270300060

Did the abnormality in PM sensor communication (U02A3) disappear?

YES NO

Procedure completed. Replace the PM sensor.

If another CAN communication system DTC Perform After-inspection work. (Clear all past
is detected, go to the diagnostic procedure DTC. Check no DTC is stored after test
for the detected DTC. drive.)
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–81

PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k)

[DIESEL]
EN01H02127030602016015

1 Check the DTC detected Engine ECU

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Check that any DTC other than CAN communication system DTC
(U****) has been detected.

SHTS021270300061

Has a DTC other than CAN communication system DTC (U****) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2–82 ENGINE (J05E)/TROUBLESHOOTING

2 Check for +B/GND short-circuit in CAN H-line

1. Set the starter key to the "LOCK" position.

+B2
LEP
GND4
LEW
GND1
LET 2. Disconnect the following sensors and controllers connected to the
+B3
LEQ
GND5
LEX
GND2
LEU
Engine_control/Diagnosis_CAN line.
+B4
LER
+B1
LEN
GND3
LEV
• DCU(53P), engine ECU, AT ECU, ABS ECU, vehicle control ECU,
CAN-TMN

CAH1
LF5
3. Use the electrical tester to check the continuity between the CAH1
CAL1

TE1B
LF6
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
minal and 16th terminal in the diagnostic connector (16P).
LF2

TE1A CAH0
LF1 LEY

TE2B CAL0
LF4 LEZ

TE2A
Measurement Tester
LF3
Standard values
conditions connections
ISGW
LES DCU vehicle-side
connector – Diag-
Starter key: LOCK nostic connector No Continuity
CAH1 – 4th
CAH1 – 16th
SHTS021270300062

Do the measurements meet the standard value?

YES NO

Go to step 3. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
 ENGINE (J05E)/TROUBLESHOOTING 2–83

3 Check for +B/GND short-circuit in CAN L-line

1. Use the electrical tester to check the continuity between the CAL1
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
+B2
LEP
GND4
LEW
GND1
LET
minal and 16th terminal in the diagnostic connector (16P).
+B3 GND5 GND2
LEQ LEX LEU

Measurement Tester
+B4 +B1 GND3 Standard values
LER LEN LEV
conditions connections

DCU vehicle-side
connector – Diag-
CAH1
LF5

CAL1

Starter key: LOCK nostic connector No Continuity

LF6

TE1B

CAL1 – 4th
LF2

TE1A CAH0
LF1 LEY

TE2B
LF4
CAL0
LEZ
CAL1 – 16th
TE2A
LF3

ISGW
LES

SHTS021270300063

Do the measurements meet the standard value?

YES NO

Go to step 4. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
2–84 ENGINE (J05E)/TROUBLESHOOTING

4 Check the terminating resistance

1. 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
LES

Measurement Tester
Standard values
TE2A
conditions connections
LF3

TE2B CAL0
LF4 LEZ
DCU (53P):
TE1A CAH0
CAL1
LF1 LEY
CAH1 – CAL1
TE1B
LF2 Starter key: LOCK 110 – 130 
CAL1
CAN_TMN:
1st – 2nd
LF6

CAH1
LF5

CAH1
+B4 +B1 GND3
LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

SHTS021270300064

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the faulty part.

After replacing the part, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–85

5 Check the resistance

1. Connect the DCU (53P) connector and CAN-TMN connector.

2. Use the electrical tester to measure the terminating resistance of

DCU (53P).
ISGW
LES
Measurement Tester
Standard values
conditions connections
TE2A

DCU (53P):
LF3

TE2B CAL0
Starter key: LOCK 45 – 75 
CAH1 – CAL1
LF4 LEZ

TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2

CAL1
LF6

CAH1
LF5

CAH1
+B4 +B1 GND3
LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

SHTS021270300065

Do the measurements meet the standard value?

YES NO

Procedure completed. Refer to "DISCONNECTION INSPECTION

CAN bus line (main line and trunk lines) FOR ENGINE CAN_H COMMUNICATION L
between terminating resistances is normal. LINE (500 k)" and check the CAN bus line.
Go to the diagnostic procedure for the
detected DTC.
2–86 ENGINE (J05E)/TROUBLESHOOTING

PRE-INSPECTION FOR ENGINE CAN COMMUNICATION LINE (500 k)

[HYBRID]
EN01H02127030602016016

1 Check the DTC detected Engine ECU

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Check that any DTC other than CAN communication system DTC
(U****) has been detected.

SHTS021270300066

Has a DTC other than CAN communication system DTC (U****) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

 ENGINE (J05E)/TROUBLESHOOTING 2–87

2 Check for +B/GND short-circuit in CAN H-line

1. Set the starter key to the "LOCK" position.

+B2
LEP
GND4
LEW
GND1
LET
2. Disconnect the following sensors and controllers connected to the
+B3
LEQ
GND5
LEX
GND2
LEU
Engine_control/Diagnosis_CAN line.
+B4
LER
+B1
LEN
GND3
LEV
• DCU(53P), engine ECU, AT ECU, ABS ECU, vehicle control ECU,
HV PCU
CAH1
LF5
3. Use the electrical tester to check the continuity between the CAH1
CAL1

TE1B
LF6
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
LF2

TE1A
LF1
CAH0
LEY
minal and 16th terminal in the diagnostic connector (16P).
TE2B CAL0
LF4 LEZ

TE2A
LF3 Measurement Tester
Standard values
conditions connections
ISGW
LES DCU vehicle-side
connector – Diag-
Starter key: LOCK nostic connector No Continuity
CAH1 – 4th
CAH1 – 16th
SHTS021270300067

Do the measurements meet the standard value?

YES NO

Go to step 3. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
2–88 ENGINE (J05E)/TROUBLESHOOTING

3 Check for +B/GND short-circuit in CAN L-line

1. Use the electrical tester to check the continuity between the CAL1
terminal in the DCU vehicle-side connector (53P) and the 4th ter-
+B2
LEP
GND4
LEW
GND1
LET
minal and 16th terminal in the diagnostic connector (16P).
+B3 GND5 GND2
LEQ LEX LEU

Measurement Tester
+B4 +B1 GND3 Standard values
LER LEN LEV
conditions connections

DCU vehicle-side
connector – Diag-
CAH1
LF5

CAL1
LF6

TE1B
Starter key: LOCK nostic connector No Continuity
CAL1 – 4th
LF2

TE1A CAH0
LF1 LEY

TE2B
LF4
CAL0
LEZ
CAL1 – 16th
TE2A
LF3

ISGW
LES

SHTS021270300068

Do the measurements meet the standard value?

YES NO

Go to step 4. Refer to "DISCONNECTION INSPECTION

FOR ENGINE CAN_H COMMUNICATION L
LINE (500 k)" and check the CAN bus line.
 ENGINE (J05E)/TROUBLESHOOTING 2–89

4 Check the DCU (terminating resistance)

1. Use the electrical tester to measure the terminating resistance of

DCU (53P).

Measurement Tester
Standard values
conditions connections
ISGW
LES

DCU (53P):
Starter key: LOCK 110 – 130 
CAH1 – CAL1
TE2A
LF3

TE2B CAL0
LF4 LEZ

TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2

CAL1
LF6

CAH1
LF5

CAH1
+B4 +B1 GND3
LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

SHTS021270300069

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the DCU.

After replacing the DCU, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–90 ENGINE (J05E)/TROUBLESHOOTING

5 Check the HV ECU (terminating resistance)

1. Use the electrical tester to measure the terminating resistance of

the HV ECU.

Measurement Tester
Standard values
conditions connections

HV ECU (26P):
Starter key: LOCK 110 – 130 
21st – 22nd

SHTS021270300070

Do the measurements meet the standard value?

YES NO

Go to step 6. Replace the HV ECU.

After replacing the ECU, confirm that no CAN
communication system DTC is detected.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–91

6 Check the resistance

1. Connect the DCU (53P) connector and HV PCU connector.

2. Use the electrical tester to measure the terminating resistance of

DCU (53P).
ISGW
LES
Measurement Tester
Standard values
conditions connections
TE2A

DCU (53P):
LF3

TE2B CAL0
Starter key: ON 45 – 75 
CAH1 – CAL1
LF4 LEZ

TE1A
LF1
CAH0
LEY CAL1
TE1B
LF2

CAL1
LF6

CAH1
LF5

CAH1
+B4 +B1 GND3
LER LEN LEV

+B3 GND5 GND2

LEQ LEX LEU

+B2 GND4 GND1

LEP LEW LET

SHTS021270300071

Do the measurements meet the standard value?

YES NO

Procedure completed. Replace the DCU.

CAN bus line (main line and trunk lines) Refer to "DISCONNECTION INSPECTION
between terminating resistances is normal. FOR ENGINE CAN_H COMMUNICATION L
Go to the diagnostic procedure for the LINE (500 k)" and check the CAN bus line.
detected DTC.
2–92 ENGINE (J05E)/TROUBLESHOOTING

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (500 k) [DIESEL]
EN01H02127030602016017

1 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8)

1. Set the starter key to the "LOCK" position.

2. Disconnect the following controller connectors connected to the

Engine_control/Diagnosis_CAN line.
• Engine ECU, AT ECU, ABS ECU, vehicle control ECU

3. Disconnect the J/C_CAN5 connector.

4. Use the electrical tester to measure the resistance between the

terminals in the CAN H-line and L-line on the DCU side, viewed
from J/C_CAN5.
SHTS021270300072
Measurement Tester
Standard values
conditions connections

J/C_CAN5:
Starter key: LOCK 110 – 130 
5th – 10th

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN5 connector, and go to CAN bus line disconnection between J/
step 2. C_CAN5 and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–93

2 Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN5 (Failure Site 7)

1. Disconnect the J/C_CAN1 (10P) connector.

2. 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).

Measurement Tester
Standard values
conditions connections

J/C_CAN1 (10P):
Starter key: LOCK 110 – 130 
5th – 10th

SHTS021270300073

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN1 (10P) connector, and CAN bus line disconnection between J/
go to step 3. C_CAN1 (10P) and J/C_CAN5
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

3 Check harness in CAN bus line between J/C_CAN2 and J/C_CAN1 (10P) (Failure Site 6)

1. Disconnect the J/C_CAN2 connector.

2. Use the electrical tester to measure the resistance between the

terminals in the CAN H-line and L-line on the J/C_CAN1 (10P)
side, viewed from J/C_CAN2.

Measurement Tester
Standard values
conditions connections

J/C_CAN2:
Starter key: LOCK 110 – 130 
6th – 17th

SHTS021270300074

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN2 connector, and go to CAN bus line disconnection between J/
step 4. C_CAN2 and J/C_CAN1 (10P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–94 ENGINE (J05E)/TROUBLESHOOTING

4 Check harness in CAN bus line between J/C_CAN1 (22P) and J/C_CAN2 (Failure Site 5)

1. Disconnect the J/C_CAN1 (22P) connector.

2. 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).

Measurement Tester
Standard values
conditions connections

J/C_CAN1 (22P):
Starter key: LOCK 110 – 130 
6th – 17th

SHTS021270300075

Do the measurements meet the standard value?

YES NO

Go to step 5. CAN bus line disconnection between J/

C_CAN1 (22P) and J/C_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

5 Check harness in CAN bus line between CAN_TMN and J/C_CAN1 (22P) (Failure Site 4)

1. Use the electrical tester to measure the resistance between the

terminals in the CAN H-line and L-line on the J/C_CAN1 (22P)
side, viewed from CAN_TMN.

Measurement Tester
Standard values
conditions connections

J/C_CAN1 (22P):
Starter key: LOCK 110 – 130 
5th – 16th

SHTS021270300076

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN1 (22P) connector, and CAN bus line disconnection between
go to step 6. CAN_TMN and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–95

6 Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1)

1. Use the electrical tester to measure the resistance between the

DLC CAN H line terminal and L line terminal.

Measurement Tester
Standard values
conditions connections

Starter key: LOCK DLC: 6th – 14th 45 – 75 

SHTS021270300077

Do the measurements meet the standard value?

YES NO

Go to step 7. CAN bus line disconnection between DLC

and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–96 ENGINE (J05E)/TROUBLESHOOTING

7 Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3)

1. Disconnect the J/C_CAN1 (10P) connector.

A V16
2. Connect the signal check harness to the engine ECU vehicle-side
V36
connector. (Do not connect harness to the ECU)

3. Use electrical tester to measure the resistance between (CANL)

terminal and (CANH) terminal at the ECU check harness. These
circuits are identified as terminal V16 and terminal V36 on the
ECU check harness A.

Measurement Tester
Standard values
conditions connections
SHTS021270300078

Signal check har-

ness (Engine ECU)
Starter key: LOCK 110 – 130 
V16 (CANL) –
V36 (CANH)

Do the measurements meet the standard value?

YES NO

Procedure completed. CAN bus line disconnection between engine

If another CAN communication system DTC ECU and J/C_CAN5
is detected, go to the diagnostic procedure Repair or replace the harness.
for the detected DTC. Perform After-inspection work. (Clear all past
Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test
DTC. Check no DTC is stored after test drive.)
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–97

DISCONNECTION INSPECTION FOR ENGINE CAN_H COMMUNICATION L

LINE (500 k) [HYBRID]
EN01H02127030602016018

1 Check harness in CAN bus line between J/C_CAN5 and DCU (Failure Site 8)

1. Set the starter key to the "LOCK" position.

2. Disconnect the following controller connectors connected to the

Engine_control/Diagnosis_CAN line.
• Engine ECU, AT ECU, ABS ECU, vehicle control ECU

3. Disconnect the J/C_CAN5 connector.

4. Use the electrical tester to measure the resistance between the

terminals in the CAN H-line and L-line on the DCU side, viewed
from J/C_CAN5.
SHTS021270300079
Measurement Tester
Standard values
conditions connections

J/C_CAN5:
Starter key: LOCK 110 – 130 
5th – 10th

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN5 connector, and go to CAN bus line disconnection between J/
step 2. C_CAN5 and the DCU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–98 ENGINE (J05E)/TROUBLESHOOTING

2 Check harness in CAN bus line between J/C_CAN2 and J/C_CAN5 (Failure Site 7)

1. Disconnect the J/C_CAN2 connector.

2. 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.

Measurement Tester
Standard values
conditions connections

J/C_CAN2:
Starter key: LOCK 110 – 130 
6th – 17th

SHTS021270300080

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN2 connector, and go to CAN bus line disconnection between J/
step 3. C_CAN2 and J/C_CAN5
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

3 Check harness in CAN bus line between J/C_CAN1 (22P) and J/C_CAN2 (Failure Sites 2 & 6)

1. Disconnect the J/C_CAN1 (22P) connector.

2. 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).

Measurement Tester
Standard values
conditions connections

J/C_CAN1 (22P):
Starter key: LOCK 110 – 130 
6th – 17th

SHTS021270300081

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN1 (22P) connector, and CAN bus line disconnection between J/
go to step 4. C_CAN1 (22P) and J/C_CAN2
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–99

4 Check harness in CAN bus line between J/C_CAN1 (10P) and J/C_CAN1 (22P) (Failure Site 5)

1. 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
conditions connections

J/C_CAN1 (10P):
Starter key: LOCK 110 – 130 
3rd – 8th

SHTS021270300082

Do the measurements meet the standard value?

YES NO

Go to step 5. CAN bus line disconnection between CAN_J/

C2 and vehicle control ECU
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)

5 Check harness in CAN bus line between HV PCU and J/C_CAN1 (10P) (Failure Site 4)

1. Use the electrical tester to measure the resistance between the

terminals in the CAN H-line and L-line on J/C_CAN1 (10P) side,
viewed from HV PCU.

Measurement Tester
Standard values
conditions connections

J/C_CAN1 (10P):
Starter key: LOCK 110 – 130 
5th – 10th

SHTS021270300083

Do the measurements meet the standard value?

YES NO

Connect the J/C_CAN1 (10P) connector, and CAN bus line disconnection between HV
go to step 6. PCU and J/C_CAN1 (10P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
2–100 ENGINE (J05E)/TROUBLESHOOTING

6 Check harness in CAN bus line between DLC and J/C_CAN1 (22P) (Failure Site 1)

1. Use the electrical tester to measure the resistance between the

DLC CAN H line terminal and L line terminal.

Measurement Tester
Standard values
conditions connections

Starter key: LOCK DLC: 6th – 14th 45 – 75 

SHTS021270300084

Do the measurements meet the standard value?

YES NO

Go to step 7. CAN bus line disconnection between DLC

and J/C_CAN1 (22P)
Repair or replace the harness.
Perform After-inspection work. (Clear all past
DTC. Check no DTC is stored after test
drive.)
 ENGINE (J05E)/TROUBLESHOOTING 2–101

7 Check harness in CAN bus line between engine ECU and J/C_CAN5 (Failure Site 3)

1. Disconnect the J/C_CAN2 connector.

A V16
2. Connect the signal check harness to the engine ECU vehicle-side
V36
connector. (Do not connect harness to the ECU)

3. Use electrical tester to measure the resistance between (CANL)

terminal and (CANH) terminal at the ECU check harness. These
circuits are identified as terminal V16 and terminal V36 on the
ECU check harness A.

Measurement Tester
Standard values
conditions connections
SHTS021270300085

Signal check har-

ness (Engine ECU)
Starter key: LOCK 110 – 130 
V16 (CANL) –
V36 (CANH)

Do the measurements meet the standard value?

YES NO

Procedure completed. CAN bus line disconnection between engine

If another CAN communication system DTC ECU and No. J/C_CAN5
is detected, go to the diagnostic procedure Repair or replace the harness.
for the detected DTC. Perform After-inspection work. (Clear all past
Perform After-inspection work. (Clear all past DTC. Check no DTC is stored after test
DTC. Check no DTC is stored after test drive.)
drive.)
2–102 ENGINE (J05E)/TROUBLESHOOTING

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 P0504

EGR actuator U1122

VNT actuator U1123

DPR regeneration switch Manual regeneration failure of DPR

Exhaust brake
Functional failure
Cruise

Aftertreatment fuel injector P20CD

 ENGINE (J05E)/TROUBLESHOOTING 2–103

ENG BASIC INSPECTION SHEET (ENGINE INSPECTION CHECK SHEET)

EN01H02127030602016020

* After inspection, indicate a check mark in the boxes below.

Inspec-
tion 1 2 3 4 5 6 7 8 9
steps
Exhaust
Fuel Air intake EGR
Inspec- Engine/ Sensor system/ VN turbo- Supply
tank, system valve/ Injector
tion area ECU system exhaust charger pump
filter parts cooler
brake
Inspect
the fuel Dam- Follow Follow Inspect
tank. age in Gas leak ability ability the
Low- Inspect the sen- from during during Inspect power
Check-
grade the air sor har- tight- inspec- inspec- the supply.
ing the
fuel, cleaner. ness ened tion tion injector Actua-
diagno-
contami- Fouled Poor fit and fas- (Devia- (Devia- drive tion and
sis code.
nants or element of the tened tion  tion  wiring. wiring of
mois- sensor areas 8% or 5% or main
ture coupler under) under) relay
inclusion
Inspect
the air
flow Inspect
meter the rota-
Inspect
for any tion sig- Inspect
the fuel
Check degra- nal actua- Inspect Inspect
hose.
Inspec- the pro- dation/ system. tion of Clogged the com- SCV
Break-
tion items gram deterio- NE or G the cooler pres- resis-
age,
part No. ration. active exhaust sion. tance.
crush or
Fouling flag and brake.
clogging
and pulsar
assem- damage
bly
direction
Inspect
Inspect Inspect
Inspect SCV
the fuel Inspect appear-
the air amper-
Check pipe. the ance of
hose. age dur-
the Connec- acceler- the
Loose- Check a ing
injector tion to ator sen- injector.
ness, valve idling.
calibra- IN/OUT sor. Pres-
crush gap. Vari-
tion and 0 to ence of
and ance in
data. wrong 100% deposit
loose amper-
assem- voltage at the
clamp age (
bly end
40 mA)
2–104 ENGINE (J05E)/TROUBLESHOOTING

Inspec-
tion 1 2 3 4 5 6 7 8 9
steps
Exhaust
Fuel Air intake EGR
Inspec- Engine/ Sensor system/ VN turbo- Supply
tank, system valve/ Injector
tion area ECU system exhaust charger pump
filter parts cooler
brake
Injec-
Inspect
tion
the Engine
Inspect quantity
boost coolant
Check the fuel compen-
sensor. temper- Inspect
the sup- filter. sation
Inspect ature the set
ply Ele- between
the sen- sensor timing.
pump ment, cylin-
sors and Output Check
specifi- separa- ders
check voltage gear
cation tor and Check
the and phases.
learning gauze through
hoses resis-
filter data
for clog- tance
monitor-
ging.
ing.
Com-
mon rail
pres-
sure
Inspect Inspect
Inter- sensor
air inclu- a com-
cooler Inspect
sion. pen-
Check body HINO
Priming sated
for free and DXⅡ fuel
opera- injection
smoke. Dam- leakage
tion and quantity.
age in and
Inspec- air Check
hoses check
tion items bleeding writing.
follow
ability to
actual
level.
Exter-
Inspect
ECU nal fuel
an injec-
data leakage
tion
monitor Check
quantity.
(Check pipes
1. Idling
HINO and
speed
DX Ⅱ hoses
2. Mid
reports.) for leak-
speed
age.
Internal
fuel
leakage
Pres-
ence of
an
increase
in
engine
oil
 ENGINE (J05E)/TROUBLESHOOTING 2–105

Inspec-
tion 1 2 3 4 5 6 7 8 9
steps
Exhaust
Fuel Air intake EGR
Inspec- Engine/ Sensor system/ VN turbo- Supply
tank, system valve/ Injector
tion area ECU system exhaust charger pump
filter parts cooler
brake
-Remove
contami-
- Check - Re-fit
nants - Inspect - Clean
parts and - Check - Inspect
and foul- -Replace - or or
based repair for dis- the relay
ing and the ele- Retighte replace replace
on each dam- connec- upstrea
replace ment. n. the turbo the
diagno- aged tion. m fuse.
low- charger. valve.
sis code. parts.
grade
fuel.
- Check
air leak-
- Clean age and
- Repro- - Inspect - Clean
or exhaust
gram - Replace - Replace or - Clean the end
replace brake
with the deformed the sen- replace the of the
the air mag-
latest parts. sor. the turbo cooler. nozzle
flow netic
part No. charger. needle.
meter. valve
opera-
tion.
- Correct
- Replace
- Write a wrong
the hose
correct assem- - Stan-
and - Adjust
calibra- bly to dard  5
retighten a gap.
tion proper q
Actions to the
data. assem-
be taken clamp.
bly.
upon
- Perform
"fail"
the sup-
judgment
ply pump - Replace - Replace
specifica- the ele- the sen-
tion ment. sor.
learning
again.
- Free
acceler-
ation
method - Replace
smoke the hose
test - Air and
Stan- bleeding retighten
dard: the
10% or clamp.
less
without
muffler.
- Inspect
- Clear
for fuel
data after
leakage
output-
(check
ting a
connec-
HINO DX
tions and
Ⅱ report.
pipings).
2–106 ENGINE (J05E)/TROUBLESHOOTING

Standard injection quantity

J05E

r/min 750
Idling (normal)
Injection quantity (mm3/st) 7 – 16

r/min 1,500
Mid-speed inspection point
Injection quantity (mm3/st) 10 or more (AT)

r/min 2,800
Standard DPR filter differential pressure
Differential pressure 1.5 kPa or under
 ENGINE (J05E)/TROUBLESHOOTING 2–107

NO DTC
EN01H02127030602016021

ENGINE LOW POWER, MISS-FIRE, HESITATION, KNOCKING, RUNNING ROUGH

Check
No Parts Check contents Judgement If fail
(Pass/Fail)

Injection quantity at 1,500r/min No load 10 (mm3/st) or Injector

1 Injector
Coolant temp. more than 80 C {176 F} more Replace

Cylinder cut-off test Find knocking Injector

2 Injector
(Detail on next page A) cylinder Replace

Check restriction or contamination of the

No restriction Filter
3 Air filter air cleaner element
Genuine parts Replace
(Detail on next page B)

Visually check No bending

4 Air hoses Fix Replace
(Detail on next page C) No leaking

No excessive dirt
Visually check
Diesel throttle inside
5 Active test by HINO DX Ⅱ Drill holes
(Intake throttle) Drilled 3 holes
(Detail on next page D)
Following target

Difference
Mass air flow test at 100% Free accelera- between old and MAF
6 Mass air flow meter
tion (Detail on next page E) new sensor less Replace
than 10%

Visually check Exhaust

No sticking
7 Exhaust Brake Open and close butterfly valve brake
No seizing
(Detail on next page F) Replace

8 Engine Compression test More than 340psi Overhaul

2–108 ENGINE (J05E)/TROUBLESHOOTING

Cylinder cut-off test

Engine 1. Park vehicle with parking brake set,

 and chock whiles.
Data monitor and Active test 2. Set engine speed at 1,500r/min by
A  cruse control switch.
Active test Setting 3. Check each cylinder for decreased
 level of knock. If the knock
Injection stop cylinder, cylinder No.xx decreases during cut out test, that
 cylinder should be considered
Start/OK abnormal fueling injector
Air Filter Visually check
(Single cab) (Single cab)

CHECK NO RESTRICTION CHECK INDICATOR

AND GENUINE PARTS

B
(Crew cab) (Crew cab)

CHECK INDICATOR
CHECK NO RESTRICTION
AND GENUINE PARTS

Air hoses Visually check

CHECK TIGHTNESS, NO BENDING CHECK TIGHTNESS, NO CHECK TIGHTNESS, NO

BENDING AND NO LEAK BENDING AND NO LEAK

C
 ENGINE (J05E)/TROUBLESHOOTING 2–109

Diesel throttle (Intake throttle) Visually check

No excessive dirt inside of throttle

body and no movement between but-
terfly valve and shaft

Diesel throttle (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 diesel throttle valve (Intake
 throttle valve) position changes
Diesel throttle valve (Intake throttle from 0% to 90% by 10% step.
valve) inspection Confirm actual diesel throttle valve
 (Intake throttle valve) position is fol-
Start inspection lowed directed diesel throttle valve
(Intake throttle valve).
Mass air flow meter check

1. Park vehicle with parking brake set,

and chock whiles.
2. Make accelerator 100% when park-
ing.
Engine Coolant temp must be more than
 80C {176F}
E Inspection Menu
 3. Click keep and white down the
Amount of intake air flow inspection value. (A)
 4. Replace initial MAF to bran new
Start inspection one.
5. Do again (2) and (3). (B)

Calculation form: {(B)-(A)} / (B) x 100

< 10
Exhaust Brake valve check

F
2–110 ENGINE (J05E)/TROUBLESHOOTING

DPR NORMAL MANUAL REGENERATION IS NOT COMPLETE

Check
No Parts Check contents Judgement If fail
(Pass/Fail)

Check carbon of fuel addition valve nozzle No carbon Cleaning

1 Fuel addition valve
and folder deposited carbon
 ENGINE (J05E)/TROUBLESHOOTING 2–111

DTC: P0005
EN01H02127030602016022

P0005: Fuel Cut Valve stuck closed

INFORMATION

Engine ECU
Fuel cut valve
EBP EB4 (FCV)
FCV
(FCV)

SHTS021270300100

1. Technical description
• The engine ECU monitors the pressure in the fuel pipe based on the value of the fuel pressure sensor.

<Description of malfunction>
• Sticking of the fuel cut valve (FCV) was detected.

2. DTC set condition

(1) DTC detection condition
• The engine revolution is 700 r/min or more.
• The difference between the actual common rail pressure and the target common rail pressure is 1 Mpa or
less.
(2) Judgement criteria
• The pressure in the fuel pipe is 0 MPa or less when the engine revolution is 750 r/min, and remains at 0.2 MPa
or less for 30 seconds even when the engine revolution becomes 1000 r/min or more.

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• DPR automatic regeneration may not be performed properly.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Power supply for fuel cut valve.
• Fuel leakage (loose joint bolt), clogging, crush, and wrong assembly in fuel pipe.
• Defect of fuel cut valve.
2–112 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0005

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and check

any DTC listed below other than P0005.
- P0006, P0007, P016F

SHTS021270300101

Is any DTC other than P0005 detected?

YES NO

Go to the relevant DTC-specific trouble- Go to step 2.

shooting.

2 Inspect the power supply for the fuel cut valve

1. Set the starter key to the "LOCK" position.

BODY GND 2. Disconnect the connector from the fuel cut valve.

3. Set the starter key to the "ON" position.

4. Using the electrical tester, measure the pressure between the fuel
cut valve vehicle side connector FCV terminal and ground.

Measurement Tester
Standard values
conditions connections

SHTS021270300102 Fuel cut valve

vehicle side con-
Starter key: LOCK nector 8 V or more
FCV terminal –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 3. Inspect the power supply circuit of the

engine ECU.
 ENGINE (J05E)/TROUBLESHOOTING 2–113

3 Inspect the fuel cut valve downstream pipe 1

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
• Wrong assembly

Was any failure found?

YES NO

Repair or replace the defective part. After Go to step 4.

repair or replacement, bleed air from the
pipe.

4 Inspect the fuel cut valve downstream pipe 2

1. Bleed air from the fuel cut valve downstream pipe and also check
that there is no clogging in the pipe.

<Inspection procedure>
- Set the starter key to the "ON" position.
- Loosen the downstream side joint bolt.
- Slowly push the feed pump on the fuel pump until fuel comes out.
! CAUTION
Use care, as a large amount of fuel may come out if the feed pump
is pushed excessively.

Is fuel drained? Is bleeding air completed?

YES NO

Replace the fuel cut valve. Go to step 5.

2–114 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the fuel cut valve upstream pipe 1

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?

YES NO

Repair or replace the defective part. After Go to step 6.

repair or replacement, bleed air from the
pipe.

6 Inspect the fuel cut valve upstream pipe 2

1. Bleed air from the fuel cut valve upstream pipe and also check that
there is no clogging in the pipe.

<Inspection procedure>
- Set the starter key to the "ON" position.
- Loosen the upstream side joint bolt.
- Slowly push the feed pump on the fuel pump until fuel comes out.
! CAUTION
Use care, as a large amount of fuel may come out if the feed pump
is pushed excessively.

Is fuel drained? Is bleeding air completed?

YES NO

Replace the fuel cut valve. Clean or replace the fuel cut valve upstream
pipe.
 ENGINE (J05E)/TROUBLESHOOTING 2–115

DTC: P0006 and P0007

EN01H02127030602016023

P0006: Malfunction of fuel cut valve (Low)

INFORMATION

Engine ECU
Fuel cut valve
EBP EB4 (FCV)
FCV
(FCV)

SHTS021270300103

1. Technical description
• –

<Description of malfunction>
• Fuel cut valve is not working properly.
• Possible magnetic valve failure or harness GND short-circuit

2. DTC set condition

(1) DTC detection condition
• Fuel cut valve inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• The condition that the fuel cut valve circuit voltage is 2.8 V or less remains for 3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• DPR automatic regeneration may not be performed properly.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• GND short-circuit in fuel cut valve signal line
• Malfunction of fuel cut valve
• Malfunction of engine ECU
2–116 ENGINE (J05E)/TROUBLESHOOTING

P0007: Malfunction of fuel cut valve (High)

INFORMATION

Engine ECU

Fuel cut valve

EBP EB4 (FCV)
FCV
(FCV)

SHTS021270300104

1. Technical description
• –

<Description of malfunction>
• Fuel cut valve is not working properly.
• Possible magnetic valve failure or +B short-circuit or disconnection

2. DTC set condition

(1) DTC detection condition
• Fuel cut valve inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• The condition that the fuel cut valve circuit voltage is 3 V or more remains for 3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• DPR automatic regeneration may not be performed properly.

6. Pre-inspection work
• Check the battery voltage and make sure it is okay.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• +B short-circuit or disconnection in exhaust brake drive signal line.
• Malfunction of exhaust brake magnetic valve.
• Malfunction of engine ECU.
 ENGINE (J05E)/TROUBLESHOOTING 2–117

INSPECTION PROCEDURE: P0006 and P0007

1 Inspect the fuel cut valve connector

1. Check the connection of the fuel cut valve connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the fuel cut valve

1. Check the installation of the fuel cut valve.

Was any failure found?

YES NO

Install the fuel cut valve correctly. Go to step 3.

Replace the fuel cut valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–118 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the fuel cut valve unit

1. Set the starter key to the "LOCK" position.

FCV 2. Disconnect the fuel cut valve connector.

BODY GND

3. Use the electrical tester to measure the resistance between the

terminals of the fuel cut valve FCV and ground.

Measurement Tester
Standard values
conditions connections

Fuel cut valve 20 C {68 F}:

Starter key: LOCK
FCV – Ground 8.0 – 9.2 
SHTS021270300105

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the fuel cut valve.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect for short-circuit of the fuel cut valve harness

1. Connect the signal check harness to the engine ECU (Do not con-
nect the harness to the ECU).
C
BODY GND 2. Use the electrical tester to measure the resistance between the
E31 terminals of the engine ECU (signal check harness) FCV (E31)
terminal and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
SHTS021270300106 Starter key: LOCK ness) 
FCV (E31) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–119

5 Inspect disconnection of the fuel cut valve harness

1. Use the electrical tester to measure the resistance between the

terminals of the fuel cut valve vehicle side connector and the
C engine ECU.
FCV
E31 Measurement Tester
Standard values
conditions connections

Fuel cut valve

vehicle side con-
nector –
Starter key: LOCK Engine ECU 2  or less
(signal check har-
SHTS021270300107 ness)
FCV – FCV (E31)

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P0006 or P0007) has been
detected.

SHTS021270300108

Has DTC (P0006 or P0007) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–120 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0016
EN01H02127030602016024

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

SHTS021270300109

1. Technical description
• A phase difference (deviation) between the engine speed main sensor (crankshaft position sensor) pulse and
engine speed sub sensor (camshaft position sensor) pulse is diagnosed.

<Description of malfunction>
• Detect the phase difference between engine speed main sensor (crankshaft position sensor) pulse and engine
speed sub sensor (camshaft position sensor) pulse.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed is in the range from 700 to 1,000 r/min.
• Engine coolant temperature is 60 C {140 F} or higher.
• A difference between an actual engine speed and a target engine speed is 20 r/min or less.
(2) Judgement criteria
• A phase difference between the engine speed main sensor (crankshaft position sensor) pulse and engine
speed sub sensor (camshaft position sensor) is 7 or more for 1 second or more continuously.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–121

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

Camshaft gear: Check assembly.
Flywheel: Check for miss assembly.
Engine speed main sensor (crankshaft position sensor): Check the installation position.
Engine speed sub sensor (camshaft position sensor): Check the installation position.
2–122 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0016

1 Inspect the camshaft gear

1. Check that the camshaft gear is properly assembled.

Was any failure found?

YES NO

Assemble the camshaft gear properly. Go to step 2.

2 Inspect the flywheel

1. Check that the flywheel is properly assembled.

Was any failure found?

YES NO

Assemble the flywheel normally. Go to step 3.

3 Inspect engine speed main sensor (crankshaft position sensor), engine speed sub sensor
(camshaft position sensor)

1. Check that the engine speed main sensor (crankshaft position

sensor) engine speed sub sensor (camshaft position sensor) are
installed to the proper position.

Was any failure found?

YES NO

Install the engine speed main sensor (crank- Procedure completed.

shaft position sensor) and the engine speed Perform "After-inspection work" of INFOR-
sub sensor (camshaft position sensor) in MATION section.
proper locations.
 ENGINE (J05E)/TROUBLESHOOTING 2–123

DTC: P0027
EN01H02127030602016025

P0027: Exhaust Brake Performance

INFORMATION

1. Technical description

<Description of malfunction>
• The engine ECU detected sticking of the exhaust brake valve.

2. DTC set condition

(1) DTC detection condition
• DPR regeneration is in process.
• The vehicle speed is 0 km/h.
• The time of 60 seconds has elapsed after the exhaust brake was actuated.
(2) Judgement criteria
• The difference between the fuel injection quantity while the exhaust brake is working and the fuel injection
quantity when the exhaust brake is not actuated is 5 mm3/st or less. And also, the difference between the air
flow while the exhaust brake is working and the air flow when the exhaust brake is not actuated is -50 mg/cyl
or more.

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• The exhaust brake does not work.
• DPR regeneration is not terminated successfully.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormality in characteristics of air flow meter
• Diesel throttle (intake throttle valve) sticking
• Bend, clogging, and crack of piping and hose
• Improper adjustment of exhaust brake valve
• Malfunction of exhaust brake valve
2–124 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0027

1 Check the DTC detected 1 [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and check

any DTC listed below other than P0027.
- P0101, P04D5, P2101, P2526

SHTS021270300110

Has a DTC other than P0027 been detected?

YES NO

Perform the relevant DTC-specific trouble- Go to step 2.

shooting.

2 Inspect the exhaust brake valve piping and hose

1. Check the piping and hose, connected to the exhaust brake valve,
for bend, clogging, and crack.

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

 ENGINE (J05E)/TROUBLESHOOTING 2–125

3 Inspect the exhaust brake valve

1. Check the exhaust brake valve for unease and sticking.

SHTS021270300111

Was any failure found?

YES NO

Clean the exhaust brake valve. Replace if Go to step 5.

necessary. After clearing or replacement, go
to Step 4.

4 Check the DTC detected 2 [HINO DX Ⅱ ]

1. Perform a DPR forced regeneration.

2. After completion of regeneration, on the screen of the diagnostic

system, select [Engine] and read the detected DTCs.

SHTS021270300112

Has DTC P0027 been detected?

YES NO

Go to step 5. Procedure completed.

2–126 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the exhaust brake valve

1. Warm up the engine. (Coolant temperature: 80 C {176 F} or

more)

2. 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.)
SHTS021270300113
- Select [Engine] on the screen of the diagnostic system.
- Select [Injection quantity] from [Data monitor and Active test].
- Turn ON/OFF the exhaust brake switch, and check the difference
between the injection quantity of the injector while the exhaust brake
is working and the injection quantity when the exhaust brake is not
actuated.

Measurement conditions Standard values

• Engine revolution: 980 r/

min
• Engine coolant tempera-
ture:
80 C {176 F} or more 10 – 18 mm3/st
• Turn OFF the air condi-
tioner, PTO, and other
devices that place load on
the engine.

Is the measured value within the standard values? (There shall be a change in the injection quan-
tity between while the exhaust brake is working and when it is not actuated.)

YES NO

Go to step 6. Adjust the butterfly opening of the exhaust

brake. (Refer to the service manual.)
 ENGINE (J05E)/TROUBLESHOOTING 2–127

6 Check the DTC detected [HINO DX Ⅱ ]

1. Perform a DPR forced regeneration.

2. After regeneration, on the screen of the diagnostic system, select

[Engine] and check the detected DTCs.

SHTS021270300114

Has DTC P0027 been detected?

YES NO

Replace the engine ECU. Procedure completed.

2–128 ENGINE (J05E)/TROUBLESHOOTING

DTC: P003A
EN01H02127030602016026

P003A: Initialization failure (VNT actuator initialize error)

INFORMATION

LEA

POWER
(12V) Power
supply block Moter driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300115

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

When the amount of operation after power has been turned ON is larger than HI
1. Initialization failure range, or when the Hall IC output does not become constant after 5 seconds
has elapsed

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
 ENGINE (J05E)/TROUBLESHOOTING 2–129

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• VNT link is stuck or cannot operate due to rust, etc.
• External link is disconnected.
2–130 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P003A

1 Check the DTC detected 1 [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P003A (for exam-
ple, U010C) has been detected.

SHTS021270300116

Has a DTC other than P003A been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 3.

After repairing, go to step 2.

2 Check the DTC detected 2 [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P003A has been detected.

SHTS021270300117

Has DTC P003A been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–131

3 Inspect the operation of the VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "LOCK" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P003A has been detected.

HINT
Turn the key LOCK and ON verifies the wiping operation of the
VNT actuator (DC motor).
SHTS021270300118

Standard values

Starter key: LOCK  ON

Has DTC P003A been detected?

YES NO

Replace the turbocharger. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.
2–132 ENGINE (J05E)/TROUBLESHOOTING

4 Check the response delay of the VNT controller

1. Select [Inspection Menu] [VNT inspection] from the menu, and

(1) inspect the response delay at the Target VNT position and Actual
VNT position.
(3)

(2) ! CAUTION
(4) Perform the inspection while the engine is stopped to avoid
(5) engine damages.

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Select [Start inspection].
SHTS021270300119 (4) Select [VNT UP].
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN].
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of 10% per step between 0 –
90%.

Standard values

The response delay should be less than 3 seconds.

Are the measurements within standard value?

YES NO

Procedure completed. Replace the turbocharger.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–133

DTC: P0045
EN01H02127030602016027

P0045: DC motor terminal open circuit or DC motor coil open circuit

INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300120

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the target and actual value of the
nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• DTC P259F detected.
• Battery voltage is in the range of 10 to 16 V
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

When 1st, 2nd and 3rd conditions simultaneously form in the following matrix:

1st 2nd 3rd

Terminal U Output Batt. Voltage ≤ 1 V (Condition (c)) ≤ 1 V (Condition (e))

Motor terminal or
coil disconnection Terminal V ≤ 1 V (Condition (a)) Output Batt. Voltage ≤ 1 V (Condition (f))

Terminal W ≤ 1 V (Condition (b)) ≤ 1 V (Condition (d)) Output Batt. Voltage

Condition of motor
(a) or (b) (c) or (d) (e) or (f)
open circuit
2–134 ENGINE (J05E)/TROUBLESHOOTING

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Faulty contact in VNT controller connector
• LEA internal disconnection
• Controller internal disconnection
 ENGINE (J05E)/TROUBLESHOOTING 2–135

INSPECTION PROCEDURE: P0045

1 Check the DTC detected 1 [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P0045 (for exam-
ple U010C) has been detected.

SHTS021270300121

Has DTC other than P0045 (for example U010C) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 3.

Go to step 2 after repair.

2 Check the DTC detected 2 [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P0045 has been detected.

SHTS021270300122

Has DTC P0045 been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–136 ENGINE (J05E)/TROUBLESHOOTING

3 Check the connector connection [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Disconnect the VNT actuator and VNT controller connector and

connect properly again.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0045 has been detected.

VNT controller

SHTS021270300123

Has DTC P0045 been detected?

YES NO

Go to step 4. Procedure completed.

(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the operation of the VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "LOCK" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P0045 has been detected.

HINT
Turning the switch OFF and ON verifies the wiping operation of
the VNT actuator (DC motor).
SHTS021270300124

Measurement conditions

Starter key: LOCK  ON

Has DTC P0045 been detected?

YES NO

Replace the VNT controller. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–137

DTC: P0047
EN01H02127030602016028

P0047: DC motor terminal short circuit, DC motor short circuit

(Short to Battery) (VNT actuator motor short to BATT)
INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300125

1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

1. Motor short-circuit When LO-side current of at least 20.7 A is detected 3 times.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–138 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Short-circuit in VNT actuator motor coil.
• VNT controller internal short.
 ENGINE (J05E)/TROUBLESHOOTING 2–139

INSPECTION PROCEDURE: P0047

1 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P0047 (for exam-
ple U010C) has been detected.
HINT
Due to CAN communication failure P0047 may have been
detected.

SHTS021270300126

Has DTC U010C been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 3.

Go to step 2 after repair.

2 Check the DTC detected (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P0047 has been detected.

SHTS021270300127

Has DTC P0047 been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–140 ENGINE (J05E)/TROUBLESHOOTING

3 Check the connector connection [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Disconnect the VNT actuator and VNT controller connector and

connect properly again.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0047 has been detected.

Has DTC P0047 been detected?

YES NO

Go to step 4. Procedure completed.

(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the operation of the VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "LOCK" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P0047 has been detected.

HINT
Turning the switch LOCK and ON verifies the wiping operation of
the VNT actuator (DC motor).
SHTS021270300128

Measurement conditions

Starter key: LOCK  ON

Has DTC P0047 been detected?

YES NO

Replace the VNT controller. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–141

DTC: P0048
EN01H02127030602016029

P0048: DC motor terminal short circuit, DC motor short circuit

(Short to GND) (VNT actuator motor short to GND)
INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300129

1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• While the engine is in operation: Always
• While the engine is stopped: During wiping operation
(2) Judgement criteria

Item Details (Reference)

1. Motor circuit short When LO-side current of at least 20.7 A is detected 3 times.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–142 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• VNT actuator motor coil disconnection.
• VNT controller internal disconnection.
 ENGINE (J05E)/TROUBLESHOOTING 2–143

INSPECTION PROCEDURE: P0048

1 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P0048 (for exam-
ple U010C) has been detected.
HINT
Due to CAN communication failure P0048 may have been
detected.

SHTS021270300130

Has DTC U010C been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 3.

Go to step 2 after repair.

2 Check the DTC detected (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P0048 has been detected.

SHTS021270300131

Has DTC P0048 been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–144 ENGINE (J05E)/TROUBLESHOOTING

3 Check the connector connection [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Disconnect the VNT actuator and VNT controller connector and

connect properly again.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0048 has been detected.

Has DTC P0048 been detected?

YES NO

Go to step 4. Procedure completed.

(Connector connection is faulty.)
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the operation of the VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "LOCK" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P0048 has been detected.

HINT
Turn the switch LOCK and ON verifies the wiping operation of the
VNT actuator (DC motor).
SHTS021270300132

Measurement conditions

Starter key: LOCK  ON

Has DTC P0048 been detected?

YES NO

Replace the VNT controller. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–145

DTC: P006E
EN01H02127030602016030

P006E: Power supply failure (Out of range low) (VNT actuator power supply too low)
INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300133

1. Technical description
• The VNT moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed and
boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

Power supply voltage failure (Low) Power supply voltage is 8 V or less for at least 6 seconds.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–146 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Failure in alternator, regulator, or other part of the power supply system
• Battery is depleted.
 ENGINE (J05E)/TROUBLESHOOTING 2–147

INSPECTION PROCEDURE: P006E

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P006E (U010C)
has been detected.
HINT
Due to CAN communication failure P006E may have been
detected.

SHTS021270300134

Has DTC U010C been detected?

YES NO

Go to diagnosis procedure of the related Go to step 3.

DTC.
After repair, go to step 2.

2 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P006E has been detected.

SHTS021270300135

Has DTC P006E been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–148 ENGINE (J05E)/TROUBLESHOOTING

3 Check the VNT controller power supply circuit

1. Set the starter key to the "LOCK" position.

GND
+B 2. Disconnect the VNT controller connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the VNT controller vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300136 VNT controller

vehicle side con-
Starter key: ON 8 V or more
nector
+B – GND

Do the measurements meet the standard value?

YES NO

Procedure completed. Check the VNT controller power supply cir-

Perform "After-inspection work" of INFOR- cuit.
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–149

DTC: P006F
EN01H02127030602016031

P006F: Power supply voltage failure

(Out of range high) (VNT actuator power supply too high)
INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300137

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

Power supply voltage failure (High) Power supply voltage is 18 V or higher for at least 6 seconds.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–150 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Failure in alternator, regulator, or other part of the power supply system
 ENGINE (J05E)/TROUBLESHOOTING 2–151

INSPECTION PROCEDURE: P006F

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P006F (U010C)
has been detected.

SHTS021270300138

Has DTC U010C been detected?

YES NO

Go to diagnosis procedure of the related Go to step 3.

DTC.
After repair, go to step 2.

2 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P006F has been detected.

SHTS021270300139

Has DTC P006F been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–152 ENGINE (J05E)/TROUBLESHOOTING

3 Check the VNT controller power supply circuit

1. Set the starter key to the "LOCK" position.

GND
+B 2. Disconnect the VNT controller connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the VNT controller vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300140 VNT controller

vehicle side con-
Starter key: ON 8 V or more
nector
+B – GND

Do the measurements meet the standard value?

YES NO

Procedure completed. Check the VNT controller power supply cir-

Perform "After-inspection work" of INFOR- cuit.
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–153

DTC: P007B
EN01H02127030602016032

P007B: Intake air temperature sensor (intercooler outlet) - rationality

INFORMATION [at Engine Startup]

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)
$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

(E2) ZDQ YWC (ETHA)

Fuel temperature sensor J5R (THF)
(THF) Y57

SHTS021270300141

1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.

<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
2–154 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average temperature of the air intake temperature sensor (built in the air flow meter) and the
intercooler outlet temperature sensor is 30 C {86 F} or more while the average temperature of the intercooler
outlet temperature sensor and the intake manifold temperature sensor is 30 C {86 F} or more.

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Intercooler outlet temperature sensor malfunction
• Failure of intake air temperature sensor (with built-in air flow meter)
• Intake air temperature sensor malfunction
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• ECU sensor power supply failure
 ENGINE (J05E)/TROUBLESHOOTING 2–155

P007B: Intake air temperature sensor (intercooler outlet) - rationality

INFORMATION [while Driving (1)]

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)
$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

(E2) ZDQ YWC (ETHA)

Fuel temperature sensor J5R (THF)
(THF) Y57

SHTS021270300142

1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.

<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
2–156 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 engine speed remains at 500 r/min or more for 5 seconds or more.

The conditions described below remain for 40 seconds or more.

• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st.cyl or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl. sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mph or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow meter) is -10 C {14 F} or more.
• Exhaust brake and DPR is not actuated.
(2) Judgement criteria
• The calculated intercooler efficiency, which is derived from the intake temperature sensor, boost pressure sen-
sor, intercooler outlet temperature sensor, and atmospheric pressure sensor, is greater than 140%.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Intercooler outlet temperature sensor malfunction
• Failure of intake air temperature sensor (with built-in air flow meter)
• 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)
• ECU sensor power supply failure
 ENGINE (J05E)/TROUBLESHOOTING 2–157

P007B: Intake air temperature sensor (intercooler outlet) - rationality

INFORMATION [while Driving (2)]

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)
$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

(E2) ZDQ YWC (ETHA)

Fuel temperature sensor J5R (THF)
(THF) Y57

SHTS021270300143

1. Technical description
• The intercooler outlet temperature sensor, which is installed downstream of the boost pressure sensor, constantly
measures the intake temperature at the intercooler outlet.

<Description of malfunction>
• The intake temperature at the intercooler outlet cannot be correctly recognized.
2–158 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 engine speed remains at 500 r/min or more for 5 seconds or more.

The conditions described below remain for 40 seconds or more.

• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st.cyl or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mile/h or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow meter) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency is less than 65%,
• the difference between the intake manifold air take temperature and the actual intake air temperature is lower
than the specified value (less than 10 C {50 F} when the EGR rate is 0%, less than 17 C {62.6 F} when the
EGR rate is 20% and less than 60 C {140 F} when the EGR rate is 60%), and
• the calculated intercooler efficiency is lower than the specified value (less than 45% when the vehicle speed is
13 mile/h or less than 65% when the vehicle speed is 25 mile/h).

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–159

8. Estimated failure factors

• Intercooler outlet temperature sensor malfunction
• Failure of intake air temperature sensor (with built-in air flow meter)
• 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)
• ECU sensor power supply failure
2–160 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P007B

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. 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.
HINT
Intercooler outlet temperature sensor characteristic abnormality
judgement is performed based on the boost pressure and EGR
SHTS021270300144
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.

Has a DTC other than P007B been detected?

(P0401, P0402, P0404, P0234, P0299, P22D3, or turbocharger/EGR system DTC)

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect intercooler outlet temperature sensor connector

1. Check the connection of the intercooler outlet temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–161

3 Inspect the intercooler outlet temperature sensor

1. Check the installation of the intercooler outlet temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intercooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the intercooler outlet temperature sensor unit

1. Set the starter key to the "LOCK" position.

THG E2 2. Disconnect the intercooler outlet temperature sensor connector.

3. Measure the resistance between the terminals of the intercooler

outlet temperature sensor using the electrical tester.

Measurement Tester
Standard values
conditions connections

Intercooler outlet 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300145 sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the intercooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–162 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the intercooler outlet temperature sensor power supply

1. Set the starter key to the "ON" position.

E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the intercooler outlet temperature sensor vehicle side con-
nector.

Measurement Tester
Standard values
conditions connections

Intercooler outlet
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300146 connector
THG – E2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.

6 Inspect for short-circuit in wire harness of intercooler outlet temperature sensor

1. Set the starter key to the "LOCK" position.

E44 D
E76 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. 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-

SHTS021270300147 nal check har-
ness)
Starter key: LOCK THA0 (E44) – 
Ground
EP2 (E76) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–163

7 Inspect for disconnection in wire harness of intercooler outlet temperature sensor

1. Connect the intercooler outlet temperature sensor connector.

E44 D 2. Measure the resistance between the terminals of engine ECU (sig-
E76 nal check harness) using the electrical tester.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THA0 (E44) –
2.435 – 1.994 k
SHTS021270300148 EP2 (E76)

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the intake air temperature sensor

1. Check the installation of the intake air temperature sensor (air flow
meter).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 9.

If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–164 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the intake air temperature sensor unit

1. Set the starter key to the "LOCK" position.

E2 THA 2. Disconnect the intake air temperature sensor (air flow meter) con-
nector.

3. Measure the resistance between the terminals of the intake tem-

perature sensor using the electrical tester.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
intake tempera-
SHTS021270300149 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k

Do the measurements meet the standard value?

YES NO

Go to step 10. Replace the intake air temperature sensor.

Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the boost pressure sensor hose

1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

Was any failure found?

YES NO

1. Replace the boost pressure sensor hose. Go to step 11.

2. Clean the intake manifold pipes
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–165

11 Inspect the boost pressure sensor power supply system

1. Set the starter key to the "LOCK" position.

E VC
2. Disconnect the boost pressure sensor connector.

3. Set the starter key to the "ON" position.

4. Measure the voltage between the terminals of the boost pressure

sensor vehicle side connector using the electrical tester.

Measurement Tester
Standard values
conditions connections

SHTS021270300150 Boost pressure

sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 12. Inspect the wire harness and engine ECU

sensor power supply output value.
Perform "After-inspection work" of INFOR-
MATION section.

12 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 13.

If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–166 ENGINE (J05E)/TROUBLESHOOTING

13 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Measure the resistance between the terminals of the sensor using

the electrical tester.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300151 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 14. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.

14 Check the DTC detected (Engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P007B has been detected.

SHTS021270300152

Has DTC P007B been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–167

DTC: P007C and P007D

EN01H02127030602016033

P007C: Intake air temperature sensor (intercooler outlet) - out of range (Out of range low)
INFORMATION

Engine ECU

$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)

(THG) X7U X4A (THG)

EGR Exhaust gas
temperature sensor (E2) Z2N ZXS (E07)

J0M YKE (VCPA)

(VC)
Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

SHTS021270300153

1. Technical description
• The intercooler outlet temperature sensor installed to the downstream of the boost pressure sensor consistently
measures temperature at the outlet of the intercooler.

<Description of malfunction>
• The intake air temperature at the intercooler outlet cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the intercooler outlet temperature sensor remains at 0.06 V (200 C {392 F})or less for 3 seconds or
longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–168 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Disconnection or short-circuit in sensor harness
• Faulty connector contact or fit
• Intercooler outlet temperature sensor failure
- Abnormal resistance
- Internal short
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–169

P007D: Intake air temperature sensor (intercooler outlet) - out of range (Out of range high)
INFORMATION

Engine ECU

$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)

(THG) X7U X4A (THG)

EGR Exhaust gas
temperature sensor (E2) Z2N ZXS (E07)

J0M YKE (VCPA)

(VC)
Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

SHTS021270300154

1. Technical description
• The intercooler outlet temperature sensor installed to the downstream of the boost pressure sensor consistently
measures temperature at the outlet of the intercooler.

<Description of malfunction>
• The intake air temperature at the intercooler outlet cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Intake air temperature is -20 C {-4 F} or more.
(2) Judgement criteria
• Output of the intercooler outlet temperature sensor remains at 4.87 V (-35 C {-31 F}) or higher for 3 seconds
or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–170 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Disconnection or short-circuit in sensor harness
• Faulty connector contact or fit
• Intercooler outlet temperature sensor failure
- Abnormal resistance
- Internal short
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–171

INSPECTION PROCEDURE: P007C and P007D

1 Inspect the intercooler outlet temperature sensor connector

1. Check the connection of the intercooler outlet temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the intercooler outlet temperature sensor

1. Check the installation of the intercooler outlet temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intercooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–172 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the intercooler outlet temperature sensor unit

1. Set the starter key to the "LOCK" position.

THG E2 2. Disconnect the intercooler outlet temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intercooler outlet temperature sensor.

Measurement Tester
Standard values
conditions connections

Intercooler outlet 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300155 sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the intercooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–173

4 Inspect for short-circuit in wire harness of intercooler outlet temperature sensor

1. Set the starter key to the "LOCK" position.

E44 D
E76 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminals and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300156 nal check har-
ness)
Starter key: LOCK THA0 (E44) – 
Ground
EP2 (E76) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

5 Inspect for disconnection in wire harness of intercooler outlet temperature sensor

1. Connect the intercooler outlet temperature sensor connector.

E44 D 2. Use the electrical tester to measure the resistance between the
E76
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THA0 (E44) –
2.435 – 1.994 k
SHTS021270300157 EP2 (E76)

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–174 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the intercooler outlet temperature sensor power supply

1. Disconnect the intercooler outlet temperature sensor connector.

E44 D
E76
2. Connect the signal check harness to the engine ECU.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the

engine ECU (signal check harness) terminals.

Measurement Tester
Standard values
conditions connections

SHTS021270300158 Engine ECU (sig-

nal check har-
Starter key: ON ness) 4.5 – 5.5 V
THA0 (E44) –
EP2 (E76)

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P007C or P007D) has been
detected.

SHTS021270300159

Has DTC (P007C or P007D) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–175

DTC: P0088
EN01H02127030602016034

P0088: Fuel system pressure - High

INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

SHTS021270300160

1. Technical description
• Common rail pressure is controlled by a discharge rate of the supply pump.
• Discharge rate of the supply pump is adjusted by the SCV (suction control valve).

<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.

2. DTC set condition

(1) DTC detection condition
• Common rail pressure is normal.
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• A calculated value of (actual common rail pressure reading – Target common rail pressure.) remains at 232
MPa or greater for 1 seconds.

3. Reset condition
• After restoration to normal condition and starter key "ON"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
• Cruise control function is not available.
2–176 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fuel filter: Clogging, dirt, damage
• Common rail pressure sensor: Irregular contact (fault in power supply, fault in GND), fault in sensor
• Supply pump: Fault in SCV, fault in learned value
• Common rail: Pressure limiter opening valve
• Harness related: Irregular contact of crankshaft position sensor and camshaft position sensor, misconnection
 ENGINE (J05E)/TROUBLESHOOTING 2–177

INSPECTION PROCEDURE: P0088

1 Inspect the start of the engine

1. Inspect the start of the engine.

Does the engine start?

YES NO

Go to step 4. Go to step 2.

2 Inspect the supply pump

1. Check if fuel is leaking or seeping out of the supply pump.

SUPPLY PUMP

SHTS021270300161

Was any failure found?

YES NO

Replace the supply pump, and go to step 4. Go to step 3.

2–178 ENGINE (J05E)/TROUBLESHOOTING

3 Function check of supply pump [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP䌡
Common rail pressure

The pressure limiter is 3. Select [Engine].

open reducing the pressure.

4. Select [Actual common rail pressure] and [Target common rail

Idling pressure] in [Data monitor and Active test].

5. Start the engine while checking the common rail pressure.

Starter 䌏䌎 (Engine starting) Hour
Standard values
SHTS021270300162
The actual common rail pressure rises and stabilizes at a
constant value.

Was any failure found?

YES NO

Replace the supply pump, go to step 4. Contact the TSM.

4 Inspect the pre fuel filter

1. Check the pre fuel filter.

• Has the replacement period expired?
• Is it dirty, damaged, or clogged?
• Is it a genuine Hino part?

SHTS021270300163

Was any failure found?

YES NO

Replace the pre fuel filter element, and go to Go to step 10.

step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–179

5 Inspect the fuel pipe

1. Check if the fuel pipe and hose between the fuel tank and pre fuel
filter are clogged, punctured, or bent.

2. Make sure the fuel pipe joint bolts are not loose.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 6.

step 6.

6 Inspect the fuel tank breather

1. Check if the breather hose is clogged, punctured, or bent.

2. Make sure the check valve is functioning normally.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 7.

step 7.

7 Inspect the fuel tank feed pipe

1. Make sure the fuel tank feed pipe is not clogging.

Was any failure found?

YES NO

Repair or replace the faulty part and, go to Go to step 8.

step 8.
2–180 ENGINE (J05E)/TROUBLESHOOTING

8 Inspect the fuel tank

1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.

Was any failure found?

YES NO

Remove the foreign object and clean the fuel Go to step 9.

tank.
Then go to step 9.

9 Inspect the supply pump gauze filter

1. Make sure the gauze filter (built into the supply pump) is not
clogged.

Was any failure found?

YES NO

Clean the gauze filter, and go to step 10. Go to step 10.

10 Inspect the fuel high-pressure pipe

1. Make sure the fuel high-pressure pipe is not leaking fuel.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 11.

step 11.

11 Inspect the fuel filter

1. Make sure the fuel filter is not clogging.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 12.

step 12.
 ENGINE (J05E)/TROUBLESHOOTING 2–181

12 Inspect the SCV connector

1. Check the connection of the SCV connector (looseness and poor

contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 13.

step 13.

13 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 14.

step 14.

14 Inspect the common rail pressure sensor power supply

1. Disconnect the common rail pressure sensor connector.

VC2 E2
2. Set the starter key to the "ON" position.

3. 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
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300164 cle side connector
VC2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 15. Replace the common rail pressure sensor

and then go to step 15.
2–182 ENGINE (J05E)/TROUBLESHOOTING

15 Inspect the engine speed main sensor (crankshaft position sensor)

1. Set the starter key to the "ON" position.

2. Select [Engine].

3. Select [NE active identification], [G active identification] in [Data

monitor and Active test].

4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.

SHTS021270300165

Was any failure found?

YES NO

Check the faulty the engine speed main sen- Go to step 16.
sor (crankshaft position sensor) and repair
or replace it as needed.
After inspection, go to step 16.

16 Inspect the fuel return pipe and hose

1. Check if the fuel return pipe and hose are clogged.

Was any failure found?

YES NO

Repair or replace the faulty part. Report the TSM.

 ENGINE (J05E)/TROUBLESHOOTING 2–183

DTC: P0096
EN01H02127030602016035

P0096: Intake air temperature sensor (intake manifold) - rationality

INFORMATION [at engine start]

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)
$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

(E2) ZDQ YWC (ETHA)

Fuel temperature sensor J5R (THF)
(THF) Y57

SHTS021270300166

1. Technical description
• The intake manifold temperature sensor installed to the intake manifold consistently measures intake manifold tem-
perature.

<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2–184 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 mm3/st. cyl 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 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average temperature difference between the intake manifold temperature sensor and the
intake air temperature sensor (built-in air flow meter) is 30 C {86 F} or more while the average temperature
difference between the intake manifold temperature sensor and the intercooler outlet temperature sensor is 30
C {86 F} or more.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Failure of intercooler outlet temperature sensor
• Failure of intake air temperature sensor (with built-in air flow meter)
• Failure of intake manifold temperature sensor
- Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
- Faulty resistance (due to sticking)
• Malfunction of ECU sensor power supply
 ENGINE (J05E)/TROUBLESHOOTING 2–185

P0096: Intake air temperature sensor (intake manifold) - rationality

INFORMATION [at engine running]

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)
$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)

(E) Z6R YKE

(EPA)

Intercooler outlet
(E2) E7Q
temperature sensor
(THG) E7P XSW
(THAO)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

(E2) ZDQ YWC (ETHA)

Fuel temperature sensor J5R (THF)
(THF) Y57

SHTS021270300167

1. Technical description
• The intake manifold temperature sensor installed to the intake manifold consistently measures intake manifold tem-
perature.

<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.
2–186 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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.

• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The engine speed is 1000 r/min or less.
• Fuel injection quantity is 35 mm3/st.cyl or less.
• Engine coolant temperature is in the range of -30 to 60 C {-22 to 140 F}.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency is greater than 65%,
• the difference between the calculated intake manifold air intake temperature and the actual intake air is higher
than 60 C {140 F} or less than -60 C {-76 F}, and
• the calculated intercooler efficiency is higher than the specified value (30% or more when the vehicle speed is
13 mile/h, 50% or more when the vehicle speed is 25 mile/h).

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Failure of intercooler outlet temperature sensor
• Failure of intake air temperature sensor (with built-in air flow meter)
• Failure of intake manifold temperature sensor
• Failure of 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)
• Malfunction of ECU sensor power supply
 ENGINE (J05E)/TROUBLESHOOTING 2–187

INSPECTION PROCEDURE: P0096

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. 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.
HINT
Intercooler outlet temperature sensor characteristic abnormality
judgement is performed based on the boost pressure and EGR
SHTS021270300168
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.

Has a DTC other than P0096 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the intake manifold temperature sensor connector

1. Check the connection of the intake manifold temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–188 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the intake manifold tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300169 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–189

5 Inspect the intake manifold temperature sensor power supply

1. Set the starter key to the "ON" position.

E2 THA
2. Use the electrical tester to measure the voltage between the termi-
nals of the intake manifold temperature sensor vehicle side con-
nector.

Measurement Tester
Standard values
conditions connections

Intake manifold
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300170 connector
THA – E2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.

6 Inspect for short-circuit of the intake manifold temperature sensor harness

1. Set the starter key to the "LOCK" position.

M54
D F
E63 2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

3. 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-

SHTS021270300171 nal check har-
ness)
Starter key: LOCK THIA (E63) – 
Ground
ETHA (M54) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–190 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect disconnection of the intake manifold temperature sensor harness

1. Connect the intake manifold temperature sensor connector.

M54
D F 2. Use the electrical tester to measure the resistance between the
E63 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
ATIA (E63) –
2.435 – 1.994 k
SHTS021270300172 ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the intake air temperature sensor (air flow meter built-in)

1. Check the installation of the intake air temperature sensor (air flow
meter built-in).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake air temperature sensor (air flow meter built-in).

Was any failure found?

YES NO

If the sensing part is dirty, clogged, or dam- Go to step 9.

aged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–191

9 Inspect the intake air temperature sensor (air flow meter built-in) unit

1. Set the starter key to the "LOCK" position.

E2 THA
2. Disconnect the intake air temperature sensor (air flow meter built-
in) connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake air temperature sensor (air flow meter built-
in).

Measurement Tester
Standard values
conditions connections

SHTS021270300173 Intake air tempera- 20 C {68 F}:

ture sensor (air 2.69 – 2.21 k
Starter key: LOCK
flow meter built-in) 60 C {140 F}:
THA – E2 0.667 – 0.493 k

Do the measurements meet the standard value?

YES NO

Go to step 10. Replace the intake air temperature sensor

(air flow meter built-in).
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the intercooler outlet temperature sensor

1. Check the installation of the intercooler outlet temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intercooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 11.

If damaged, replace the intercooler outlet
temperature sensor
Perform "After-inspection work" of INFOR-
MATION section.
2–192 ENGINE (J05E)/TROUBLESHOOTING

11 Inspect the intercooler outlet temperature sensor unit

1. Set the starter key to the "LOCK" position.

THG E2 2. Disconnect the intercooler outlet temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intercooler outlet temperature sensor.

Measurement Tester
Standard values
conditions connections

Intercooler outlet 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300174 sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 12. Replace the intercooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.

12 Inspect the boost pressure sensor hose.

1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

Was any failure found?

YES NO

1. Replace the boost pressure sensor hose. Go to step 13.

2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–193

13 Inspect the boost pressure sensor power supply system

1. Set the starter key to the "LOCK" position.

E
2. Disconnect the boost pressure sensor connector.
VC

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300175 Boost pressure

sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 14. Inspect the wire harness and engine ECU

sensor power supply output valve.
Perform "After-inspection work" of INFOR-
MATION section.

14 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0096 has been detected.

SHTS021270300176

Has DTC P0096 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–194 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0097 and P0098

EN01H02127030602016036

P0097: Intake air temperature sensor (intake manifold) - out of range (Out of range low)
INFORMATION

Engine ECU

$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G YWC (ETHA)
temperature sensor (THA) X0Q XZJ (THIA)

SHTS021270300177

1. Technical description
• The intake air temperature sensor installed to the intake manifold consistently measures intake manifold tempera-
ture.

<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Intake manifold temperature sensor output ≤ 0.06 V (200 C {392 F}) for at least 3 seconds.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–195

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Disconnection or short-circuit in sensor harness
• Poor connector contact or faulty connector fit.
• Intake manifold temperature sensor:
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
- Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply, malfunction of internal circuit.
2–196 ENGINE (J05E)/TROUBLESHOOTING

P0098: Intake air temperature sensor (intake manifold) - out of range (Out of range high)
INFORMATION

Engine ECU

$XV (PC1S)
EBK YWL
(E1) (EP1)
(PCR1) EBJ XZG (PCR1)

(VC1) EBH YWK (VCP1)

Common rail
pressure sensor (E2) EBN YWM (EP2)
XZH
(PCR2) EBM (PCR2)
(VC2) EBL YWH
(VCP2)
$XW
(PC2S)
Intake manifold (E2) Z7G YWC (ETHA)
temperature sensor (THA) X0Q XZJ (THIA)

SHTS021270300178

1. Technical description
• The intake manifold temperature sensor installed to the intake manifold consistently measures intake manifold tem-
perature.

<Description of malfunction>
• The intake manifold temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Intake manifold temperature sensor output remains less than 4.87 V (-35 C {-31 F}) for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–197

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Disconnection or short-circuit in sensor harness
• Irregular contact, improper engagement
• Intake manifold temperature sensor:
- Abnormality in resistance of sensor
- Internal short-circuit
• Failure in engine ECU sensor power supply, malfunction of internal circuit
2–198 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0097 and P0098

1 Inspect the intake manifold temperature sensor connector

1. Check the connection of the intake manifold temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Remove all contaminants and clogging. Go to step 3.

Replace if damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–199

3 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300179 sor 50 C {122 F}:
E2 – THA 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–200 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect for short-circuit of the intake manifold temperature sensor harness

1. Set the starter key to the "LOCK" position.

M54
D F
E63 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300180 nal check har-
ness)
Starter key: LOCK THIA (E63) – 
Ground
ETHA (M54) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–201

5 Inspect disconnection of the intake manifold temperature sensor harness

1. Connect the intake manifold temperature sensor connector.

M54
D F 2. Use the electrical tester to measure the resistance between the
E63 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

20 C {68 F}:
nal check har-
7.336 – 5.794 k
Starter key: LOCK ness)
50 C {122 F}:
THIA (E63) –
2.435 – 1.994 k
SHTS021270300181 ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect the sensor power supply

1. Connect the signal check harness to the engine ECU.

M54
D F 2. Set the starter key to the "ON" position.
E63
3. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
SHTS021270300182 Starter key: ON ness) 4.5 – 5.5 V
THIA (E63) –
ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine ECU.

2–202 ENGINE (J05E)/TROUBLESHOOTING

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0097 or P0098) has been
detected.

SHTS021270300183

Has DTC (P0097 or P0098) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–203

DTC: P00AF
EN01H02127030602016037

P00AF: Controller error (VNT actuator CPU malfunction)

INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300184

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure.
• The LEA has a sensor to detect the movement of the actuator, always monitoring the reading and actual value of
the nozzle vane opening.
• Wiping operation is performed while the engine is stopped for the purpose of removing soot and oil coming out from
the range of vane operation and checking the turbo mechanical operating range for abnormality.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

1. ROM failure ROM readout data differ from previous data.

2. RAM failure RAM write data and read data do not match.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–204 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• CPU failure inside VNT controller
 ENGINE (J05E)/TROUBLESHOOTING 2–205

INSPECTION PROCEDURE: P00AF

1 Check the DTC detected (Engine ECU) 1

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if P00AF (for example, U010C) has

been detected.

SHTS021270300185

Has a DTC other than P00AF been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 3.

DTC.
After the repair, go to step 2.

2 Check the DTC detected (Engine ECU) 2

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P00AF has been detected.

SHTS021270300186

Has DTC P00AF been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–206 ENGINE (J05E)/TROUBLESHOOTING

3 Check the operation of the VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "OFF" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P00AF has been detected.

HINT
Turning the starter key "LOCK" and "ON" verifies the wiping oper-
SHTS021270300187 ation of the VNT actuator (DC motor).

Measurement conditions

Starter key: LOCK  ON

Has DTC P00AF been detected?

YES NO

Replace the VNT controller. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–207

DTC: P0101
EN01H02127030602016038

P0101: Air flow meter - rationality

INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300188

1. Technical description
• The air flow meter mounted on the air cleaner constantly measures the intake air quantity.

<Description of malfunction>
• Air flow meter value cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Engine speed is between 720 r/min and 980 r/min.
• Engine speed variation is 234.4 r/min/sec or less.
• Fuel injection rate is between 0 mm3/st. cyl. sec and 80 mm3/st. cyl.
• Fuel injection rate variation is 78.1 mm3/st. cyl sec. or less.
• Engine coolant temperature is 55 C {131 F} or less.
• EGR valve opening is 0% or less (EGR-cut status)
• Exhaust brake is not actuated.
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.15
or no greater than 0.75. And:
• Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• The condition "(Average boost pressure minus average atmospheric pressure) was ≥18 kPa" when the starter
key turned off and engine was stopped after previous DCY is not continued for more than 3 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–208 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
• EGR valve malfunction
• Diesel throttle valve (intake throttle valve) malfunction
• Intercooler failure (due to dirt, clogging, etc.)
• Engine ECU sensor power supply (air flow meter dedicated 12 V power supply) failure or internal circuit failure
 ENGINE (J05E)/TROUBLESHOOTING 2–209

INSPECTION PROCEDURE: P0101

1 Inspect the air cleaner element

1. Check the air cleaner element is dirty, clogged or damaged.

2. Make sure the element is a Hino genuine part.

Was any failure found?

YES NO

Clean or replace the air cleaner element. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Check the intake system

1. Check the intake hose and verify that there are no disconnections,
clogging, punctures, or cracks.

2. Check the breather hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.

3. Check the intercooler hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.

Was any failure found?

YES NO

Repair or replace the intake system hoses. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–210 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If dirt, clogging or damage was found,
replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect for short-circuits in wire harness of air flow meter

1. Set the starter key to the "LOCK" position.

C D
E12 2. Disconnect the air flow meter connector.

3. Connect the signal check harness to the engine ECU vehicle side
E74 E78 harness. (Do not connect harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminals and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300189
Engine ECU (sig-
nal check har-
ness)
VAF (E12) –
Starter key: LOCK 
Ground
VG (E74) – Ground
EVG (E78) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–211

5 Inspect for disconnection in wire harness of air flow meter

1. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminal and the air flow meter
C vehicle side connector terminal.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (sig-
D
FC nal check har-
ness) – air flow
meter vehicle side
E74 E78
Starter key: LOCK 1  or less
connector
VAF (E12) – +B
VG (E74) – FC
EVG (E78) – E2G

SHTS021270300190

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Replace the air flow meter.

1. Set the starter key to the "LOCK" position.

2. Replace the air flow meter with a new one.

3. Start the engine.

4. After thirty seconds, stop the engine and set the starter key to the
"LOCK" position.

5. Set the starter key to the "ON" position.

6. Select [Engine] and check if P0101 has been detected.

SHTS021270300191

Has DTC P0101 been detected?

YES NO

Go to step 7. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–212 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect the EGR valve

1. Check the EGR valve for damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 7.

valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–213

8 Check the response delay of the EGR valve

1. Set the starter key to the "ON" position.

(1)

2. Check the time lag (following characteristics) of the target EGR

(3)
(2) valve opening and actual EGR valve opening.

(4) ! CAUTION
(5) Perform the inspection while the engine is stopped to avoid
engine damages.
<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
SHTS021270300192
(4) Select [EGR opening UP]:
• Check each step from 0% – 90% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
(5) Select [EGR opening DOWN]:
• Check each step from 90% – 0% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
HINT
In EGR openings from 0% – 90%, 1 step corresponds to a 10%
change.

Standard values

The response delay should be less than 5 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 9. Replace the EGR valve.

Perform "After-inspection work" of INFOR-
MATION section.
2–214 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the diesel throttle valve (intake throttle valve)

1. Stop the engine.

2. Check the operating status of the diesel throttle valve (intake throt-
tle valve) (for incorrect opening or sticky valve).

Was any failure found?

YES NO

Replace the diesel throttle valve (intake throt- Go to step 10.

tle valve).
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the intercooler

1. Check if there is an obstruction due to clogging inside the inter-

cooler.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 11.

intercooler.
Replace the intercooler if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–215

11 Check the DTC detected

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0101 has been detected.

SHTS021270300193

Has DTC P0101 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–216 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0104
EN01H02127030602016039

P0104: Air flow meter - out of range

INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300194

1. Technical description
• The air flow meter installed to the air cleaner consistently measures an intake air volume.

<Description of malfunction>
• The air flow meter value cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• Engine speed remains at 725 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the output of the air flow meter is less than 2.00 kHz (3.9 kg/h) remains for 2 seconds or
more, or the condition that the output of the air flow meter is greater than 9.8 kHz (1632 kg/h) remains for 2
seconds or more.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted

5. 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>

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–217

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Sensor disconnected from the measured part or sensing unit malfunctioning (due to dirt, clogging, damage, etc.
• Engine ECU sensor power supply (air flow meter dedicated 12 V power supply) malfunction or internal circuit mal-
function
• Sensor harness disconnection, short-circuit
• Poor connector contact or faulty connector fit
• Sensor harness high frequency noise
2–218 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0104

1 Check the DTC detected (Engine ECU) 1

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0104 (for example, P0642, P0643,

P0652, P0653) has been detected.

SHTS021270300195

Has a DTC (for example, P0642, P0643, P0652, P0653) other than P0104 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the air flow meter connector

1. Check the connection of the air flow meter connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–219

3 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect for short-circuit of the air flow meter harness

1. Set the starter key to the "LOCK" position.

C D
E12 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

E74 E78 3. Disconnect the air flow meter connector.

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300196
Engine ECU (sig-
nal check har-
ness)
VG (E74) – Ground
Starter key: LOCK 
EVG (E78) –
Ground
VAF (E12) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–220 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect disconnection of the air flow meter harness

1. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and air flow
C meter vehicle side connector.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (sig-
D
FC nal check har-
ness) – Air flow
meter vehicle side
E74 E78
Starter key: LOCK 1  or less
connector
VG (E74) – FC
EVG (E78) – E2G
VAF (E12) – +B

SHTS021270300197

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–221

6 Inspect the air flow meter power supply

1. Connect the signal check harness to the engine ECU.

+B E2G
2. Set the starter key to the "ON" position.

3. Use the electrical tester to measure the voltage between the termi-
nals of the air flow meter vehicle side connector.

Measurement Tester
Standard values
conditions connections

Air flow meter

vehicle side con-
Starter key: ON 10 – 16 V
SHTS021270300198 nector
+B – E2G

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.
2–222 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect the air flow meter signal

1. Set the starter key to the "LOCK" position.

E74 E78
D 2. Connect the air flow meter connector.

3. Start the engine.

4. Use the oscilloscope to measure the signal voltage between the

terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300199 Engine ECU (sig-

After engine warm nal check har-
up, with engine ness) 5 – 6 kHz
idling VG (E74) –
EVG (E78)

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the air flow meter.

Perform "After-inspection work" of INFOR-
MATION section.

8 Check the DTC detected (Engine ECU) 2

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0104 has been detected.

SHTS021270300200

Has DTC P0104 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–223

DTC: P0106
EN01H02127030602016040

P0106: Boost pressure sensor - rationality

INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(VC) J0M YKF (VCPA)
Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

SHTS021270300201

1. Technical description
• The boost pressure sensor mounted on the diesel throttle (intake throttle valve) outlet constantly measures the
boost pressure.

<Description of malfunction>
• Boost pressure cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Engine speed is between 720 r/min and 980 r/min.
• Engine speed variation is 234.4 r/min/sec or less.
• Fuel injection rate is between 0 mm3/st. cyl and 80 mm3/st. cyl.
• Fuel injection rate variation is 78.1 mm3/st. cyl or less.
• Engine coolant temperature is 55 C {131 F} or less.
• EGR valve opening is 0% or less (EGR-cut status)
• Exhaust brake is not actuated
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.15
or no greater than 0.75.
• And: Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• When prior DCY starter key is turned "LOCK" and engine is stopped, (Average boost pressure – average
atmospheric pressure) is ≥ 18 kPa, and this condition continues for at least 3 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–224 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• Engine output is insufficient.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.)
• Abnormal sensor resistance (stuck sensor)
• Engine ECU sensor power supply failure, internal circuit failure
 ENGINE (J05E)/TROUBLESHOOTING 2–225

INSPECTION PROCEDURE: P0106

1 Inspect the boost pressure sensor connector

1. Check the connection of the boost pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

3. Make sure there is no dirt, damage or clogging in the pipes or

hoses unit of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If dirt, clogging or damage was found,
replace the boost pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–226 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect for short-circuits in wire harness of boost pressure sensor

1. Set the starter key to the "LOCK" position.

F E67 D
E77 2. Disconnect the boost pressure sensor connector.
M51

3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

4. 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
SHTS021270300202
Engine ECU (sig-
nal check har-
ness)
VCPA (M51) –
Starter key: LOCK Ground 
PIM (E67) –
Ground
EPA (E77) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–227

4 Inspect for disconnection in wire harness of boost pressure sensor

1. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) and boost pressure sensor
F vehicle side connector terminals.
M51
PIM Measurement Tester
E
Standard values
VC conditions connections

D Engine ECU (sig-

E67
nal check har-
E77
ness) – boost
pressure sensor
Starter key: LOCK vehicle side con- 
nector
VCPA (M51) – VC
PIM (E67) – PIM
EPA (E77) – E

SHTS021270300203

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–228 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the boost pressure sensor power supply

1. Connect the engine ECU vehicle side harness to the engine ECU.

E
2. Set the starter key to the "ON" position.
VC

3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300204 side connector
VC – E

Do the measurements meet the standard value?

YES NO

Replace the boost pressure sensor. Replace the engine ECU.

Go to step 6 after replacement. Perform "After-inspection work" of INFOR-
MATION section.

6 Check the DTC detected (Engine ECU)

1. Warm up the engine (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0106 has been detected.

SHTS021270300205

Has DTC P0106 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–229

DTC: P0107
EN01H02127030602016041

P0107: Boost pressure sensor - out of range (Out of range low)

INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(VC) J0M YKF (VCPA)
Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

SHTS021270300206

1. Technical description
• The boost pressure sensor install in the outlet of the diesel throttle (intake throttle valve) consistently detects boost
pressure.

<Description of malfunction>
• Boost pressure cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.3 V (32.4 kPa) or less for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–230 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Failure in engine ECU sensor power supply or internal circuit
• Looseness or poor contact of connector
 ENGINE (J05E)/TROUBLESHOOTING 2–231

INSPECTION PROCEDURE: P0107

1 Inspect the boost pressure sensor connector

1. Check the connection of the boost pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–232 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect for short-circuit of the boost pressure sensor harness

1. Set the starter key to the “LOCK” position.

F 2. Disconnect the boost pressure sensor connect.

M51
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections
D E67 Engine ECU (sig-
E77 nal check har-
ness)
VCPA (M51) –
Starter key: LOCK Ground 
PIM (E67) –
Ground
EPA (E77) –
Ground
SHTS021270300207

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–233

4 Inspect disconnection of the boost pressure sensor harness

1. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and the boost
F pressure sensor vehicle side connector.
M51 PIM
E VC Measurement Tester
Standard values
conditions connections

D Engine ECU (sig-

nal check har-
ness) – Boost
pressure sensor
E67 vehicle side con-
E77 Starter key: LOCK 1
nector
(1) VCPA (M51) –
VC
(2) PIM (E67) – PIM
(3) EPA (E77) – E

SHTS021270300208

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–234 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the boost pressure sensor power supply

1. Connect the engine ECU vehicle side harness to the engine ECU.

E
2. Set the starter key to the "ON" position.
VC

3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300209 side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 6. Replace the engine ECU.

6 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0107 has been detected.

SHTS021270300210

Has DTC P0107 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–235

DTC: P0108
EN01H02127030602016042

P0108: Boost pressure sensor - out of range (Out of range high)

INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(VC) J0M YKF (VCPA)
Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

SHTS021270300211

1. Technical description
• The boost pressure sensor installed at the outlet of the diesel throttle (intake throttle valve) consistently measures
boost pressure.

<Description of malfunction>
• The boost pressure cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the boost pressure sensor remains greater than 3.67 V (327.4 kPa) for 3 seconds or longer.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–236 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Short-circuit in the sensor
 ENGINE (J05E)/TROUBLESHOOTING 2–237

INSPECTION PROCEDURE: P0108

1 Inspect the boost pressure sensor connector

1. Check the connection of the boost pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–238 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect for short-circuit of the boost pressure sensor harness

1. Set the starter key to the "LOCK" position.

F D E67 2. Disconnect the boost pressure connector.
M51 E77

3. Connect the signal check harness to the engine ECU vehicle side
connector. (Do not connect the harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300212
Engine ECU (sig-
nal check har-
ness)
VCPA (M51) –
Starter key: LOCK Ground 
PIM (E67) –
Ground
EPA (E77) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–239

4 Inspect disconnection of the boost pressure sensor harness

1. Connect the boost pressure sensor connector.

F 2. Use the electrical tester to measure the resistance between the

M51 terminals of the engine ECU and the boost pressure sensor vehi-
E PIM cle side connector (signal check harness).
VC
Measurement Tester
D Standard values
conditions connections

Engine ECU (sig-

nal check har-
E77
E67 ness) – Boost
pressure sensor
Starter key: LOCK vehicle side con- 1
nector
VCPA (M51) – VC
PIM (E67) – PIM
EPA (E77) – E

SHTS021270300213

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the boost pressure sensor power supply

1. Connect the vehicle side harness connect to the engine ECU.

E
2. Set the starter key to the "ON" position.
VC

3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300214 side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 6. Replace the engine ECU.

2–240 ENGINE (J05E)/TROUBLESHOOTING

6 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0108 has been detected.

SHTS021270300215

Has DTC P0108 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–241

DTC: P0111
EN01H02127030602016043

P0111: Intake air temperature sensor (air flow meter built-in) - rationality
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300216

1. Technical description
• The intake air temperature sensor with built-in air flow meter constantly measures the intake air temperature.

<Description of malfunction>
• Intake air temperature is not correctly recognized.

2. DTC set condition

(1) DTC detection condition

The following conditions continue for at least 20 seconds:

• Engine speed is 1,000 r/min or less.
• Fuel injection rate is at least 35 mm3/st. cyl or less.
• Engine coolant temperature is between -30 C {-22 F} to 55 C {131 F}.
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

The following conditions continue for at least 3 seconds:

• Difference between intake air temperature (air flow meter) and intercooler outlet temperature is at least 30 C
{86 F}, and difference between intake air temperature (air flow meter) and intake manifold air temperature is
at least 30 C {86 F}.

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–242 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.).
• Faulty resistance (due to sticking).
• Engine ECU sensor power supply or internal circuit failure.
 ENGINE (J05E)/TROUBLESHOOTING 2–243

INSPECTION PROCEDURE: P0111

1 Inspect the intake air temperature sensor connector

1. Check the connection of the intake air temperature sensor (air flow
meter) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the intake air temperature sensor

1. Check the installation of the intake air temperature sensor (air flow
meter).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damage was found, replace the air flow
meter.
Perform "After-inspection work" of INFOR-
MATION section.
2–244 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the intake air temperature sensor unit

1. Set the starter key to the "LOCK" position.

E2 THA
2. Disconnect the intake air temperature sensor (air flow meter) con-
nector.

3. Measure the resistance between the terminals of the sensor using

the electrical tester.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Intake air tempera-
SHTS021270300217 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the intake air temperature sensor.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the intake air temperature sensor power supply

1. Set the starter key to the "ON" position.

THA E2
2. Measure the voltage between the terminals of the intake air tem-
perature sensor vehicle side connector using the electrical tester.

Measurement Tester
Standard values
conditions connections

Intake air tempera-

ture sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
THA – E2
SHTS021270300218

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–245

5 Inspect for short-circuits in wire harness of intake air temperature sensor

1. Set the starter key to the "LOCK" position.

D E47 2. Connect the signal check harness to the engine ECU vehicle side
E58
harness. (Do not connect harness to the ECU.)

3. 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-

SHTS021270300219 nal check har-
ness)
Starter key: LOCK THA (E47) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect for disconnection in wire harness of intake air temperature sensor

1. Connect the intake air temperature sensor connector.

E47
2. Use the electrical tester to measure the resistance between the
D E58
terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

20 C {68 F}:
nal check har-
2.69 – 2.21 k
Starter key: LOCK ness)
60 C {140 F}:
THA (E47) –
0.667 – 0.493 k
SHTS021270300220 ETHW (E58)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–246 ENGINE (J05E)/TROUBLESHOOTING

7 Check the DTC detected (Engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0111 has been detected.

SHTS021270300221

Has DTC P0111 detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–247

DTC: P0112 and P0113

EN01H02127030602016044

P0112: Intake air temperature sensor (air flow meter built-in) - out of range
(Out of range low)
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300222

1. Technical description
• The intake air temperature sensor built in the air flow meter consistently measures intake air temperature.

<Description of malfunction>
• The intake air temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (built in air flow meter) remains less than 0.09 V (90 C {194 F})
for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–248 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
 ENGINE (J05E)/TROUBLESHOOTING 2–249

P0113: Intake air temperature sensor (air flow meter built-in) - out of range
(Out of range high)
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300223

1. Technical description
• The intake air temperature sensor built in the air flow meter consistently measures intake air temperature.

<Description of malfunction>
• The intake air temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5seconds or more.
(2) Judgement criteria
• Output of the intake air temperature sensor (built in air flow meter) remains less than 4.17 V (-42 C {-43.6 F})
for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–250 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormality in resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
• Short-circuit in the sensor
 ENGINE (J05E)/TROUBLESHOOTING 2–251

INSPECTION PROCEDURE: P0112 and P0113

1 Inspect the intake air temperature sensor connector

1. Check the connection of the intake air temperature sensor (air flow
meter) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the intake air temperature sensor

1. Check the installation of the intake air temperature sensor (air flow
meter).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake air temperature sensor

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the intake air tempera-
ture sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–252 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the intake air temperature sensor unit

1. Set the starter key to the "LOCK" position.

E2 THA
2. Disconnect the connector of intake air temperature sensor (air flow
meter built-in).

3. Measure the resistance between the terminals of the intake air

temperature sensor (built-in air flow meter).

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Intake air tempera-
SHTS021270300224 2.69 – 2.21 k
Starter key: LOCK ture sensor
60 C {140 F}:
THA – E2
0.667 – 0.493 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the intake air temperature sensor.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the intake air temperature sensor power supply

1. Set the starter key to the "ON" position.

THA E2
2. Measure the voltage between the terminals of the intake air tem-
perature sensor (built-in air flow meter) (engine sub harness side).

Measurement Tester
Standard values
conditions connections

Intake air tempera-

ture sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
THA – E2
SHTS021270300225

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–253

5 Inspect for short-circuit in wire harness of intake air temperature sensor

1. Set the starter key to the "LOCK" position.

E47
D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. 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-

SHTS021270300226 nal check har-
ness)
Starter key: LOCK THA (E47) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–254 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect for disconnection in wire harness of intake air temperature sensor

1. Connect the intake air temperature sensor connector.

E47
D E58 2. 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-

20 C {68 F}:
nal check har-
2.69 – 2.21 k
Starter key: LOCK ness)
60 C {140 F}:
THA (E47) –
0.667 – 0.493 k
SHTS021270300227 ETHW (E58)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0112 or P0113) has been
detected.

SHTS021270300228

Has DTC (P0112 or P0113) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–255

DTC: P0115
EN01H02127030602016045

P0115: Malfunction of coolant temperature sensor and intake air temperature sensor
INFORMATION

Coolant temperature
sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E) YKC (ETHW)

Coolant temperature
sensor 2

XS1 (THW2) XDN (THWO)

Body earth ZKP (E22) YWC (ETHA)

SHTS021270300229

1. Technical description
• Two engine coolant temperature sensors are installed in thermostat case and constantly measure the engine cool-
ant temperature.
• Although some exhaust gas components operate after the engine coolant temperature has risen to some degree
(engine warm up), when an engine coolant temperature sensor reads a value lower than the actual temperature, it
means it is not working properly. Diagnosis is therefore required to detect if there is something wrong with the char-
acteristics of the engine coolant temperature sensor.

<Description of malfunction>
• Failure of both engine coolant temperature sensors is detected.

2. DTC set condition

(1) DTC detection condition
• Engine speed is at least 500 r/min or engine is stopped.
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• When it is deemed that both engine coolant temperature sensors are malfunctioning.

3. Reset condition
• Problem does not recur in the same driving cycle.
• Normal operation is restored after set the starter key to the "LOCK" position when in subsequent driving cycles,
readings are in the normal range within the above detection conditions.
• Three driving cycles must be deemed normal for MIL to be OFF.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–256 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal resistance of the engine coolant temperature sensor.
• Engine ECU sensor power supply failure.
 ENGINE (J05E)/TROUBLESHOOTING 2–257

INSPECTION PROCEDURE: P0115

1 Inspect the coolant temperature sender No.1 connector

1. Check the connection of the coolant temperature sender No.1 con-

nector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the coolant temperature sender No.1

1. Check the installation of the coolant temperature sender No.1.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of coolant temperature sender No.1.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the coolant temperature
sender No.1.
Perform "After-inspection work" of INFOR-
MATION section.
2–258 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the coolant temperature sender No.1 unit

1. Set the starter key to the "LOCK" position.

E THW
2. Disconnect the coolant temperature sender No.1.

3. Use the electrical tester to measure the resistance between the

terminals of the coolant temperature sender No.1.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Coolant tempera-
2.59 – 2.32 k
Starter key: LOCK ture sender No.1
SHTS021270300230 80 C {176 F}:
THW – E
0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the coolant temperature sender

No.1.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the coolant temperature sender No.1 power supply

1. Set the starter key to the "ON" position.

THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the coolant temperature sender No.1 vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Coolant tempera-
ture sender No.1
Starter key: ON vehicle side con- 4.5 – 5.5 V
SHTS021270300231 nector
THW – E

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–259

5 Check for short-circuit in wire harness of coolant temperature sender No.1

1. Set the starter key to the "LOCK" position.

E66 D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. 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-

SHTS021270300232 nal check har-
ness)
Starter key: LOCK THW (E66) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Check for disconnection in wire harness of coolant temperature sender No.1

1. Connect the coolant temperature sender No.1 connector.

E66 D E58 2. 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-

20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300233 ETHW (E58)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–260 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect the coolant temperature sender No.2 connector

1. Check the connection of the coolant temperature sender No.2 con-

nector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 8.

Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the coolant temperature sender No.2

1. Check the installation of the coolant temperature sender No.2.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the coolant temperature sender No.2.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 9.

If damaged, replace the coolant temperature
sender No.2.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–261

9 Inspect the coolant temperature sender No.2 unit

1. Set the starter key to the "LOCK" position.

E22 THW2
2. Disconnect the coolant temperature sender No.2 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the coolant temperature sender No.2.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Coolant tempera-
2.59 – 2.32 k
Starter key: LOCK ture sender No.2
SHTS021270300234 80 C {176 F}:
THW2 – E22
0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 10. Replace the coolant temperature sender

No.2.
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the coolant temperature sender No.2 power supply

1. Set the starter key to the "ON" position.

THW2 E22
2. Use the electrical tester to measure the voltage between the termi-
nals of the coolant temperature sender No.2.

Measurement Tester
Standard values
conditions connections

Coolant tempera-
ture sender No.2
Starter key: ON vehicle side con- 4.5 – 5.5 V
nector
SHTS021270300235 THW2 – E22

Do the measurements meet the standard value?

YES NO

Go to step 13. Go to step 11.

2–262 ENGINE (J05E)/TROUBLESHOOTING

11 Check for short-circuit in wire harness of coolant temperature sender No.2

1. Set the starter key to the "LOCK" position.

D E69 F M54
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. 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-

SHTS021270300236 nal check har-
ness)
Starter key: LOCK THWO (E69) – 
Ground
ETHA (M54) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 12. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

12 Check for disconnection in wire harness of coolant temperature sender No.2

1. Connect the coolant temperature sender No.2 connector.

D E69 F M54 2. 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-

20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THWO (E69) –
0.326 – 0.310 k
SHTS021270300237 ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 13. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–263

13 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0115 has been detected.

SHTS021270300238

Has DTC P0115 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–264 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0117 and P0118

EN01H02127030602016046

P0117: Coolant temperature sender No.1 - out of range (Out of range low)
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300239

1. Technical description
• The engine coolant temperature sensor installed to the thermostat case consistently measures the engine coolant
temperature.

<Description of malfunction>
• The engine coolant temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.2 V (122 C {251.6 F}) or less for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–265

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. 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
• Engine ECU sensor power supply failure or internal circuit failure
• Disconnection or short-circuit in sensor harness
• Irregular contact
2–266 ENGINE (J05E)/TROUBLESHOOTING

P0118: Coolant temperature sender No.1 - out of range (Out of range high)
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300240

1. Technical description
• The engine coolant temperature sensor installed to the thermostat case consistently measures the engine coolant
temperature.

<Description of malfunction>
• The engine coolant temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Intake air temperature is -20 C {-4 F} or higher.
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.77 V (-37 C {-34.6 F}) or greater for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–267

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

Engine coolant temperature sensor:

• Short-circuit in the sensor
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
• Disconnection or short-circuit in sensor harness
• Irregular contact
2–268 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0117 and P0118

1 Inspect the engine coolant temperature sensor connector

1. Check the connection of the engine coolant temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine coolant temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–269

3 Inspect the engine coolant temperature sensor unit

1. Set the starter key to the "LOCK" position.

E THW
2. Disconnect the engine coolant temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the engine coolant temperature sensor.

Measurement Tester
Standard values
conditions connections

Engine coolant 20 C {68 F}:

temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300241 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the engine coolant temperature sen-

sor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the actuation power supply wire harness of the engine coolant temperature sensor

1. Set the starter key to the "ON" position.

THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the engine coolant temperature sensor vehicle side con-
nector.

Measurement Tester
Standard values
conditions connections

Engine coolant
temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300242 connector
THW – E

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
2–270 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect for short-circuit of the engine coolant temperature sensor harness

1. Set the starter key to the "LOCK" position.

E66 D E58 2. Connect the signal check harness to the engine ECU. (Do not con-
nect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300243 nal check har-
ness)
Starter key: LOCK THW (E66) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect disconnection of the engine coolant temperature sensor harness

1. Connect the engine coolant temperature sensor connector.

E66 D E58 2. 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-

20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300244 ETHW (E58)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–271

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0117 or P0118) has been
detected.

SHTS021270300245

Has DTC (P0117 or P0118) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–272 ENGINE (J05E)/TROUBLESHOOTING

DTC: P011A
EN01H02127030602016047

P011A: Engine coolant temperature sensor - rationality

INFORMATION

Coolant temperature
sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E) YKC (ETHW)

Coolant temperature
sensor 2

XS1 (THW2) XDN (THWO)

Body earth ZKP (E22) YWC (ETHA)

SHTS021270300246

1. Technical description
• Two engine coolant temperature sensors are installed in thermostat case and constantly measure the engine cool-
ant temperature.
• Although some exhaust gas components operate after the engine coolant temperature has risen to some degree
(engine warm up), when an engine coolant temperature sensor reads a value lower than the actual temperature, it
means it is not working properly. Diagnosis is therefore required to detect if there is something wrong with the char-
acteristics of the engine coolant temperature sensor.

<Description of malfunction>
• Incompatible readings from the 2 engine coolant temperature sensors are detected.

2. DTC set condition

(1) DTC detection condition
• Engine speed is at least 500 r/min or engine is stopped.
• Battery voltage is in the range of 10 to 16 V.
• Intake air temperature is -20 C {-4 F} or higher.
(2) Judgement criteria
• Difference between the 2 engine coolant temperature sensors is at least 15 C {59 F}.

3. Reset condition
• Problem does not recur in the same driving cycle.
• Normal operation is restored when in subsequent driving cycles, readings are in the normal range within the above
detection conditions.
• Three driving cycles must be deemed normal for MIL to be OFF.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–273

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal resistance of the engine coolant temperature sensor
• Failure in engine ECU sensor power supply
2–274 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P011A

1 Inspect the coolant temperature sender No.1 connector

1. Check the connection of the coolant temperature sender No.1 con-

nector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the coolant temperature sender No.1

1. Check the installation of the coolant temperature sender No.1.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the coolant temperature sender No.1.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the coolant temperature
sender No.1.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–275

3 Inspect the coolant temperature sender No.1 unit

1. Set the starter key to the "LOCK" position.

E THW
2. Disconnect the coolant temperature sender No.1 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the coolant temperature sender No.1.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Coolant tempera-
2.59 – 2.32 k
Starter key: LOCK ture sender No.1
SHTS021270300247 80 C {176 F}:
THW – E
0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the coolant temperature sender

No.1.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the coolant temperature sender No.1 power supply

1. Set the starter key to the "ON" position.

THW E
2. Use the electrical tester to measure the voltage between the termi-
nals of the coolant temperature sender No.1 vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Coolant tempera-
ture sender No.1
Starter key: ON vehicle side con- 4.5 – 5.5 V
SHTS021270300248 nector
THW – E

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
2–276 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect for short-circuit of the coolant temperature sender No.1 harness

1. Set the starter key to the "LOCK" position.

E66 D E58 2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the engine ECU.)

3. 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-

SHTS021270300249 nal check har-
ness)
Starter key: LOCK THW (E66) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect disconnection of the coolant temperature sender No.1 harness

1. Connect the coolant temperature sender No.1 connector.

E66 D E58 2. 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-

20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THW (E66) –
0.326 – 0.310 k
SHTS021270300250 ETHW (E58)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–277

7 Inspect the coolant temperature sender No.2 connector

1. Check the connection of the coolant temperature sender No.2 con-

nector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 8.

Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the coolant temperature sender No.2

1. Check the installation of the coolant temperature sender No.2.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the coolant temperature sender No.2.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 9.

If damaged, replace the coolant temperature
sender No.2.
Perform "After-inspection work" of INFOR-
MATION section.
2–278 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the coolant temperature sender No.2 unit

1. Set the starter key to the "LOCK" position.

E22 THW2
2. Disconnect the coolant temperature sender No.2 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the coolant temperature sender No.2.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Coolant tempera-
2.59 – 2.32 k
Starter key: LOCK ture sender No.2
SHTS021270300251 80 C {176 F}:
E22 – THW2
0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 10. Replace the coolant temperature sender

No.2.
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the coolant temperature sender No.2 power supply

1. Set the starter key to the "ON" position.

THW2 E22
2. Use the electrical tester to measure the voltage between the termi-
nals of the coolant temperature sender No.2 vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Coolant tempera-
ture sender No.2
Starter key: ON vehicle side con- 4.5 – 5.5 V
SHTS021270300252 nector
THW2 – E22

Do the measurements meet the standard value?

YES NO

Go to step 13. Go to step 11.

 ENGINE (J05E)/TROUBLESHOOTING 2–279

11 Inspect for short-circuit of the coolant temperature sender No.2 harness

1. Set the starter key to the "LOCK" position.

D E69 F M54
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the engine ECU.)

3. 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-

SHTS021270300253 nal check har-
ness)
Starter key: LOCK THWO (E69) – 
Ground
ETHA (M54) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 12. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

12 Inspect disconnection of the coolant temperature sender No.2 harness

1. Connect the coolant temperature sender No.2 connector.

D E69 F M54 2. 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-

20 C {68 F}:
nal check har-
2.59 – 2.32 k
Starter key: LOCK ness)
80 C {176 F}:
THWO (E69) –
0.326 – 0.310 k
SHTS021270300254 ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 13. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–280 ENGINE (J05E)/TROUBLESHOOTING

13 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P011A has been detected.

SHTS021270300255

Has DTC P011A been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–281

DTC: P0122 and P0123

EN01H02127030602016048

P0122: Intake throttle valve position sensor 1 - out of range (Out of range low)
INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300256

1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle (intake throttle), a sensor designed to detect a travel of the valve consistently monitors a
measurement reading and an actual opening.

<Description of malfunction>
• Low voltage failure of diesel throttle (intake throttle valve) position sensor is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Diesel throttle (intake throttle valve) position sensor remains at 0.2 V (5 C {41 F}) or less for 3 seconds or
longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–282 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Engine ECU sensor power supply failure or internal circuit failure
• Disconnection or short-circuit in sensor harness
• Irregular contact
 ENGINE (J05E)/TROUBLESHOOTING 2–283

P0123: Intake throttle valve position sensor 1 - out of range (Out of range high)
INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300257

1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle (intake throttle), a sensor designed to detect a travel of the valve consistently monitors a
measurement reading and an actual opening.

<Description of malfunction>
• High voltage failure of diesel throttle (intake throttle valve) position sensor is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.8 V (120 C {248 F}) or less for 3 seconds or longer.

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–284 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

• Abnormal resistance of sensor
• Engine ECU internal circuit failure
• Sensor power supply short-circuit in sensor harness
• Sensor internal short
 ENGINE (J05E)/TROUBLESHOOTING 2–285

INSPECTION PROCEDURE: P0122 and P0123

1 Inspect the diesel throttle (intake throttle valve) position sensor 1 connector

1. Check the connection of the diesel throttle (intake throttle valve)

position sensor 1 connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the diesel throttle (intake throttle valve) position sensor 1

1. Check the installation of the diesel throttle (intake throttle valve)

position sensor 1.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the diesel throttle (intake throttle valve) position sensor 1.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the diesel throttle (intake
throttle valve) position sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
2–286 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the diesel throttle (intake throttle valve) position sensor 1 unit

1. Set the starter key to the "LOCK" position.

VTA VC 2. Disconnect the connector of the diesel throttle (intake throttle

valve) position sensor 1 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the diesel throttle (intake throttle valve) position sen-
sor 1 connector.

Measurement Tester
Standard values
conditions connections

VC E2 Diesel throttle
(intake throttle
valve) position (1) 180 
Starter key: LOCK sensor 1 (2) 3 k
(1) VTA – VC (3) 3 k
(2) VC – E2
(3) VTA – E2

VTA E2

SHTS021270300258

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the diesel throttle (intake throttle

valve) position sensor 1.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–287

4 Inspect the diesel throttle (intake throttle valve) position sensor 1 power supply

1. Set the starter key to the "ON" position.

2. Use the electrical tester to measure the voltage between the termi-
E2 VC nals of the diesel throttle (intake throttle valve) position sensor 1
vehicle side connector.

Measurement Tester
Standard values
conditions connections

Diesel throttle
(intake throttle
valve) position
Starter key: ON 4.5 – 5.5 V
SHTS021270300259 sensor 1 vehicle
side connector
VC – E2

Do the measurements meet the standard value?

YES NO

Go to step 5. Go to step 6.

5 Inspect the diesel throttle (intake throttle valve) position sensor 1 ground circuit

1. Set the starter key to the "LOCK" position.

E2 VTA
2. Use the electrical tester to measure the resistance between the
terminals of the diesel throttle (intake throttle valve) position sen-
sor 1 vehicle side connector.

Measurement Tester
Standard values
conditions connections

Diesel throttle
(intake throttle
valve) position
Starter key: LOCK 25 – 35 k
SHTS021270300260 sensor 1 vehicle
side connector
VTA – E2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.
2–288 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect for short-circuits in the wire harness of the diesel throttle (intake throttle valve) posi-
tion sensor 1

1. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
F
M52
2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
VCTA (M52) –
Starter key: LOCK Ground 
D VTA1 (E62) –
E62 E77 Ground
EPA (E77) –
Ground

SHTS021270300261

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–289

7 Inspect for disconnection in the wire harness of the diesel throttle (intake throttle valve) posi-
tion sensor 1

1. Connect the diesel throttle (intake throttle valve) position sensor 1

connector.
M52 F D E62

2. Use the electrical tester to measure the resistance between the

terminal of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
(1) VCTA (M52) – (1) 2  or more
M52 F D Starter key: LOCK VTA1 (E62) (2) 3 k
E77
(2) VCTA (M52) – (3)  
EPA (E77)
(3) VTA1 (E62) –
EPA (E77)

D
E62 E77

SHTS021270300262

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–290 ENGINE (J05E)/TROUBLESHOOTING

8 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0122 or P0123) has been
detected.

SHTS021270300263

Has DTC (P0122 or P0123) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–291

DTC: P0126
EN01H02127030602016049

P0126: Abnormally in thermostat (Fixing the thermostat after warm-up)

INFORMATION

Coolant temperature
sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E) YKC (ETHW)

X71 X4K (VG)

(FC)
XCV XMH
(E2G) (EVG)
XCT X2U
(+B) (VAF)
Z65
(E2) X72 X82
(THA) (THA)
Intake air temperature sensor
(built in the air flow meter)

ZKT
(GND)
VKF XMK
(TOIL) (THO)

Exhaust temperature sensor No.1

SHTS021270300264

1. Technical description
• When engine coolant temperature is below 76.5 °C {169.7 F}, the thermostat closes the coolant passage to secure
the warm-up performance of the engine by preventing coolant from flowing into the radiator. When coolant temper-
ature reaches 76.5 °C {169.7 F} or more, coolant is let into the radiator to prevent overheat.
• If a malfunction occurs with the thermostat open, engine coolant temperature drops excessively due to overcooling,
which prolongs the unavailable condition of the exhaust system parts which operate when engine coolant tempera-
ture is high to some extent. It also degrades fuel consumption and heater performance. Accordingly, the thermostat
must be checked for any abnormalities.

<Description of malfunction>
• If measured engine coolant temperature is lower than a certain value although estimated coolant temperature is
high, it is determined that the thermostat is abnormal.

2. DTC set condition

(1) DTC detection condition
• The conditions below remain for 5 seconds or more.
- Coolant temperature reaches 65 °C {149 F} or more once after engine start.
- Estimated coolant temperature exceeds 60 °C {140 F}.
- Starter key "ON".
- Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• After engine warm-up, estimated coolant temperature is 60 °C {140 F} or more but measured coolant temper-
ature remains below 60 °C {140 F}

3. Reset condition
• After normal recovery

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
2–292 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Entry of foreign matter into the thermostat
• Damage of the thermostat spring
 ENGINE (J05E)/TROUBLESHOOTING 2–293

INSPECTION PROCEDURE: P0126

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0126 has been
detected.

SHTS021270300265

Has DTC other than P0126 been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the thermostat

1. Remove the thermostat from engine.

2. Check the thermostat for the entry of foreign matter and spring
damage.

3. Dip the thermostat in warm water of 90 °C {194 F} and check that
the valve lifts by 10 mm or more.

4. After the step 3, dip the thermostat in cold water and check that
10 mm or more the valve closes within 5 minutes.

SHTS021270300266

Was any failure found?

YES NO

Replace the thermostat. Go to step 3.

2–294 ENGINE (J05E)/TROUBLESHOOTING

3 Check the DTC detected (Engine ECU)

1. Warm up the engine (water temperature: 80 C or more).

2. Set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if DTC P0126 has been detected.

SHTS021270300267

Has DTC P0126 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Clear the trouble history.
 ENGINE (J05E)/TROUBLESHOOTING 2–295

DTC: P0128
EN01H02127030602016050

P0128: Thermostat - The coolant temperature does not reach a warmed-up temperature
INFORMATION

Engine coolant
temperature sensor

Intercooler
Radiator
Thermostat

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC (ETHW)

Coolant temperature sensor 1 Engine ECU

SHTS021270300268

1. Technical description
• The thermostat prevents coolant from flowing into the radiator when the engine coolant temperature is less than
76.5 C {169.7 F}, in order to secure the engine warm up function. When the temperature rises above 76.5 C
{169.7 F}, the valve opens and allows coolant to flow into the radiator, thereby preventing the engine from over-
heating.
• If the thermostat fails and the valve stays open, it is difficult for the engine coolant temperature to rise, so the
exhaust components that work after the engine coolant temperature has reached a certain value (warm up) will not
operate for a long time. The thermostat must therefore be diagnosed to see if it is working properly.

<Description of malfunction>
• In order to detect a malfunction of the thermostat, the above failure is determined when the actual engine coolant
temperature is a certain amount lower than the predicted temperature.

2. DTC set condition

(1) DTC detection condition
• Engine speed ≥ 700 r/min
• Engine coolant temperature at engine start-up ≤ 45.5C {113.9 F}.
• Engine coolant temperature is 76 C {168.8 F} or more after running the engine for 60 seconds or more.

(2) Judgement criteria

• The condition that the actual engine coolant temperature is less than 65 C {149 F} remains for 5 seconds or
more.

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–296 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

- Inclusion of foreign matters in the thermostat
- Damaged spring in the thermostat
- Engine coolant temperature sensor failure
 ENGINE (J05E)/TROUBLESHOOTING 2–297

INSPECTION PROCEDURE: P0128

1 Inspect the engine coolant temperature sensor connector

1. Check the connection of the engine coolant temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine coolant temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–298 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the engine coolant temperature sensor unit

1. Set the starter key to the "LOCK" position.

E THW
2. Disconnect the engine coolant temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the engine coolant temperature sensor.

Measurement Tester
Standard values
conditions connections

Engine coolant 20 C {68 F}:

temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300269 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the engine coolant temperature sen-

sor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the thermostat

1. Check if the thermostat is damaged due to the incursion of foreign

substances or if the spring is damaged.

Was any failure found?

YES NO

Replace the thermostat. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–299

5 Inspect the thermostat valve-opening temperature

1. 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?

YES NO

Replace the thermostat. Go to step 6.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect the thermostat valve-open time

1. Check valve opening time.

After taking out from hot water, submerge in water and check that
the valve closes within 5 minutes.

Was any failure found?

YES NO

Replace the thermostat. Go to step 7.

Perform "After-inspection work" of INFOR-
MATION section.
2–300 ENGINE (J05E)/TROUBLESHOOTING

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0128 has been detected.

SHTS021270300270

Has DTC P0128 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–301

DTC: P0148
EN01H02127030602016051

P0148: Abnormality in post injection

INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

Engine ECU

X49 (#4) $XY (I1+S)

Injector 4 X8Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (I2+S)
Injector 3 X8X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)

SHTS021270300271

1. Technical description

<Description of malfunction>
• The engine ECU detected abnormality in post injection.
2–302 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) DTC detection condition
• The vehicle speed is 0 km/h.
• A change in the engine revolution is 938 r/min/sec or less.
• A change in the fuel injection quantity is 312 mm3/st/sec or less.
• A change in the fuel pressure is 93.7 MPa/sec or less.
• The target operating current of the supply pump is not less than 1500 mA but not more than 1800 mA.
(2) Judgement criteria
• A change in the operating current of the supply pump upon post injection falls below the specified value.
• Malfunction determination time: 10 seconds

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Fuel injection pipe: Breakage, crack, fuel leakage
• Cylinder: Compression leakage
• Injector: Clogging, keeping injecting
 ENGINE (J05E)/TROUBLESHOOTING 2–303

INSPECTION PROCEDURE: P0148

1 Check the DTC detected 1 [HINO DX Ⅱ ]

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. On the screen of the diagnostic system, select [Engine] and check

DTC P0148 detected as present malfunction.

SHTS021270300272

Is DTC P0148 detected as present malfunction?

YES NO

Go to step 2 (It is detected as present mal- Go to step 9. (It is recorded as past malfunc-
function) tion)

2 Check the DTC detected 2 [HINO DX Ⅱ ]

1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272

SHTS021270300273

Has a DTC other than P0263, P0266, P0269 and P0272 been detected?

YES NO

Go to diagnosis procedure of the related Go to step 3.

DTC.
2–304 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the fuel line

1. 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

Injector
Pre fuel
filter

Supply pump

Suction line
Positive pressure line
Fuel tank
High pressure line
Return line

SHTS021270300274

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Go to step 4 after repair or replacement.
 ENGINE (J05E)/TROUBLESHOOTING 2–305

4 Inspect the pre fuel filter

1. Check that the pre fuel filter is not dirty or clogged or damaged.

Was any failure found?

YES NO

Replace the pre fuel filter. Go to step 5.

Go to step 5 after replacement

5 Check the DTC detected 3 [HINO DX Ⅱ ]

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P0148) has been detected.

SHTS021270300275

Has DTC (P0148) been detected?

YES NO

Go to step 6. Procedure completed.

2–306 ENGINE (J05E)/TROUBLESHOOTING

6 Perform the cylinder cut-off test (HINO DX Ⅱ )

1. Start the engine and maintain the engine revolution at 1,500 r/min
using the cruise function.

2. Check the engine sound before the test (during normal operation).

3. On the screen of the diagnostic system, select [Engine], and per-

form [Cut off test] in [Data monitor and Active test].
• For the detailed procedure, refer to the separate sheet "Cut off test".

<Cylinder cut-off test>

- Test to determine cylinder combustion abnormality of the engine usu-
SHTS021270300276
ally operated by four cylinders, according to the sound difference
when the fuel injection from any one of the cylinders is stopped.

Did you find the engine sound different?

YES NO

<One of the sounds A to D is always larger <No clear difference> Go to step 8.

than others or same as α> Replace the defec-
tive injector. After replacement, go to step 7.

7 Check the DTC detected 4 [HINO DX Ⅱ ]

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P0148) has been detected.

SHTS021270300277

Has DTC (P1048) been detected?

YES NO

Go to step 8. Procedure completed.

 ENGINE (J05E)/TROUBLESHOOTING 2–307

8 Replace the common rail assembly [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Replace common rail assembly.

3. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

4. Stop the engine.

5. Set the starter key to the "ON" position.

6. Select [Engine] and check if the DTC (P0148) has been detected.
SHTS021270300278

Has DTC (P0148) been detected?

YES NO

Go to step 9. Procedure completed.

9 Check the injector clamp

1. Check that the injector clamp is not loose.

2. Check that there is no "insufficient engagement" of the injector

BOLT clamp claw.

INJECTOR

INJECTION PIPE
INJECTOR
CLAMP

INJECTION
PIPE OIL SEAL
O-RING

SHTS021270300279

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 10.

2–308 ENGINE (J05E)/TROUBLESHOOTING

10 Check the valve clearance

1. 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

Intake valve:
0.30 mm (0.0118 in.)
Cross head Cold engine
Exhaust valve:
0.45 mm (0.0177 in.)

SHTS021270300280

Cylinder number 1 2 3 4

Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

No.1 cylinder at the compres-

   
sion stroke top dead center

No.4 cylinder at the compres-

∆ ∆ ∆ ∆
sion stroke top dead center

Do the measurements meet the standard value?

YES NO

Go to step 11. Adjust the valve clearance.

 ENGINE (J05E)/TROUBLESHOOTING 2–309

11 Check the engine compression pressure

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Remove the all injectors.

SST 4. Set the special service tool (SST) and measure the compression.
To
engine Measurement
Standard values
conditions

SHTS021270300281 Standard values:

Engine revolution: 150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}

Do the measurements meet the standard value?

YES NO

Go to step 12. Engine overhaul.

12 Inspect the engine speed main sensor (Crankshaft position sensor)

1. Inspect the condition of engine speed main sensor (crankshaft

Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).

2. Check the installation of the engine speed main sensor. (Crank-

shaft position sensor)

Connector

Flywheel housing

SHTS021270300282

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 13.

2–310 ENGINE (J05E)/TROUBLESHOOTING

13 Check the DTC detected 5 [HINO DX Ⅱ ]

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, check DTC P0148.

SHTS021270300283

Has DTC (P0148) been detected?

YES NO

Inspect the crankshaft, connecting rods, fly- Procedure completed.

wheel, and other parts of the drive system.
 ENGINE (J05E)/TROUBLESHOOTING 2–311

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>
To determine combustion abnormality of the arbitrary cylinder according to sound difference.

<Know-how & examples>

Combustion abnormality of the arbitrary cylinder is determined according to sound difference to take proper measures.

1 Cylinder cut-off test

1. Start the engine and maintain the engine revolution at 1,500 r/min
using the cruise function.

2. Check the engine sound before the test (during normal operation).
Active test Setting
Data monitor and Active test
(Assume α as the sound.)

3. On the screen of the diagnostic system, select [Engine], and select

[Active test Setting] in [Data monitor and Active test].

SHTS021270300284
2–312 ENGINE (J05E)/TROUBLESHOOTING

4. 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. (This is not abnor-
Select the cylinder to deactivate
mal.)

5. As the cylinder #1, stop the fuel injection of the cylinders #2, #3,
and #4 in this order.
(Assume B, C, and D as the measured sounds respectively.)
HINT
• If sound abnormality is not clear, repeat the steps 4 and 5.
• If any of the sounds A to D is same as α, make sure to check for
communication abnormality.

Injection is stopped when OK is selected.

SHTS021270300285

Can engine sound difference be identified?

YES NO

<One of the sounds A to D is always larger <No clear difference>

than others or same as α. > Go to inspection.
Replace the defective injector.
 ENGINE (J05E)/TROUBLESHOOTING 2–313

DTC: P016E and P016F

EN01H02127030602016052

P016E: Fuel system pressure control - high

INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

SHTS021270300286

1. Technical description
• The common rail pressure is controlled by the discharge of the supply pump.
• The supply pump discharge rate is adjusted by the SCV (suction control valve).

<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.

2. DTC set condition

(1) DTC detection condition
• Engine speed ≥ 700 r/min.
• Fuel injection quantity ≥ 5 mm3/st. cyl.
• Fuel injection quantity fluctuation < -26.6 mm3/st. cyl.
• Target current value of SCV ≤ 1,500 mA.
(2) Judgement criteria
• (Actual common rail pressure – target common rail pressure) ≥ 15 MPa for 15 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–314 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Fuel filter: Clogging, dirt, damage
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
 ENGINE (J05E)/TROUBLESHOOTING 2–315

P016F: Fuel system pressure control - low

INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

SHTS021270300287

1. Technical description
• The common rail pressure is controlled by the discharge of the supply pump.
• The supply pump discharge rate is adjusted by the SCV (suction control valve).

<Description of malfunction>
• Abnormally high fuel pressure inside common rail is detected.

2. DTC set condition

(1) DTC detection condition
• Engine speed ≥ 700 r/min.
• Fuel injection quantity ≥ 5 mm3/st. cyl.
• Fuel injection quantity fluctuation < 40.6 mm3/st. cyl.
• Target current value of SCV ≤ 1250 mA.
(2) Judgement criteria
• (Actual common rail pressure – target common rail pressure) ≥ 15 MPa for 15 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–316 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Fuel filter: Clogging, dirt, damage
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
 ENGINE (J05E)/TROUBLESHOOTING 2–317

INSPECTION PROCEDURE: P016E and P016F

1 Inspect the start of the engine

1. Inspect the start of the engine.

Does the engine start?

YES NO

Go to step 4. Go to step 2.

2 Inspect the supply pump

1. Check if fuel is leaking or seeping out of the supply pump.

Was any failure found?

YES NO

Replace the supply pump, and go to step 4. Go to step 3.

3 Function check of supply pump [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP
Common rail pressure

The pressure limiter is 3. Select [Engine].

open reducing the pressure.

4. Select [Actual common rail pressure] from the [Data monitor and
Idling Active test].

5. Start the engine while checking the common rail pressure.

Starter (Engine starting) Hour

Standard values
SHTS021270300288
The actual common rail pressure rises and stabilizes at a
constant value.

Was any failure found?

YES NO

Replace the supply pump, and go to step 4. Contact the Hino national service manager.
2–318 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the pre fuel filter

1. 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?

YES NO

Replace the pre fuel filter element, and go to Go to step 10.

step 5.

5 Inspect the fuel pipe

1. Check if the fuel pipe and hose between the fuel tank and pre fuel
filter are clogged, punctured, or bent.

2. Make sure the fuel pipe joint bolts are not loose.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 6.

step 6.

6 Inspect the fuel tank breather

1. Check if the breather hose is clogged, punctured, or bent.

2. Make sure the check valve is functioning normally.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 7.

step 7.
 ENGINE (J05E)/TROUBLESHOOTING 2–319

7 Inspect the fuel tank feed pipe

1. Make sure the fuel tank feed pipe is not clogged.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 8.

step 8.

8 Inspect the fuel tank

1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.

Was any failure found?

YES NO

Remove the foreign objects and clean the Go to step 9.

fuel tank.
Then go to step 9.

9 Inspect the supply pump gauze filter

1. Make sure the gauze filter (built into the supply pump) is not
clogged.

Was any failure found?

YES NO

Clean the gauze filter, and go to step 10. Go to step 10.

2–320 ENGINE (J05E)/TROUBLESHOOTING

10 Inspect the fuel high-pressure pipe.

1. Make sure the fuel high-pressure pipe is not leaking fuel.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 11.

step 11.

11 Inspect the fuel filter

1. Make sure the fuel filter is not clogged.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 12.

step 12.

12 Inspect the SCV connector

1. Check the connection of the SCV connector (looseness and poor

contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 13.

step 13.

13 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 14.

step 14.
 ENGINE (J05E)/TROUBLESHOOTING 2–321

14 Inspect the common rail pressure sensor power supply

1. Disconnect the common rail pressure sensor connector.

VC2 E2
2. Set the starter key to the "ON" position.

3. 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
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300289 cle side connector
VC2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 15. Repair the common rail pressure sensor and

then go to step 15.

15 Inspect the engine speed main sensor (crankshaft position sensor)

1. Set the starter key to the "ON" position.

2. Select [Engine].

3. Select [NE sensor active flag], [G sensor active flag] from the [Data
monitor and Active test].

4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.

SHTS021270300290

Was any failure found?

YES NO

Check any faulty sensor and repair or Go to step 16.

replace it as needed.
After inspection, go to step 16.
2–322 ENGINE (J05E)/TROUBLESHOOTING

16 Inspect the fuel return pipe and hose

1. Check if the fuel return pipe and hose are clogged.

Was any failure found?

YES NO

Repair or replace the faulty part. Contact the Hino national service manager.
 ENGINE (J05E)/TROUBLESHOOTING 2–323

DTC: P0182 and P0183

EN01H02127030602016053

P0182: Fuel temperature sensor Low

INFORMATION

Engine ECU
Y57 (THF) J5R (THF)
Fuel temperature sensor ZDQ (E2) YWC (ETHA)
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail pressure sensor EBN YWM (EP2)
(E2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300291

1. Technical description
• The fuel temperature sensor consistently measures fuel temperature.
• The fuel temperature sensor is installed to the supply pump.

<Description of malfunction>
• The fuel temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Output of the fuel temperature sensor remains at 0.1 V or less for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–324 ENGINE (J05E)/TROUBLESHOOTING

8. 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
 ENGINE (J05E)/TROUBLESHOOTING 2–325

P0183: Fuel temperature sensor High

INFORMATION

Engine ECU
Y57 (THF) J5R (THF)
Fuel temperature sensor ZDQ (E2) YWC (ETHA)
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail pressure sensor EBN YWM (EP2)
(E2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300292

1. Technical description
• The fuel temperature sensor consistently measures fuel temperature.
• The fuel temperature sensor is installed to the supply pump.

<Description of malfunction>
• The fuel temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Output of the fuel temperature sensor remains at 4.85 V or greater for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–326 ENGINE (J05E)/TROUBLESHOOTING

8. 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
 ENGINE (J05E)/TROUBLESHOOTING 2–327

INSPECTION PROCEDURE: P0182 and P0183

1 Inspect the fuel temperature sensor connector

1. Check the connection of the fuel temperature sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the fuel temperature sensor

1. Check the installation of the fuel temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the fuel temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the fuel temperature sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
2–328 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the fuel temperature sensor unit

1. Set the starter key to the "LOCK" position.

E2 THF 2. Disconnect the connector of the fuel temperature sensor connec-

tor.

3. Use the electrical tester to measure the resistance between the

terminals of the fuel temperature sensor connector.

Measurement Tester
Standard values
conditions connections

Fuel temperature
20 C {68 F}:
SHTS021270300293 Starter key: LOCK sensor
2.32 – 2.59 k
THF – E2

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the fuel temperature sensor.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the fuel temperature sensor power supply

1. Set the starter key to the "ON" position.

THF E2
2. Use the electrical tester to measure the voltage between the termi-
nals of the fuel temperature sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

Fuel temperature
sensor vehicle
Starter key: ON 4.5 – 5.5 V
side connector
THF – E2
SHTS021270300294

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–329

5 Inspect for short-circuits in wire harness of fuel temperature sensor

1. Set the starter key to the "LOCK" position.

E48 D F M54
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminal of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300295 nal check har-
ness)
Starter key: LOCK THF (E48) – 
Ground
ETHA (M54) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–330 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect disconnection of the fuel temperature sensor harness

1. Connect the connector of the fuel temperature sensor.

E48 D F M54
2. 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-
20 C {68 F}:
Starter key: LOCK ness)
2.32 – 2.59 k
THF (E48) –
SHTS021270300296 ETHA (M54)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0182 or P0183) has been
detected.

SHTS021270300297

Has DTC (P0182 or P0183) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–331

DTC: P0191
EN01H02127030602016054

P0191: Fuel rail pressure sensor (main and sub) - out of range
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300298

1. Technical description
• The common rail pressure sensor consistently measures the common rail pressure.

<Description of malfunction>
• The common rail pressure is not detected normally.

2. DTC set condition

(1) DTC detection condition
• The starter key is set to the ON position.
• The battery voltage is 10 to 16 V or less.
• The engine has been stopped or the engine revolution stays at or above 500 r/min for 5 seconds or more.
(2) Judgement criteria
• Both the common rail pressure sensor main and sub have malfunctioned.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.

<Symptoms on the vehicle due to malfunction>

• –
2–332 ENGINE (J05E)/TROUBLESHOOTING

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fuel filter: Clogging, dirt, damage
• Common rail pressure sensor: faulty contact (power supply fault or GND fault), sensor failure
• Supply pump: SCV fault, learning value fault
• Common rail: pressure limiter valve open
• Harness-related malfunction: faulty contact or wrong connection in engine speed main sensor or engine speed sub
sensor
 ENGINE (J05E)/TROUBLESHOOTING 2–333

INSPECTION PROCEDURE: P0191

1 Inspect the start of the engine

1. Inspect the start of the engine.

Does the engine start?

YES NO

Go to step 4. Go to step 2.

2 Inspect the supply pump

1. Check if fuel is leaking or seeping out of the supply pump.

Was any failure found?

YES NO

Replace the supply pump, and go to step 4. Go to step 3.

3 Function check of supply pump [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

Actual common rail pressure
Specified common rail pressure
2. Set the starter key to the "ON" position.
222MP
Common rail pressure

The pressure limiter is 3. Select [Engine].

open reducing the pressure.

4. Select [Actual common rail pressure] from the [Data monitor and
Idling Active test].

5. Start the engine while checking the common rail pressure.

Starter (Engine starting) Hour

Standard values
SHTS021270300299
The actual common rail pressure rises and stabilizes at a
constant value.

Was any failure found?

YES NO

Replace the supply pump, and go to step 4. Contact the Hino national service manager.
2–334 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the pre fuel filter

1. 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?

YES NO

Replace the pre fuel filter element, and go to Go to step 10.

step 5.

5 Inspect the fuel pipe

1. Check if the fuel pipe and hose between the fuel tank and pre fuel
filter are clogged, punctured, or bent.

2. Make sure the fuel pipe joint bolts are not loose.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 6.

step 6.
 ENGINE (J05E)/TROUBLESHOOTING 2–335

6 Inspect the fuel tank breather

1. Check if the breather hose is clogged, punctured, or bent.

2. Make sure the check valve is functioning normally.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 7.

step 7.

7 Inspect the fuel tank feed pipe

1. Make sure the fuel tank feed pipe is not clogged.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 8.

step 8.

8 Inspect the fuel tank

1. Drain fuel out of the fuel tank and check if there are foreign objects
inside the tank.

Was any failure found?

YES NO

Remove the foreign objects and clean the Go to step 9.

fuel tank.
Then go to step 9.
2–336 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the supply pump gauze filter

1. Make sure the gauze filter (built into the supply pump) is not
clogged.

Was any failure found?

YES NO

Clean the gauze filter, and go to step 10. Go to step 10.

10 Inspect the fuel high-pressure pipe.

1. Make sure the fuel high-pressure pipe is not leaking fuel.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 11.

step 11.

11 Inspect the fuel filter

1. Make sure the fuel filter is not clogged.

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 12.

step 12.
 ENGINE (J05E)/TROUBLESHOOTING 2–337

12 Inspect the SCV connector

1. Check the connection of the SCV connector (looseness and poor

contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 13.

step 13.

13 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Repair or replace the faulty part, and go to Go to step 14.

step 14.
2–338 ENGINE (J05E)/TROUBLESHOOTING

14 Inspect the common rail pressure sensor power supply

1. Disconnect the common rail pressure sensor connector.

VC2 E2
2. Set the starter key to the "ON" position.

3. 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
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300300 cle side connector
VC2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 15. Repair the common rail pressure sensor and

then go to step 15.

15 Inspect the engine speed main sensor (crankshaft position sensor)

1. Set the starter key to the "ON" position.

2. Select [Engine].

3. Select [NE Active identification], [G Active identification] in [Data

monitor and Active test].

4. Start the engine and confirm that the engine main speed sensor
(NE) and sub speed sensor (G) operate (stay ON) continuously.

SHTS021270300301

Was any failure found?

YES NO

Check any faulty sensor and repair or Go to step 16.

replace it as needed.
After inspection, go to step 16.
 ENGINE (J05E)/TROUBLESHOOTING 2–339

16 Inspect the fuel return pipe and hose

1. Check if the fuel return pipe and hose are clogged.

Was any failure found?

YES NO

Repair or replace the faulty part. Contact the Hino national service manager.
2–340 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0192 and P0193

EN01H02127030602016055

P0192: Fuel rail pressure sensor (main) - out of range (Out of range low)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300302

1. Technical description
• The common rail pressure sensor consistently measures common rail pressure.

<Description of malfunction>
• Common rail pressure cannot be correctly sensed.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the common rail pressure sensor (main) remains at 0.7 V (-10.7 MPa) or lower for 0.2 seconds or
longer.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–341

8. 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.
2–342 ENGINE (J05E)/TROUBLESHOOTING

P0193: Fuel rail pressure sensor (main) - out of range (Out of range high)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300303

1. Technical description
• The common rail pressure sensor consistently measures common rail pressure.

<Description of malfunction>
• Common rail pressure cannot be correctly sensed.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the common rail pressure sensor (main) remains at 4.49 V (260 MPa) or higher for 0.2 seconds or
longer.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–343

8. 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
2–344 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0192 and P0193

1 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the common rail pressure sensor

1. Check the installation of the common rail pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–345

3 Inspect the common rail pressure sensor unit

1. Set the starter key to the "LOCK" position.

VC2
PCR2 2. Disconnect the connector of the common rail pressure sensor con-
E2 PCR2 VC2 nector.
(main) (main) (main)
VC1 PCR1 E1 3. Use the electrical tester to measure the resistance between the
(sub) (sub) (sub)
terminals of the common rail pressure sensor connector.

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor
PCR2 (1) VC2 (main) – (1) 1.05 – 3.55 k
E2 Starter key: LOCK
E2 PCR2 VC2 PCR2 (main) (2) 6.7 – 18.7 k
(main) (main) (main) (2) PCR2 (main) –
VC1 PCR1 E1 E2 (main)
(sub) (sub) (sub)

SHTS021270300304

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the common rail pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–346 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the common rail pressure sensor power supply

1. Set the starter key to the "ON" position.

VC2 E2
2. 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
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC2 – E2
SHTS021270300305

Do the measurements meet the standard value?

YES NO

Go to step 5. Go to step 6.

5 Inspect the common rail pressure sensor signal circuit

1. Set the starter key to the "LOCK" position.

VC2 PCR2
2. Use the electrical tester to measure the resistance between the
terminals of the common rail pressure sensor vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300306 VC2 – PCR2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.
 ENGINE (J05E)/TROUBLESHOOTING 2–347

6 Inspect for short-circuits in wire harness of the common rail pressure sensor

1. Set the starter key to the "LOCK" position.

VC2 2. Disconnect the connector of the engine ECU.

GROUND

3. Use the electrical tester to measure the resistance between the

common rail pressure sensor vehicle side connector terminals and
ground.

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor vehi-
PCR2 Starter key: LOCK cle side connector  
GROUND VC2 – Ground
PCR2 – Ground

SHTS021270300307

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–348 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect disconnection of the common rail pressure sensor harness

1. Connect the connector of the common rail pressure sensor.

C D E76
2. Connect the signal check harness to the engine ECU vehicle side
E33 harness. (Do not connect the harness to the ECU.)

3. 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-
E65 D ness)
E64 E76
VCP2 (E33) –
Starter key: LOCK EP2 (E76) 2  or more
PCR2 (E64) –
EP2 (E76)
PC2S (E65) –
EP2 (E76)

SHTS021270300308

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–349

8 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0192 or P0193) has been
detected.

SHTS021270300309

Has DTC (P0192 or P0193) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–350 ENGINE (J05E)/TROUBLESHOOTING

DTC: P01A5
EN01H02127030602016056

P01A5: Fuel rail pressure sensor (sub) - out of range (Out of range low)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300310

1. Technical description
• The common rail pressure sensor (sub) constantly measures the common rail pressure.

<Technical Description>
• Common rail pressure is not correctly recognized.
• Possible failure of common rail pressure sensor (sub) or harness GND short-circuit

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• Engine stall condition or engine speed above 500 r/min continues for 5 seconds.
(2) Judgement criteria
• Common rail pressure sensor (sub) voltage is below 1.2 V (-10.7 MPa) for 0.2 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–351

8. 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
2–352 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P01A5

1 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the common rail pressure sensor

1. Check the installation of the common rail pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of common rail pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–353

3 Inspect the common rail pressure sensor unit

1. Set the starter key to the "LOCK" position.

PCR1 2. Disconnect the common rail pressure sensor connector.

VC1 E2 PCR2 VC2
(main) (main) (main)
3. Measure the resistance between the terminals of the sensor using
VC1 PCR1 E1 the electrical tester.
(sub) (sub) (sub)

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor
(1) VC1 (sub) – (1) 1.05 – 3.55 k
Starter key: LOCK
PCR1 (sub) (2) 6.7 – 18.7 k
E1
PCR1 E2 PCR2 VC2 (2) PCR1 (sub) –
(main) (main) (main) E1 (sub)
VC1 PCR1 E1
(sub) (sub) (sub)

SHTS021270300311

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the common rail pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–354 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the common rail pressure sensor power supply

1. Set the starter key to the "ON" position.

E1 VC1
2. 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

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC1 – E1
SHTS021270300312

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the common rail pressure sensor signal circuit

1. Set the starter key to the "LOCK" position.

PCR1 VC1
2. Use the electrical tester to measure the resistance between the
terminals in the common rail pressure sensor vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300313 VC1 – PCR1

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.
 ENGINE (J05E)/TROUBLESHOOTING 2–355

6 Inspect for short-circuits in wire harness of the common rail pressure sensor

1. Set the starter key to the "LOCK" position.

VC1
2. Disconnect the engine ECU connector.
GROUND

3. Use the electrical tester to measure the resistance between the

common rail pressure sensor vehicle side connector terminals and
ground.

Measurement Tester
Standard values
conditions connections

Common rail pres-

PCR1 sure sensor vehi-
GROUND Starter key: LOCK cle side connector  
VC1 – Ground
PCR1 – Ground

SHTS021270300314

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–356 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect disconnection of the common rail pressure sensor harness

1. Connect the common rail pressure sensor connector.

E13
C D E56
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

E49
E56 D E68
nal check har-
ness)
VCP1(E13) –
Starter key: LOCK EP1(E56) 2  or more
PCR1(E49) –
EP1(E56)
PC1S(E68) –
EP1(E56)

SHTS021270300315

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

8 Check the DTC detected (Engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80C

{176F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P01A5 has been detected.

SHTS021270300316

Has DTC P01A5 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–357

DTC: P01A6
EN01H02127030602016057

P01A6: Fuel rail pressure sensor (sub) - out of range (Out of range high)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

SHTS021270300317

1. Technical description
• The common rail pressure sensor (sub) constantly measures the common rail pressure.

<Technical Description>
• Common rail pressure is not correctly identified.
• Possible failure of common rail pressure sensor (sub) or harness disconnection or +B short.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• Engine stall condition or engine speed above 500 r/min continues for 5 seconds.
(2) Judgement criteria
• Common rail pressure sensor (sub) voltage is above 4.79 V (245.7 MPa) for 0.2 seconds.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–358 ENGINE (J05E)/TROUBLESHOOTING

8. 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
 ENGINE (J05E)/TROUBLESHOOTING 2–359

INSPECTION PROCEDURE: P01A6

1 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the common rail pressure sensor

1. Check the installation of the common rail pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of common rail pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the common rail pres-
sure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–360 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the common rail pressure sensor unit

1. Set the starter key to the "LOCK" position.

PCR1 2. Disconnect the common rail pressure sensor connector.

VC1 E2 PCR2 VC2
(main) (main) (main)
3. Measure the resistance between the terminals of the sensor using
VC1 PCR1 E1 the electrical tester.
(sub) (sub) (sub)

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor
(1) VC1 (sub) – (1) 1.05 – 3.55 k
Starter key: LOCK
E1
PCR1 (sub) (2) 6.7 – 18.7 k
PCR1 E2 PCR2 VC2 (2) PCR1 (sub) –
(main) (main) (main) E1 (sub)
VC1 PCR1 E1
(sub) (sub) (sub)

SHTS021270300318

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the common rail pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–361

4 Inspect the common rail pressure sensor power supply

1. Set the starter key to the "ON" position.

E1 VC1
2. 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

Common rail pres-

sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC1 – E1
SHTS021270300319

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the common rail pressure sensor signal circuit

1. Set the starter key to the "LOCK" position.

PCR1 VC1
2. Use the electrical tester to measure the resistance between the
terminals of the common rail pressure sensor vehicle side connec-
tor.

Measurement Tester
Standard values
conditions connections

Common rail pres-

sure sensor vehi-
Starter key: LOCK 200 – 250 k
cle side connector
SHTS021270300320 VC1 – PCR1

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.
2–362 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect for short-circuits in wire harness of the common rail pressure sensor

1. Set the starter key to the "LOCK" position.

VC1
2. Disconnect the engine ECU connector.
GROUND

3. Use the electrical tester to measure the resistance between the

common rail pressure sensor vehicle side connector terminals and
ground.

Measurement Tester
Standard values
conditions connections

Common rail pres-

PCR1 sure sensor vehi-
GROUND Starter key: LOCK cle side connector  
VC1 – Ground
PCR1 – Ground

SHTS021270300321

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–363

7 Inspect disconnection of the common rail pressure sensor harness

1. Connect the common rail pressure sensor connector.

E13
C D E56
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

E49
E56 D E68
nal check har-
ness)
VCP1 (E13) –
Starter key: LOCK EP1 (E56) 2  or more
PCR1 (E49) –
EP1 (E56)
PC1S (E68) –
EP1 (E56)

SHTS021270300322

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

8 Check the DTC detected (Engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P01A6 has been detected.

SHTS021270300323

Has DTC P01A6 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–364 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0200
EN01H02127030602016058

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 injector driver Fuel
current adjust circuit injector

Fuel injector
drive

SHTS021270300324

1. Technical description
• –

<Description of malfunction>
• Excessively high voltage has been detected in the injector charge circuit.

2. DTC set condition

(1) DTC detection condition
- Starter key "ON".
- Battery voltage is in the range of 10 to 16 V.
- Fuel injector; deactivated.
(2) Judgement criteria
- Fuel injector driver charge circuit voltage > 105 V
- Failure timer ≥ 0.384 seconds

3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• Diag light: OFF
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.
• PTO is not available
• EGR valve is fully closed.
• VNT is fully open.
 ENGINE (J05E)/TROUBLESHOOTING 2–365

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.
• PTO cannot be used.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• ECU failure.
• Temporary operating error due to radio wave interference or noise.
2–366 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0200

1 Check the engine ECU internal circuit [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check the communication between HINO DX Ⅱ

and the engine ECU.

4. Erase the malfunction history.

5. Set the starter key to the "LOCK" position.

When communication with the engine ECU is
interrupted while the engine ECU is connected to 6. In HINO DX Ⅱ , make sure the engine ECU main relay is OFF. (This
the HINO DXⅡ, the connection symbol at the left cuts off the communication between HINO DX Ⅱ and the engine
bottom of the HINO DXⅡ screen (the figure below) ECU.)
becomes disconnected.

7. Set the starter key to the "ON" position.

8. Select [Engine] and check if P0200 has been detected.

SHTS021270300325

Has DTC P0200 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–367

DTC: P0201, P0202, P0203 and P0204

EN01H02127030602016059

P0201: Fuel injector - disconnection (#1cyl)

P0202: Fuel injector - disconnection (#2cyl)
P0203: Fuel injector - disconnection (#3cyl)
P0204: Fuel injector - disconnection (#4cyl)
INFORMATION

Engine ECU
38 Injector sub
(#10)
18 11 3 2
(#1)
17 8 8 1 Injector1
(IJ1+)
28
(#40)
8 10 et-ra 2 2
(#4)
6 6 6 1 Injector2
(IJ2+)
25
(#20) et ra ev
5 2 10 2
(#2)
26 5 5 1 Injector3
(I2+S)
39 ra-ev
(#30)
19 3 11 2
(#3)
37 7 7 1 Injector4
(I1+S)

SHTS021270300326

1. Technical description
• An injection rate is controlled to a valve opening duration of the injector.
• The valve opening duration of the injector is adjusted by the solenoid valve.

<Description of malfunction>
• #1 injector failure or possible harness disconnection (P0201)
• #2 injector failure or possible harness disconnection (P0202)
• #3 injector failure or possible harness disconnection (P0203)
• #4 injector failure or possible harness disconnection (P0204)

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed is higher than 0.
• The fuel injector driver charge circuit is active.
(2) Judgement criteria
• The fuel injector driver circuit remains at 0A until it reaches a threshold.
(Approximately 4 seconds at 750 r/min. This may vary depending on engine speed.)

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.
2–368 ENGINE (J05E)/TROUBLESHOOTING

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Looseness or poor contact of connector
• vehicle side harness disconnection (engine ECU – injector central connector)
• Injector harness disconnection or short-circuit
• Disconnected coil in the injector
• Malfunction of ECU
 ENGINE (J05E)/TROUBLESHOOTING 2–369

INSPECTION PROCEDURE: P0201, P0202, P0203 and P0204

1 Inspect the engine ECU connector, injector connector

1. Inspect the connection of the engine ECU connector and the tar-
get's injector connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect disconnection of the engine ECU harness

1. Set the starter key to the "LOCK" position.

E15 E16 E18 E20
E14 E19 2. Connect the signal check harness to the engine ECU. (Do not con-
C nect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
E34 E36 E38 E40
conditions connections
E35 E39 Engine ECU (sig-
SHTS021270300327 nal check har-
Starter key: LOCK ness) 2
Refer to the injec-
tor’s table

<Injector's table>

#1 injector #2 injector #3 injector #4 injector

#1 (E15) – IJ1+(E14) #4 (E20) – I2+S (E18) #2 (E19) – I2+S (E18) #3 (E16) – IJ1+ (E14)
#1 (E15) – I1+S(E34) #4 (E20) – IJ2+ (E38) #2 (E19) – IJ2+ (E38) #3 (E16) – I1+S (E34)
#10 (E35) – IJ1+(E14) #40 (E40) – I2+S (E18) #20 (E39) – I2+S (E18) #30 (E36) – IJ1+ (E14)
#10 (E35) – I1+S(E34) #40 (E40) – IJ2+ (E38) #20 (E39) – IJ2+ (E38) #30 (E36) – I1+S (E34)

Do the measurements meet the standard value?

YES NO

Go to step 3. Go to step 4.
2–370 ENGINE (J05E)/TROUBLESHOOTING

3 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0201, P0202, P0203 and
P0204) has been detected.

SHTS021270300328

Has DTC (P0201, P0202, P0203 and P0204) has been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.

4 Check for disconnection in wire harness of injector central connector

1. Disconnect the injector central connector.

2. Use the electrical tester to measure the resistance between the

terminals in the injector central connector (engine side).
4 3 2 1
8 7 6 5
Measurement Tester
12 11 10 9 Standard values
conditions connections

Injector central
connector (engine
side)
Starter key: LOCK #1 injector: 3 – 8 2
SHTS021270300329 #2 injector: 2 – 6
#3 injector: 10 – 5
#4 injector: 11 – 7

Do the measurements meet the standard value?

YES NO

Repair or replace the wire harness between Go to step 5.

the injector central connector and engine
ECU.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–371

5 Inspect disconnection of the injector harness

1. Disconnect the target's injector harness connector.

2. 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 connector (injec-
0.37 – 0.57 
tor side) terminals

SHTS021270300330

Do the measurements meet the standard value?

YES NO

Repair or replace the wire harness between Go to step 6.

the injector central connector and injector
harness connector.
Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect the injector unit

1. Measure the resistance between the target's injector terminal and

the injector body.

Measurement Tester
Standard values
conditions connections

Injector terminal –
Starter key: LOCK More than 10 M
injector body

SHTS021270300331

Do the measurements meet the standard value?

YES NO

Repair or replace the target's injector har- Replace the injector.

ness. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
2–372 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0217
EN01H02127030602016060

P0217: Engine coolant over temperature condition

INFORMATION

Coolant temperature
sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E) YKC (ETHW)

SHTS021270300332

1. Technical description
• Measure the engine coolant temperature with the coolant temperature sensor.

<Description of malfunction>
• Engine overheating is detected.

2. DTC set condition

(1) DTC detection condition
• The engine must not be stopped.
(2) Judgement criteria
• The coolant temperature value of the engine coolant temperature sensor is above 115 C {239 F} for 30 sec-
onds.

3. Reset condition
• After normal operation is restored

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON
• After fixed time, the engine stopped.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–373

8. Estimated failure factors

(1) 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
(2) Malfunction of cooling fan, malfunction of fan clutch
(3) Malfunction of coolant temperature sensor
2–374 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0217

1 Inspect the engine

1. Refer to "Engine Overheating" in the "Engine Introduction/Trouble-

shooting" Workshop Manual and check the related problem areas.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the cooling fan

1. Check the installation and damage condition of the cooling fan.

Was any failure found?

YES NO

Properly install the cooling fan. Go to step 3.

Replace the cooling fan if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the fan clutch

1. Check the installation condition of the cooling fan clutch and check
for silicone oil leakage from the clutch.

Was any failure found?

YES NO

Properly install the cooling fan clutch. Go to step 4.

Replace the cooling fan clutch if it is leaking.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–375

4 Inspect the coolant temperature sensor connector

1. Check the connection of the engine coolant temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the engine coolant temperature sensor

1. Check the installation of the engine coolant temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine coolant temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 6.

If damaged, replace the engine coolant tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–376 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the engine coolant temperature sensor unit

1. Set the starter key to the "LOCK" position.

E THW
2. Disconnect the engine coolant temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the engine coolant temperature sensor.

Measurement Tester
Standard values
conditions connections

Engine coolant 20 C {68 F}:

temperature sen- 2.59 – 2.32 k
Starter key: LOCK
SHTS021270300333 sor 80 C {176 F}:
THW – E 0.326 – 0.310 k

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine coolant temperature sen-

sor.
Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0217 has been detected.

SHTS021270300334

Has DTC P0217 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–377

DTC: P0219
EN01H02127030602016061

P0219: Engine overspeed condition

INFORMATION

Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J X3F (NE-)
(NE+) J0H XK4 (NE+)

SHTS021270300335

1. Technical description
• The engine ECU detects the engine speed using the engine speed main sensor (crankshaft position sensor)
mounted on the flywheel housing.

<Description of malfunction>
• Engine speed above rated value is detected.

2. DTC set condition

(1) DTC detection condition
While the engine is in operation
(2) Judgement criteria
An engine speed of more than 3,000 r/min

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
• Cruise control function is not available.
• Accelerator is fully closed.
• EGR valve is fully closed.
• VNT is fully open.
• Diesel throttle (intake throttle valve) is fully closed.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–378 ENGINE (J05E)/TROUBLESHOOTING

8. 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)
 ENGINE (J05E)/TROUBLESHOOTING 2–379

INSPECTION PROCEDURE: P0219

1 Inspect the engine oil level.

1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the standard value.

Rivet Oil level gauge

FULL ADD

Preferred level

Gauge end

SHTS021270300336

Is the engine oil quantity within the standard value?

YES NO

Go to step 2. Adjust the engine oil quantity according to

the standard value.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine speed main sensor connector

1. Check the connection of the engine speed main sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–380 ENGINE (J05E)/TROUBLESHOOTING

3 Check the engine speed main sensor

1. Check the installation of the engine speed main sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine speed main sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the engine speed main
sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the engine speed main sensor power supply

1. Set the starter key to the "LOCK" position.

NE- NE+ 2. Disconnect the engine speed main sensor connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed main sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300337 Engine speed

main sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
NE+ – NE-

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–381

5 Check for disconnection in wire harness of engine speed main sensor

1. Set the starter key to the "LOCK" position.

NE- 2. Connect the signal check harness to the engine ECU vehicle side
NE+ harness. (Do not connect the harness to the ECU.)

D 3. Use the electrical tester to measure the resistance between the

E72
engine ECU (signal check harness) and each terminal in the
E52
engine speed main sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300338 Engine ECU (sig-

nal check har-
ness) – engine
speed main sen-
Starter key: LOCK Less than 2 
sor vehicle side
connector
NE+ (E52) – NE+
NE- (E72) – NE-

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–382 ENGINE (J05E)/TROUBLESHOOTING

6 Check for short-circuit in wire harness of engine speed main sensor

1. Use the electrical tester to measure the resistance between each

D terminal in the engine ECU (signal check harness) and ground.
E52
E72
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK NE+ (E52) – 
Ground
NE- (E72) –
SHTS021270300339 Ground

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–383

7 Check the engine speed main sensor signal

1. Connect the signal check harness to the engine ECU.

E52 D E72 2. Connect the engine speed main sensor connector.

3. Start the engine.

4. Use the oscilloscope to measure the voltage between the termi-

nals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300340 Engine ECU (sig-

nal check har-
Engine idling ness) 56 pulse
NE+ (E52) –
NE- (E72)

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SHTS021270300341

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the engine speed main sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–384 ENGINE (J05E)/TROUBLESHOOTING

8 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0219 has been detected.

SHTS021270300342

Has DTC P0219 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–385

DTC: P0222 and P0223

EN01H02127030602016062

P0222: Intake throttle valve position sensor 2 - out of range (Out of range low)
INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300343

1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle (intake throttle), a sensor designed to detect a travel of the valve consistently monitors an
actual opening to compare with command value.

<Description of malfunction>
• Low voltage failure of diesel throttle (intake throttle valve) position sensor is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 0.2 V (5 degrees) or less for 3 seconds or longer.

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–386 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Failure in engine ECU sensor power supply or internal circuit
• Looseness or poor contact of connector
 ENGINE (J05E)/TROUBLESHOOTING 2–387

P0223: Intake throttle valve position sensor 2 - out of range (Out of range high)
INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300344

1. Technical description
• The diesel throttle (intake throttle) controls valves steplessly to control boost pressure and intake air volume.
• Inside the diesel throttle (intake throttle), a sensor designed to detect a travel of the valve consistently monitors an
actual opening to compare with command value.

<Description of malfunction>
• Abnormally high voltage of diesel throttle (intake throttle valve) position sensor is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Output of the sensor remains at 4.8 V (120 degrees) or less for 3 seconds or longer.

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–388 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

• Abnormal resistance of sensor
• Disconnection or short-circuit in sensor harness
• Sensor internal short-circuit
• Engine ECU internal circuit failure
 ENGINE (J05E)/TROUBLESHOOTING 2–389

INSPECTION PROCEDURE: P0222 and P0223

1 Inspect the diesel throttle (intake throttle valve) position sensor 2 connector

1. Check the connection of the diesel throttle (intake throttle valve)

position sensor 2 connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the diesel throttle (intake throttle valve) position sensor 2

1. Check the installation of the diesel throttle (intake throttle valve)

position sensor 2.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the diesel throttle (intake throttle valve) position sensor 2.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the diesel throttle (intake
throttle valve) position sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
2–390 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the diesel throttle (intake throttle valve) position sensor 2 unit

1. Set the starter key to the "LOCK" position.

VC VTA2 2. Disconnect the diesel throttle (intake throttle valve) position sensor
2 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the diesel throttle (intake throttle valve) position sen-
sor 2.

Measurement Tester
Standard values
conditions connections

Diesel throttle
VC E2
(intake throttle
valve) position (1) 180 
Starter key: LOCK sensor 2 (2) 3 k
(1) VC – VTA2 (3) 3 k
(2) VC – E2
(3) VTA2 – E2

VTA2 E2

SHTS021270300345

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the diesel throttle (intake throttle

valve) position sensor 2.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–391

4 Inspect the diesel throttle (intake throttle valve) position sensor 2 power supply

1. Set the starter key to the "ON" position.

2. Use the electrical tester to measure the voltage between the termi-
E2 VC nals of the diesel throttle (intake throttle valve) position sensor 2
vehicle side connector.

Measurement Tester
Standard values
conditions connections

Diesel throttle
(intake throttle
valve) position
Starter key: ON 4.5 – 5.5 V
SHTS021270300346 sensor 2 vehicle
side connector
VC – E2

Do the measurements meet the standard value?

YES NO

Go to step 5. Go to step 6.

5 Inspect the diesel throttle (intake throttle valve) position sensor 2 signal circuit

1. Set the starter key to the "LOCK" position.

E2 VTA2
2. Use the electrical tester to measure the resistance between the
terminals of the diesel throttle (intake throttle valve) position sen-
sor 2 vehicle side connector.

Measurement Tester
Standard values
conditions connections

Diesel throttle
(intake throttle
valve) position
Starter key: LOCK 25 – 35 k
SHTS021270300347 sensor 2 vehicle
side connector
VTA2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.
2–392 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect for short-circuits in wire harness of diesel throttle (intake throttle valve) position sen-
sor 2

1. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
F
M52 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
VCTA (M52) –
E46 D Starter key: LOCK Ground 
E77
VTA2 (E46) –
Ground
EPA (E77) –
Ground

SHTS021270300348

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–393

7 Inspect for disconnections in wire harness of intake throttle valve

1. Connect the diesel throttle (intake throttle valve) position sensor 2

connector.
M52 F D E46
2. 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-
ness)
(1) VCTA (M52) – (1) 2  or more
M52 F D
E77 Starter key: LOCK VTA2 (E46) (2) 3 k
(2) VCTA (M52) – (3) 3 k
EPA (E77)
(3) VTA2 (E46) –
EPA (E77)

E46 D
E77

SHTS021270300349

Do the measurements meet the standard value?

YES NO

Go to step 8. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–394 ENGINE (J05E)/TROUBLESHOOTING

8 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0222 or P0223) has been
detected.

SHTS021270300350

Has DTC (P0222 or P0223) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–395

DTC: P0234
EN01H02127030602016063

P0234: Overboost
INFORMATION

Engine ECU

DCU
(ETHW)

YM5 (CAN+)
(PCR1)

(PCR2)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
(THW)

XMH (EVG)

X82 (THA)
(EP1)

(EP2)

YKE (EPA)

X2U (VAF)
X0G (PIM)

X4K (VG)
X28
YKC
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW
X66 (THW)

Actuator power
(VC) J0M

(E) Z6R
(PIM) J0L

(CANH)

(CANH)
relay

(CANL)

(CANL)
Z5G (E)
Coolant temperature

XCV
XCT
EBM

#XG
EBH
EBN

NFA

NFA
EBK

#XV
X71

Z65
EBL

X72
EBJ
sensor 1

(L)
X36
(FC)
(E2G)
(+B)
(E2)
(THA)
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

VNT EGR
controller actuator
Boost pressure

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
sensor
Y2E Y4J Z90
Common rail Intake air
Body earth pressure sensor temperature sensor L2J #E1 #ET
(air flow sensor built in)

SHTS021270300351

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure. It observes a deviation between the target boost pressure and actual boost pressure to check
if the actual pressure is higher than the target pressure.

<Description of malfunction>
• Boost pressure is higher than the stipulated value.

2. DTC set condition

(1) DTC detection condition
• Water temperature at engine start-up is 0 C {32 F} or more.
• The condition that the intake air temperature at engine start-up is less than 0 C {32 F} remains for 500 sec-
onds or more.
• The condition that the intake air temperature at the engine start-up is higher than 0 C {32 F} remains in the
range of 30 to 200 seconds.

The conditions described below remain for 4 seconds or more.

• The target boost pressure is 40 kPa (gauge) or more.
• If the engine speed is 750 r/min, fuel injection quantity is 100 mm3/st. cyl or more.
• If the engine speed is in range of 1250 to 1750 r/min, fuel injection quantity is 60 mm3/st.cyl or more.
• If the engine speed is 2500 r/min, fuel injection quantity is 120mm3/st.cyl or more.
• Atmospheric pressure is higher than 75 kPa.
• DPR auto-regeneration is inactive.
2–396 ENGINE (J05E)/TROUBLESHOOTING

(2) 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.
• If target boost pressure is 220 to 250 kPa, the deviation of boost pressure detected is 45 kPa or more.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Turbocharger noise or damage
• Insufficient output or engine stall because of DPR filter clogging due to abnormal soot generation

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that DTC is not detected after test run (10 minutes after engine startup).

8. Estimated failure factors

• VNT actuator failure (VNT nozzle closed-side failure)
• EGR valve failure (EGR valve closed-side failure)
• Clogged boost pressure sensor hose
• Boost pressure sensor failure (abnormal voltage, power supply or ground fault)
 ENGINE (J05E)/TROUBLESHOOTING 2–397

INSPECTION PROCEDURE: P0234

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0234 (for exam-
ple, P0045, P0401) has been detected.

SHTS021270300352

Has a DTC other than P0234 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the boost pressure sensor hose.

1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

Was any failure found?

YES NO

1. Replace the boost pressure sensor hose. Go to step 3.

2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
2–398 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the boost pressure sensor power supply system

1. Set the starter key to the "LOCK" position.

E
2. Disconnect the boost pressure sensor connector.
VC

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300353 Boost pressure

sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 4. Inspect the harness and engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–399

4 Inspect the response delay of the VNT controller

1. Set the starter key to the "LOCK" position.

(1)
2. Connect the vehicle to HINO DX Ⅱ .
(3)

(2) 3. Set the starter key to the "ON" position and select [Engine].
(4)
(5) 4. Select [Inspection Menu], then inspect the response delay at the
Target VNT position and Actual VNT position.
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
SHTS021270300354
<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Click [Start inspection].
(4) Select [VNT UP]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target VNT position to the Actual VNT position,

the response delay should be within 3 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the turbocharger.

Perform "After-inspection work" of INFOR-
MATION section.
2–400 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Click [Start inspection].
(4) Click [EGR opening UP]:
SHTS021270300355
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Click [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Check that P0234 is not detected again to Replace the EGR valve.
complete the check. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–401

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
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

Engine ECU

X49 (#4) $XY (I1+S)

Injector 4 X8Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (I2+S)
Injector 3 X8X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)

SHTS021270300356
2–402 ENGINE (J05E)/TROUBLESHOOTING

1. 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.

<Description of malfunction>
• If the speed of the #1 cylinder is found abnormal, the DTC P0263 will be detected.
• If the speed of the #2 cylinder is found abnormal, the DTC P0266 will be detected.
• If the speed of the #3 cylinder is found abnormal, the DTC P0269 will be detected.
• If the speed of the #4 cylinder is found abnormal, the DTC P0272 will be detected.

2. DTC set condition

(1) 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 mm3/st. cyl.
• The exhaust brake and PTO are inactive.
2. All the following conditions continue for more than 10 seconds.
• The engine speed is within the below table.
• Gear position unchanged
• The fuel injection quantity is less than 45 mm3/st. cyl.
• The coolant temperature is above 60 C {140 F}.
• The accelerator opening is 0%.
• The vehicle speed is 0 mile/h.
• Barometric pressure ≥ 75 kPa (10.8 psi)
• The exhaust brake and PTO are inactive.
Engine speed (r/min)

Manual Transmission Automatic Transmission

D range N/A 725-775

N range 725-775 N/A

P range N/A N/A

(2) Judgement criteria

• If the #1 cylinder speed measured by the engine speed main sensor is low, the fuel injection quantity retains a
value lower by 30 to 45 mm3/st.cyl or more for 20 seconds or more.
• If the #1 cylinder speed measured by the engine speed main sensor is high, the fuel injection quantity retains
a value higher by 10 to 20 mm3/st.cyl or less for 20 seconds or more.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–403

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Injector: clogged or stays open
2–404 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0263, P0266, P0269 and P0272

1 Check the DTC detected 1 (Engine ECU)

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if any following DTCs (cylinder #1:

P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected
as an "Active".
SHTS021270300357

Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected as an
"Active"?

YES NO

Go to step 2 (Detected as an "Active".) Go to step 9. (Recorded as an "Inactive".)

2 Check the DTC detected 2 (engine ECU)

1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272

SHTS021270300358

Has other "Active" DTC been detected?

YES NO

Go to diagnosis procedure of the related Go to step 3.

DTC.
 ENGINE (J05E)/TROUBLESHOOTING 2–405

3 Inspect the fuel line

1. 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

Injector
Pre fuel
filter

Supply pump

Suction line
Positive pressure line
Fuel tank
High pressure line
Return line

SHTS021270300359

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Go to step 4 after repair or replacement.

4 Inspect the pre fuel filter

1. Check that the pre fuel filter is not dirty or clogged.

Was any failure found?

YES NO

Replace the pre fuel filter. Go to step 5.

Go to step 5 after replacement.
2–406 ENGINE (J05E)/TROUBLESHOOTING

5 Check the DTC detected 3 (engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any followings DTCs (cylinder #1:

P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.

SHTS021270300360

Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?

YES NO

Go to step 6. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

6 Perform the cylinder cut-off test (HINO DX Ⅱ )

1. Use the cruise function to run the engine at 1,500 r/min.

2. Check the engine sound during normal operation. (before Cut-off

test)

3. Use HINO DXⅡ's [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>

- This method is generally used to check combustion abnormalities by
SHTS021270300361
stopping the fuel injection for one of the cylinder of a four-cylinder
engine and verifying the engine sound or performance.

Did you find the engine sound different?

YES NO

<One of the A to D is always large or same as <There is no clear difference>

α> Go to step 8
Replace the abnormal injector.
After replace, go to step 7.
 ENGINE (J05E)/TROUBLESHOOTING 2–407

7 Check the DTC detected 4 (engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any followings DTCs (cylinder #1:

P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.

SHTS021270300362

Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?

YES NO

Go to step 8. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

8 Replace the common rail assembly

1. Set the starter key to the "LOCK" position.

2. Replace common rail assembly.

3. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

4. Stop the engine.

5. Set the starter key to the "ON" position.

6. Select [Engine] and check if any followings DTCs (cylinder #1:

SHTS021270300363
P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.

Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?

YES NO

Go to step 9. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–408 ENGINE (J05E)/TROUBLESHOOTING

9 Check the injector clamp

1. Check that the injector clamp is not loose.

2. Check that there is no "insufficient engagement" of the injector

BOLT clamp claw.

INJECTOR

INJECTION PIPE
INJECTOR
CLAMP

INJECTION
PIPE OIL SEAL
O-RING

SHTS021270300364

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 10.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–409

10 Check the valve clearance

1. 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

Intake valve:
0.3 mm (0.0118 in.)
Cross head Cold engine
Exhaust valve:
0.45 mm (0.0177 in.)

SHTS021270300365

Cylinder number 1 2 3 4

Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

No.1 cylinder at the compres-

   
sion stroke top dead center

No.4 cylinder at the compres-

∆ ∆ ∆ ∆
sion stroke top dead center

Do the measurements meet the standard value?

YES NO

Go to step 11. Adjust the valve clearance.

Perform "After-inspection work" of INFOR-
MATION section.
2–410 ENGINE (J05E)/TROUBLESHOOTING

11 Check the engine compression pressure

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Remove the air cleaner.

SST 4. Remove the all injectors.

To
engine 5. Set the special service tool (SST) and measure the compression
on each cylinder one at a time on all 6 cylinders.

SHTS021270300366
Measurement
Standard values
conditions

Standard values:
Engine revolution: 150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}

Do the measurements meet the standard value?

YES NO

Go to step 12. Repair base engine to correct low compres-

sion.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–411

12 Inspect the engine speed main sensor (Crankshaft position sensor)

1. Inspect the condition of engine speed main sensor (crankshaft

Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).

2. Check the installation of the engine speed main sensor. (Crank-

shaft position sensor)

Connector

Flywheel housing

SHTS021270300367

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 13.

Perform "After-inspection work" of INFOR-
MATION section.

13 Check the DTC detected 5 (engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any followings DTCs (cylinder #1:

P0263, #2: P0266, #3: P0269 and #4: P0272) have been detected.

SHTS021270300368

Have any DTCs (cylinder #1: P0263, #2: P0266, #3: P0269 and #4: P0272) been detected?

YES NO

Inspect the crankshaft, connecting rods, fly- Procedure completed.

wheel, and other parts of the drive system. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
2–412 ENGINE (J05E)/TROUBLESHOOTING

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
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

Engine ECU

X49 (#4) $XY (I1+S)

Injector 4 X8Y (#40) X2X (#3)
X1Z (#30)
X47 (#3) $XX (I2+S)
Injector 3 X8X (#30) X2W (#2)
X20 (#20)
X45 (#2) %X2 (IJ2+)
Injector 2 X0B (#20) X01 (#4)
X3L (#40)
X42 (#1) %X1 (IJ1+)
Injector 1 X43 (#10) X2V (#1)
X19 (#10)

SHTS021270300369

1. Technical description
• The engine speed main sensor (crankshaft position sensor) monitors the engine speed of #1 – #4 cylinders.
• The average injection quantity into #1 – #4 cylinders is increased and decreased so that the engine speed of each
cylinder is kept constant.

<Description of malfunction>
• Abnormal average injection quantity into #1 – #4 cylinders is detected.
 ENGINE (J05E)/TROUBLESHOOTING 2–413

2. DTC set condition

(1) 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.
• Gear position is D range.
• Fuel injection quantity < 45 mm3/st. cyl.
• Engine coolant temperature ≥ 60 C {140 F}.
• Throttle opening is 0%.
• Vehicle speed is 0 mph.
• Barometric pressure ≥ 75 kPa.
• Exhaust brake and PTO are not in operation.
(2) Judgement criteria
• If the speed of all of cylinders from #1 – #4 measured by the engine speed main sensor is low, the status
where the fuel injection quantity decreases by 30 to 45 mm3/st. cyl or more continues for 20 seconds or more.
• If the speed of all of cylinders from #1 – #4 measured by the engine speed main sensor is low, the status
where the fuel injection quantity decreases by 10 to 20 mm3/st. cyl or more remains for 20 seconds or more.

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Large vibration during idling.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Injector: clogging, constantly injecting
• Use of low-grade fuel
• Crankshaft position sensor phase shifting.
2–414 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P026C and P026D

1 Check the DTC detected 1 (Engine ECU)

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P026C or P026D) has been
detected as an "Active".

SHTS021270300370

Has DTC (P026C or P026D) been detected as an "Active"?

YES NO

Go to step 2 (Detected as an "Active") Go to step 9. (Recorded as an "Inactive")

2 Check the DTC detected 2 (engine ECU)

1. Check if the following DTC are not detected at the same time in the
results of step 1.
• P0263, P0266, P0269, P0272

SHTS021270300371

Has other "Active" DTC been detected?

YES NO

Go to diagnosis procedure of the related Go to step 3.

DTC.
 ENGINE (J05E)/TROUBLESHOOTING 2–415

3 Inspect the fuel line

1. 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

Injector
Pre fuel
filter

Supply pump

Suction line
Positive pressure line
Fuel tank
High pressure line
Return line

SHTS021270300372

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Go to step 4 after repair or replacement.
2–416 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the pre fuel filter

1. Check that the pre fuel filter is not dirty or clogged or damaged.

Was any failure found?

YES NO

Replace the pre fuel filter. Go to step 5.

Go to step 5 after replacement.

5 Check the DTC detected (Engine ECU)

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected.

SHTS021270300373

Has DTC (P026C or P026D) been detected?

YES NO

Go to step 6. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–417

6 Perform the cylinder cut-off test (HINO DX Ⅱ )

1. Use the cruise function to run the engine at 1,500 r/min.

2. Check the engine sound during normal operation. (before Cut-off

test)

3. 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>

- This method is generally used to check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
SHTS021270300374
engine and verifying the engine sound or performance.

Did you find the engine sound different?

YES NO

<There is a clear difference in sound or per- <There is no difference in sound or perfor-

formance when the injection is cut-off> mance when the injection is cut-off>
Go to step 8. Replace the injector.
Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.)
Go to step 7 after replacement.

7 Check the DTC detected (Engine ECU)

1. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected.

SHTS021270300375

Has DTC (P026C or P026D) been detected?

YES NO

Go to step 8. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–418 ENGINE (J05E)/TROUBLESHOOTING

8 Replace the common rail assembly

1. Set the starter key to the "LOCK" position.

2. Replace common rail assembly.

3. Perform the engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

4. Stop the engine.

5. Set the starter key to the "ON" position.

6. Select [Engine] and check if the DTC (P026C or P026D) has been
SHTS021270300376
detected.

Has DTC (P026C or P026D) been detected?

YES NO

Go to step 9. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–419

9 Check the injector clamp

1. Check that the injector clamp is not loose.

2. Check that there is no "insufficient engagement" of the injector

BOLT clamp claw.

INJECTOR

INJECTION PIPE
INJECTOR
CLAMP

INJECTION
PIPE OIL SEAL
O-RING

SHTS021270300377

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 10.

Perform "After-inspection work" of INFOR-
MATION section.
2–420 ENGINE (J05E)/TROUBLESHOOTING

10 Check the valve clearance

1. 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

Intake valve:
0.30 mm (0.0118 in.)
Cross head Cold engine
Exhaust valve:
0.45 mm (0.0177 in.)

SHTS021270300378

Cylinder number 1 2 3 4

Valve arrangement Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust

No.1 cylinder at the compres-

   
sion stroke top dead center

No.4 cylinder at the compres-

∆ ∆ ∆ ∆
sion stroke top dead center

Do the measurements meet the standard value?

YES NO

Go to step 11. Adjust the valve clearance.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–421

11 Check the engine compression pressure

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine.

3. Remove the all injectors.

SST 4. Set the special service tool (SST) and measure the compression.
To
engine Measurement
Standard values
conditions

SHTS021270300379 Standard values:

Engine revolution: 150 r/min 3.2-3.4 MPa {33-35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}

Do the measurements meet the standard value?

YES NO

Go to step 12. Engine overhaul.

Perform "After-inspection work" of INFOR-
MATION section.
2–422 ENGINE (J05E)/TROUBLESHOOTING

12 Inspect the engine speed main sensor (Crankshaft position sensor)

1. Inspect the condition of engine speed main sensor (crankshaft

Engine speed main sensor (Crankshaft position sensor) position sensor) connector (looseness or poor contact).

2. Check the installation of the engine speed main sensor. (Crank-

shaft position sensor)

Connector

Flywheel housing

SHTS021270300380

Was any failure found?

YES NO

Repair or replace the faulty parts. Go to step 13.

Perform "After-inspection work" of INFOR-
MATION section.

13 Check the DTC detected (Engine ECU)

1. Perform an engine warm up. (engine coolant temperature: 80 C

{176 F} or more)

2. Stop the engine

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P026C or P026D) has been
detected.

SHTS021270300381

Has DTC (P026C or P026D) been detected?

YES NO

Inspect the crankshaft, connecting rods, fly- Procedure completed.

wheel, and other parts of the drive system. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–423

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 & examples>

Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.

1 Cylinder cut-off test

1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.

2. Check that the engine sound at the time of before cut-off test nor-
Active test Setting
Data monitor and Active test
mal operation. (The sound at this time shall be α.)

3. Select [Data monitor and Active test].

SHTS021270300382
2–424 ENGINE (J05E)/TROUBLESHOOTING

4. 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. (No abnormality.)
Select the cylinder to deactivate
5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder.
No. 1. (The measure sounds shall be B, C and D respectively.)
HINT
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• If the sound of A – D is the same of α, always check for a com-
munication problem.

Injection is stopped when OK is selected.

SHTS021270300383

Did you find the engine sound different?

YES NO

(One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no

same as α) clear difference
Replace the injector Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–425

DTC: P0299
EN01H02127030602016066

P0299: Underboost
INFORMATION

Coolant temperature
sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E) YKC (ETHW)
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM (EP2)
pressure sensor (E2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(VC) J0M YKF (VCPA)
Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

(FC) X71 X4K (VG)

(E2G) XCV XMH (EVG)
Intake air
temperature sensor (+B) XCT X2U (VAF)
(air flow sensor built in) (E2) Z65
(THA) X72 X82 (THA)

SHTS021270300384

1. Technical description
• The VNT actuator moves the nozzle vane steplessly by the LEA (Linear Electric Actuator) to control the turbo speed
and boost pressure. It compares the target boost pressure and actual boost pressure to check if the actual pressure
is lower than the target pressure.

<Description of malfunction>
• The boost pressure is lower than the stipulated value.

2. DTC set condition

(1) DTC detection condition
• Water temperature at the engine start-up is 0 C {32 F} or above.

The conditions described below remain for 4 seconds or more.

• The target boost pressure is 40 kPa (gauge) or more.
• If the engine speed is 750 r/min, fuel injection quantity is 100 mm3/st. cyl or more.
• If the engine speed is in range of 1250 to 1750 r/min, fuel injection quantity is 60 mm3/st.cyl or more.
• If the engine speed is 2500 r/min, fuel injection quantity is 120 mm3/st.cyl or more.
• Atmospheric pressure is higher than 75 kPa.
• DPR auto-regeneration is not actuated.
(2) Judgement criteria
• Deviation between the target boost pressure and the actual boost pressure: the condition that the deviation
exceeds the range of -30 to -50 kPa remains 30 seconds or more.
• If target boost pressure is 140 to 220 kPa, the deviation of boost pressure detected is -30 kPa or less.
• If target boost pressure is 220 to 250 kPa, the deviation of boost pressure detected is -40 kPa or less.
2–426 ENGINE (J05E)/TROUBLESHOOTING

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormality in air intake system (disconnected boost hose)
• Turbocharger failure (stuck turbine)
• Malfunction of boost pressure sensor
• Malfunction of air flow meter
• Malfunction of VNT
• Malfunction of EGR valve
 ENGINE (J05E)/TROUBLESHOOTING 2–427

INSPECTION PROCEDURE: P0299

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0299 (for exam-
ple, P0045, P0401) has been detected.

SHTS021270300385

Has a DTC other than P0299 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the boost pressure sensor hose.

1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

Was any failure found?

YES NO

1. Replace the boost pressure sensor hose. Go to step 3.

2. Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
2–428 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the boost pressure sensor power supply system

1. Set the starter key to the "LOCK" position.

E
2. Disconnect the boost pressure sensor connector.
VC

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300386 Boost pressure

sensor vehicle
Starter key: ON 4.75 – 5.25 V
side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 4. Inspect the harness and engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–429

4 Inspect the response delay of the VNT controller

1. Select [Inspection Menu] from the menu, then inspect the

(1) response delay at the Target VNT position and Actual VNT posi-
tion.
(3)
! CAUTION
(2) Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Click [Start inspection].
(4) Select [VNT UP]:
SHTS021270300387
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target VNT position to the Actual VNT position,

the response delay should be within 3 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the turbocharger.

Perform "After-inspection work" of INFOR-
MATION section.
2–430 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Click [Start inspection].
(4) Click [EGR opening UP]:
SHTS021270300388
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Click [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Check that P0299 is not detected again to Replace the EGR valve.
complete the check. Perform "After-inspection work" of INFOR-
Perform "After-inspection work" of INFOR- MATION section.
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–431

DTC: P0300
EN01H02127030602016067

P0300: All injector (#1 - #4) Misfire

INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

SHTS021270300389

1. Technical description
• The engine speed main sensor (crankshaft position sensor) monitors the engine speed of #1 – #4 cylinders.
• The average injection quantity into #1 – #4 cylinders is increased and decreased so that the engine speed of each
cylinder is kept constant.

<Description of malfunction>
• Two or more of the following DTCs are detected: P0301, P0302, P0303, P0304.
2–432 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 mm3/st. cyl.
• Exhaust brake and PTO are not in operation.
2. All the following conditions continue for at least 10 seconds:
• Engine speed is in the range of 725-775 r/min.
• Gear position is D range.
• Fuel injection quantity < 45 mm3/st. cyl.
• Engine coolant temperature ≥ 60 C {140 F}.
• Throttle opening is 0%.
• Vehicle speed is 0 mile / h.
• Atmospheric pressure is 75 kPa or more.
• Exhaust brake and PTO are not in operation.
(2) Judgement criteria
• Failure is determined when two or more of P0301, P0302, P0303, and P0304 are detected for 3 seconds.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Injector: clogging, constantly injecting
 ENGINE (J05E)/TROUBLESHOOTING 2–433

INSPECTION PROCEDURE: P0300

1 Inspect the fuel pipes

1. 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
Pre fuel
filter

Supply pump

Suction line
Positive pressure line
Fuel tank
High pressure line
Return line

SHTS021270300390

Was any failure found?

YES NO

Repair or replace the faulty part, Go to step 3.

go to step 2.
2–434 ENGINE (J05E)/TROUBLESHOOTING

2 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0300 has been detected.

SHTS021270300391

Has DTC P0300 been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

3 Perform the cylinder cut-off test

1. Use the cruise function to run the engine at 1,500 r/min.

2. Check the engine sound during normal operation.

3. Select [Engine], and [Data monitor and Active test] to perform a

cut-off test.
For details, refer to "Flow-Cut off test" procedure.

<Cylinder cut-off test>

- This method is generally used to check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
engine and verifying the injectors' sound.
SHTS021270300392

Did you notice a difference in engine sound?

YES NO

<There is a clear difference in sound or per- <There is no difference in sound or perfor-

formance when the injection is cut-off> mance when the injection is cut-off>
Go to step 4. Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.)
Go to step 5 after replacement.
 ENGINE (J05E)/TROUBLESHOOTING 2–435

4 Check the DTC detected (Engine ECU) 2

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0300 has been detected.

SHTS021270300393

Has DTC P0300 been detected?

YES NO

Go to step 5. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

5 Replace the common rail assembly [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Replace the common rail assembly with a new one.

3. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

4. Stop the engine and set the starter key to the "ON" position.

5. Select [Engine] and check if P0300 has been detected.

SHTS021270300394

Has DTC P0300 been detected?

YES NO

Go to step 6. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–436 ENGINE (J05E)/TROUBLESHOOTING

6 Check the compression ratio

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine.

3. Remove injectors from all cylinders.

SST 4. Install the special tool (SST) and measure the compression ratio of
TO each cylinder.
ENGINE
Measurement conditions Standard values

SHTS021270300395 Standard values:

3.2 – 3.4 MPa {33 – 35 kgf/
Engine revolution: 150 r/min
cm2}
Limit: 2.3 MPa {24 kgf/cm2}

Do the measurements meet the standard value?

YES NO

Go to step 7. Overhaul the engine.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU) 3

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0300 has been detected.

SHTS021270300396

Has DTC P0300 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–437

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 & examples>

Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.

1 Cylinder cut-off test

1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.

2. Check that the engine sound at the time of normal operation. (The
Active test Setting
Data monitor and Active test
sound at this time shall be α.)

3. Select [Data monitor and Active test].

SHTS021270300397
2–438 ENGINE (J05E)/TROUBLESHOOTING

4. 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. (This is not abnor-
Select the cylinder to deactivate
mal.)
As the engine is running with combustion of one cylinder less
than normal, it is normal that the vibrations increase.
For an engine with no injection or reduced injection quantity,
injection stop causes no vibration change.
For engines increasing the injection quantity for some cylinders,
the vibrations become larger when all cylinders are operating, and
the vibrations decrease when injection is stopped for the defec-
tive cylinder.

5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder No. 1. (The measure sounds
Injection is stopped when OK is selected.
shall be B, C and D respectively.)
HINT

SHTS021270300398
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• if one of the sounds A to D is the same as α, always check for a
communication problem of the injector.

Did you notice a difference in engine sound?

YES NO

<One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no

same as α> clear difference
Replace the abnormal injector. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–439

DTC: P0301, P0302, P0303 and P0304

EN01H02127030602016068

P0301: #1 Misfire
P0302: #2 Misfire
P0303: #3 Misfire
P0304: #4 Misfire
INFORMATION

Injection
pipe
Injector
Common rail
Pressure feeding pipe
Leakage pipe

Pressure
limiter

Overflow pipe Through feed pipe

Supply pump
Overflow
valve

Pre fuel filter Fuel tank

Fuel filter

SHTS021270300399

1. 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.

<Description of malfunction>
• If the speed of the #1 cylinder is found abnormal, the DTC P0301 will be detected.
• If the speed of the #2 cylinder is found abnormal, the DTC P0302 will be detected.
• If the speed of the #3 cylinder is found abnormal, the DTC P0303 will be detected.
• If the speed of the #4 cylinder is found abnormal, the DTC P0304 will be detected.
2–440 ENGINE (J05E)/TROUBLESHOOTING

2. DTC set condition

(1) 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 mm3/st. cyl.
• The exhaust brake and PTO are inactive.
2. All the following conditions continue for more than 10 seconds.
• The engine speed is in the range of 725-775 r/min.
• Gear position is D range.
• The fuel injection quantity is less than 45 mm3/st. cyl.
• The coolant temperature is above 60C {140 F}.
• The accelerator opening is 0%.
• The vehicle speed is 0 mile/h.
• Barometric pressure ≥ 75 kPa.
• The exhaust brake and PTO are inactive.
(2) Judgement criteria

If all the following conditions continue for more than 10 seconds, diagnostic judgment will take place.
• The fuel injection quantity is more than 40 mm3/st. cyl.
• The speed of each cylinder measured by engine speed main sensor (crankshaft position sensor) becomes
abnormal.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fuel injection line: break, crack, fuel leak
• Cylinder: compression leak
• Common rail: flow damper operational error
• Injector: clogged or stays open
 ENGINE (J05E)/TROUBLESHOOTING 2–441

INSPECTION PROCEDURE: P0301, P0302, P0303 and P0304

1 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if any DTC other than (P0301, P0302,
P0303 or P0304) has been detected.

SHTS021270300400

Has any DTC other than (P0301, P0302, P0303 or P0304) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2–442 ENGINE (J05E)/TROUBLESHOOTING

2 Inspect the fuel injection pipe between common rail and injector

1. 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
Pre fuel
filter

Supply pump

Suction line
Positive pressure line
Fuel tank
High pressure line
Return line

SHTS021270300401

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Go to step 3 after repair or replacement.
 ENGINE (J05E)/TROUBLESHOOTING 2–443

3 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or

P0304) has been detected.

SHTS021270300402

Has DTC (P0301, P0302, P0303 or P0304) been detected?

YES NO

Go to step 4. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

4 Perform the cylinder cut-off test

1. Start the engine and use the cruise function to run the engine at
1,500 r/min.

2. Check the engine sound during normal operation.

3. Select [Engine], and [Data monitor and Active test] to perform a

cut-off test.
For details, refer to the cut-off test procedure.

<Cylinder cut-off test>

- This method is generally used to Check combustion abnormalities by
stopping the fuel injection for one of the cylinder of a four-cylinder
SHTS021270300403
engine and verifying the injectors' sound.

Did you find the engine sound different?

YES NO

<There is a clear difference in sound or per- <There is no difference in sound or perfor-

formance when the injection is cut-off> mance when the injection is cut off>
Go to step 5. Replace the injector (Replace the failed injec-
tor detected by the cut-off test, not the injec-
tor noted in the DTC.).
Go to step 5 after replacement.
2–444 ENGINE (J05E)/TROUBLESHOOTING

5 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or

P0304) has been detected.

SHTS021270300404

Has DTC been detected?

YES NO

Go to step 6. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.

6 Replace the common rail assembly

1. Set the starter key to the "LOCK" position.

2. Replace the common rail assembly.

3. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

4. Stop the engine and the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0301, P0302, P0303 or

P0304) has been detected.

SHTS021270300405

Has DTC (P0301, P0302, P0303 or P0304) been detected?

YES NO

Go to step 7. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–445

7 Check the engine compression pressure

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine.

3. Remove the all injectors

SST 4. Set the special service tool (SST) and measure the compression.
TO
ENGINE Measurement conditions Standard values

3.2 – 3.4 MPa

SHTS021270300406 Engine revolution: 150 r/min {33 – 35 kgf/cm2}
Limit: 2.3 MPa {24 kgf/cm2}

Do the measurements meet the standard value?

YES NO

Go to step 8. Overhaul the engine.

Perform "After-inspection work" of INFOR-
MATION section.

8 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P0301, P0302, P0303 or

P0304) has been detected.

SHTS021270300407

Has DTC (P0301, P0302, P0303 or P0304) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–446 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 any cylinder.

<Purpose>
Evaluation of combustion abnormalities of each cylinder by sound difference.

<Know-how & examples>

Detect combustion abnormalities of any cylinder from differences in the sound and perform the required corrections.

1 Cylinder cut-off test

1. Start the engine and use the cruise control function to run the
engine at 1,500 r/min.

2. Check that the engine sound at the time of normal operation. (The
Active test Setting
Data monitor and Active test
sound at this time shall be α.)

3. Select [Data monitor and Active test].

SHTS021270300408
 ENGINE (J05E)/TROUBLESHOOTING 2–447

4. 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. (This is not abnor-
Select the cylinder to deactivate
mal.)
As the engine is running with combustion of one cylinder less
than normal, it is normal that the vibrations increase.
For an engine with no injection or reduced injection quantity,
injection stop causes no vibration change.
For engines increasing the injection quantity for some cylinders,
the vibrations become larger when all cylinders are operating, and
the vibrations decrease when injection is stopped for the defec-
tive cylinder.

5. Sequentially stop the injection for cylinders No. 2, No. 3 and No. 4
in the same way as for a cylinder No. 1. (The measure sounds
Injection is stopped when OK is selected.
shall be B, C and D respectively.)
HINT

SHTS021270300409
• When the difference in the sound is difficult to detect, repeat
steps 4 and 5.
• if one of the sounds A to D is the same as α, always check for a
communication problem of the injector.

Did you notice a difference in engine sound?

YES NO

<One out of A to D is abnormally loud or the Comparison of the sounds A to D shows no

same as α> clear difference
Replace the injector. Procedure completed.
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–448 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0335
EN01H02127030602016069

P0335: Engine speed main sensor (Crankshaft position sensor) - disconnection

INFORMATION

Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J X3F (NE-)
(NE+) J0H XK4 (NE+)

SHTS021270300410

1. Technical description
• The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed
main sensor (crankshaft position sensor).

<Description of malfunction>
• Pulses from the engine speed main sensor (crankshaft position sensor) cannot be sensed.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed of 0 r/min or more
(2) Judgement criteria
• With the engine running, engine speed main sensor does not detect pulses for continuous 0.8 seconds or lon-
ger. (at 750 r/min)

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Regeneration failure of DPR.
• PTO is not available.
• Vehicle start control is not available.
• Auxiliary brake is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.
• Regeneration of DPR dose not work.
• PTO cannot be used.
• Vehicle start control dose not work.
• Auxiliary brake cannot be used.

<Symptoms on the vehicle due to malfunction>

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–449

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• 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)
• Harness disconnection or short-circuit
2–450 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0335

1 Inspect the engine speed main sensor (crankshaft position sensor) connector

1. Check the connection of the engine speed main sensor (crank-

shaft position sensor) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine speed main sensor (crankshaft position sensor)

1. Check the installation of the engine speed main sensor (crankshaft

position sensor).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine speed main sensor (crankshaft position sensor).

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine speed main
sensor (crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–451

3 Inspect the engine speed main sensor (crankshaft position sensor) unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the engine speed main sensor (crankshaft position

NE- NE+ sensor) connector.

3. Use the electrical tester to measure the resistance between the

terminals of the engine speed main sensor (crankshaft position
sensor).

Measurement Tester
Standard values
conditions connections

SHTS021270300411 Engine speed

main sensor
20 C {68 F}:
Starter key: LOCK (crankshaft posi-
108.5 – 142.5 
tion sensor)
NE+ – NE-

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the engine speed main sensor

(crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
2–452 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the engine speed main sensor (crankshaft position sensor) power supply

1. Set the starter key to the "ON" position.

NE- NE+ 2. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed main sensor (crankshaft position sensor)
vehicle side connector.

Measurement Tester
Standard values
conditions connections

Engine speed
main sensor
(crankshaft posi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300412 tion sensor) vehi-
cle side connector
NE+ – NE-

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–453

5 Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har-
ness

1. Set the starter key to the "LOCK" position.

E52 D
2. Connect the signal check harness to the engine ECU. (Do not con-
E72
nect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300413 nal check har-
ness)
Starter key: LOCK NE+ (E52) – 
Ground
NE- (E72) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–454 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness

1. Connect the engine speed main sensor (crankshaft position sen-

sor) connector.
E52 D E72
2. 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-
20 C {68 F}:
Starter key: LOCK ness)
108.5 – 142.5 
SHTS021270300414 NE+ (E52) – NE-
(E72)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0335 has been detected.

SHTS021270300415

Has DTC P0335 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–455

DTC: P0336
EN01H02127030602016070

P0336: Engine speed main sensor (Crankshaft position sensor) - rationality

INFORMATION

Engine ECU
ZTZ
(SNE)
Engine speed main sensor (NE-) J0J X3F (NE-)
(NE+) J0H XK4 (NE+)

SHTS021270300416

1. Technical description
• The engine speed main sensor (crankshaft position sensor) consistently measures pulses from the engine speed
main sensor (crankshaft position sensor).

<Description of malfunction>
• Pulses from the engine speed main sensor (crankshaft position sensor) cannot be correctly sensed.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed of 500 r/min or more
(2) Judgement criteria
• Make a judgment when the abnormal number of engine speed main sensor pulses (not 56 pulses) per engine
revolution is continuously detected. For example, 50 seconds at 750 r/min

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. 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)
• Harness disconnection or short-circuit
2–456 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0336

1 Inspect the engine speed main sensor (crankshaft position sensor) connector

1. Check the connection of the engine speed main sensor (crank-

shaft position sensor) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine speed main sensor (crankshaft position sensor)

1. Check the installation of the engine speed main sensor (crankshaft

position sensor).

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine speed main sensor (crankshaft position sensor).

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine speed main
sensor (crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–457

3 Inspect the engine speed main sensor (crankshaft position sensor) power supply

1. Set the starter key to the "LOCK" position.

NE- NE+ 2. Disconnect the engine speed main sensor (crankshaft position
sensor) connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed main sensor (crankshaft position sensor)
vehicle side connector.

Measurement Tester
SHTS021270300417 Standard values
conditions connections

Engine speed
main sensor
(crankshaft posi-
Starter key: ON 4.5 – 5.5 V
tion sensor) vehi-
cle side connector
NE+ – NE-

Do the measurements meet the standard value?

YES NO

Go to step 6. Go to step 4.
2–458 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect disconnection of the engine speed main sensor (crankshaft position sensor) harness

1. Set the starter key to the "LOCK" position.

NE- 2. Connect the signal check harness to the engine ECU engine
NE+ speed main sensor (crankshaft position sensor to the ECU)

D 3. Use the electrical tester to measure the resistance between the

E72
terminals of the engine ECU and engine speed main sensor
E52
(crankshaft position sensor) vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300418 Engine ECU (sig-

nal check har-
ness) – engine
speed main sen-
sor (crankshaft
Starter key: LOCK Less than 2 
position sensor)
vehicle side con-
nector
NE+ (E52) – NE+
NE- (E72) – NE-

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–459

5 Inspect for short-circuit of the engine speed main sensor (crankshaft position sensor) har-
ness

1. Use the electrical tester to measure the resistance between the

D terminals of the engine ECU and ground.
E52
E72
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK NE+ (E52) – 
Ground
NE- (E72) –
SHTS021270300419 Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–460 ENGINE (J05E)/TROUBLESHOOTING

6 Check the engine speed main sensor (crankshaft position sensor) signal

1. Connect the signal check harness to the engine ECU.

E52 D E72 2. Connect the engine speed main sensor (crankshaft position sen-
sor) connector.

3. Start the engine.

4. Use the oscilloscope to measure the signal voltage between the

terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections
SHTS021270300420
Engine ECU (sig-
nal check har-
With engine idling ness) Pulse 56
NE+ (E52) –
NE- (E72)

1 rotation

56 peaks (pulse)

0V

No pulse (No gear tooth)

SHTS021270300421

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine speed main sensor

(crankshaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–461

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0336 has been detected.

SHTS021270300422

Has DTC P0336 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–462 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0340
EN01H02127030602016071

P0340: Engine speed sub sensor (Camshaft position sensor) - disconnection

INFORMATION

Engine ECU

(G-) N44 X4Z (G-)

Engine speed sub sensor (G1) N43 XZA (G+)
(VG) N45 EB5 (VCG)

SHTS021270300423

1. Technical description
• The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub
sensor (camshaft position sensor).

<Description of malfunction>
• Pulses from the engine speed sub sensor (camshaft position sensor) cannot be sensed.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed of 0 r/min or more
(2) Judgement criteria
• With the engine running, the engine speed sub sensor (camshaft position sensor) does not detect pulses for
continuous 0.8 seconds or longer. (at 750 r/min)

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• HINO STOP&START SYSTEM is not available.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Loose/disconnected sensor or failure in sensing area (contamination, clogging or breakage)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–463

INSPECTION PROCEDURE: P0340

1 Inspect the engine speed sub sensor (camshaft position sensor) connector

1. Check the connection of the engine speed sub sensor (camshaft

position sensor) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine speed sub sensor (camshaft position sensor)

1. Check the installation of the engine speed sub sensor (camshaft

position sensor).
• Check that there are no loose mounting bolts.
• Check that the sensor is installed so that it is pushed to the root with-
out gap with the sensor flange mounting surface.
• Check that they are not mounted diagonally.
HINT
In case of foreign matter and corrosion on the sensor mounting
surface, the gap between the cam shaft gear and sensor may
become inaccurate, and error may occur without any pulse signal
from the sensor. In such case, please inspect the mounting sur-
face.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine speed sub sensor (camshaft position sensor).

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine speed sub
sensor (camshaft position sensor).
If there is corrosion on the sensor mounting
surface, polish the mounting surface or
replace the cylinder head.
Perform "After-inspection work" of INFOR-
MATION section.
2–464 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the sensor power supply 1

1. Disconnect the engine speed sub sensor (camshaft position sen-

sor) connector.

G- VG 2. Set the starter key to the "ON" position.

3. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed sub sensor (camshaft position sensor)
vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300424 Engine speed sub

sensor (camshaft
position sensor)
Starter key: ON 4.5 – 5.5 V
vehicle side con-
nector
G- – VG

Do the measurements meet the standard value?

YES NO

Go to step 5. Go to step 4.
 ENGINE (J05E)/TROUBLESHOOTING 2–465

4 Inspect the sensor power supply 2

1. Set the starter key to the "LOCK" position.

2. Connect the signal check harness to the engine ECU.

E53 D
3. Connect the engine speed sub sensor (camshaft position sensor)
connector.

E54 4. Set the starter key to the "ON" position.

5. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

SHTS021270300425
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
Starter key: ON ness) 4.5 – 5.5 V
G- (E54) –
VCG (E53)

Do the measurements meet the standard value?

YES NO

Repair or replace the harness. Replace the engine ECU.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.

5 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0340 has been detected.

SHTS021270300426

Has DTC P0340 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–466 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0341
EN01H02127030602016072

P0341: Engine speed sub sensor (Camshaft position sensor) - rationality

INFORMATION

Engine ECU

(G-) N44 X4Z (G-)

Engine speed sub sensor (G1) N43 XZA (G+)
(VG) N45 EB5 (VCG)

SHTS021270300427

1. Technical description
• The engine speed sub sensor (camshaft position sensor) consistently measures pulses from the engine speed sub
sensor (camshaft position sensor).

<Description of malfunction>
• Pulses from the engine speed sub sensor (camshaft position sensor) cannot be correctly sensed.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• Engine speed of 500 r/min or more
(2) Judgement criteria
• The number of the engine speed sub sensor pulses per 2 engine revolutions is continuously abnormal (other
than 5 pulses). (For example, 100 seconds for 750 r/min).

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–467

8. 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)
• Harness disconnection or short-circuit
2–468 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0341

1 Inspect the engine speed sub sensor (camshaft position sensor) connector

1. Check the connection of the engine speed sub sensor (camshaft

position sensor) connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the engine speed sub sensor (camshaft position sensor)

1. Check the installation of the engine speed sub sensor (camshaft

position sensor).
• Check that there are no loose mounting bolts.
• Check that the sensor is installed so that it is pushed to the root with-
out gap with the sensor flange mounting surface.
• Check that they are not mounted diagonally.
HINT
In case of foreign matter and corrosion on the sensor mounting
surface, the gap between the cam shaft gear and sensor may
become inaccurate, and error may occur without any pulse signal
from the sensor. In such case, please inspect the mounting sur-
face.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the engine speed sub sensor (camshaft position sensor).

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the engine speed sub
sensor (camshaft position sensor).
If there is corrosion on the sensor mounting
surface, polish the mounting surface or
replace the cylinder head.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–469

3 Inspect for short-circuit of the engine speed sub sensor (camshaft position sensor) harness

1. Set the starter key to the "LOCK" position.

E54
D E73 2. Connect the signal check harness to the engine ECU vehicle side
E53
harness. (Do not connect the harness to the ECU.)

3. Disconnect the engine speed sub sensor (camshaft position sen-

sor) connector.

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU and ground.

Measurement Tester
SHTS021270300428 Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK VCG (E53) – 
Ground
G- (E54) – Ground
G+ (E73) – Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–470 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect disconnection of the engine speed sub sensor (camshaft position sensor) harness

1. Use the electrical tester to measure the resistance between the

E54 terminals of the engine ECU (signal check harness) and engine
D E73 G- speed sub sensor (camshaft position sensor) vehicle side connec-
E53
G1 tor.

VG Measurement Tester
Standard values
conditions connections

Engine speed sub

sensor (camshaft
position sensor)
vehicle side con-
nector – Engine
SHTS021270300429
Starter key: LOCK Less than 2 
ECU (signal check
harness)
VG – VCG (E53)
G- – G- (E54)
G1 – G+ (E73)

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–471

5 Inspect the engine speed sub sensor (camshaft position sensor) power supply

1. Set the starter key to the "LOCK" position.

2. Connect the signal check harness to the engine ECU.

G- VG
3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed sub sensor (camshaft position sensor)
vehicle side connector.

Measurement Tester
Standard values
conditions connections
SHTS021270300430
Engine speed sub
sensor (camshaft
position sensor)
Starter key: LOCK 4.5 – 5.5 V
vehicle side con-
nector
G- – VG

Do the measurements meet the standard value?

YES NO

Go to step 6. Replace the engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.
2–472 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the engine speed sub sensor (camshaft position sensor) signal

1. Connect the engine speed sub sensor (camshaft position sensor)

connector.
D B
2. Start the engine.
E73
V80
3. Use the oscilloscope to measure the signal voltage between the
terminals in the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300431 nal check har-
With engine idling ness) Pulse 5
G+ (E73) – E4
(V80)

2 rotation

5V

0V

SHTS021270300432

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine speed sub sensor (cam-

shaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–473

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0341 has been detected.

SHTS021270300433

Has DTC P0341 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–474 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0381
EN01H02127030602016073

P0381: Glow lamp (wait-to-start lamp) - circuit

INFORMATION

Engine ECU
Combination meter
(GIND) J33 J04 (GLW-)

SHTS021270300434

1. 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>
• Disconnection, +B short-circuit or GND short-circuit is likely to have occurred in the glow light circuit.

2. DTC set condition

(1) DTC detection condition

<Glow light in non-drive status>

• Glow light in non-drive status
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.

<Glow light in drive status>

• Glow light in drive status
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

<Glow light in non-drive status>

• Voltage of the glow light circuit remains at 7 V or lower for 10 seconds or longer.

<Glow light in drive status>

• Voltage of the glow light circuit remains at 8.4 V or higher for 3 seconds or longer.

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Glow light fails to operate.
 ENGINE (J05E)/TROUBLESHOOTING 2–475

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Failure of glow light (in combination meter)
• Disconnection or short-circuit in sensor harness
• Irregular contact (disconnection or poor fit of connector)
• GND short-circuit in engine ECU internal power supply
2–476 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0381

1 Inspect the combination meter connector

1. Check the connection of the combination meter connector (loose-

ness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Check the combination meter operation

1. Set the starter key to the "ON" position.

2. Check the operation of the combination meter (various instruments

and displays).

Was any failure found?

YES NO

Inspect the combination meter. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–477

3 Check the glow light circuit

1. Set the starter key to the "LOCK" position.

V7
A B 2. Connect the signal check harness to the engine ECU.
V80
3. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

Starter key ON:
nal check har-
SHTS021270300435 Starter key: 10 V or more
ness)
ON/LOCK Starter key LOCK:
GIND (V7) – E4
Less than 7 V
(V80)

Do the measurements meet the standard value?

YES NO

Go to step 6. Go to step 4.
2–478 ENGINE (J05E)/TROUBLESHOOTING

4 Check for short-circuit in wire harness of glow light

1. Set the starter key to the "LOCK" position.

A V7 2. Disconnect the signal check harness from the engine ECU. (Leave
the vehicle side engine ECU connector connected.)

3. Disconnect the combination meter 40P connector.

4. Use the electrical tester to measure the resistance between the

GIND (V7) terminal in the engine ECU (signal check harness) and
ground.

Measurement Tester
SHTS021270300436 Standard values
conditions connections

Engine ECU (sig-

nal check har-
Starter key: LOCK ness) 
GIND (V7) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–479

5 Check for disconnection in glow light wire harness

1. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) and the combination meter
40P vehicle side connector terminals.
A V7
Measurement Tester
Standard values
conditions connections
GLW- Engine ECU (sig-
nal check har-
ness) –
Starter key: LOCK combination Less than 1 
meter 40P vehicle
SHTS021270300437 side connector
GIND (V7) – GLW-

Do the measurements meet the standard value?

YES NO

Replace the combination meter. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.

6 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0381 has been detected.

SHTS021270300438

Has DTC P0381 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–480 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0401
EN01H02127030602016074

P0401: EGR low flow

INFORMATION

Reference Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth Z5G (E)
A B YKC (ETHW)
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
B (VC1) EBH YWK (VCP1)
Common rail EBN YWM (EP2)
A pressure sensor (E2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
Gas passage $XW (PC2S)
(E2) Z7G YWC (ETHA)
Intake manifold
temperature sensor (THA) X0Q XZJ (THIA)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

(FC) X71 X4K (VG)

A-A B-B (E2G) XCV XMH (EVG)
Intake air
temperature sensor (+B) XCT X2U (VAF)
(air flow sensor built in) (E2) Z65
(THA) X72 X82 (THA)

SHTS021270300439

1. Technical description
• The measured EGR rate, which is calculated from the air flow meter, boost pressure sensor, and intake manifold
temperature sensor, is compared with the predicted EGR rate, and malfunction is detected.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Either the fuel injection rate is 30 - 90 mm3/st. cyl. with an engine speed of 2,000 – 2,250 r/min, or the rate is
30 - 50 mm3/st. cyl. with an engine speed of 2,250 – 2,500 r/min.
• Engine speed fluctuation ≤ 117.2 r/min/sec.
• Fuel injection rate fluctuation ≤ 54.7 mm3/st. cyl. sec.
• Predicted EGR flow rate ≥ 35 g/sec.
• Atmospheric pressure ≥ 75 kPa.
• Exhaust brake is not actuated.
(2) Judgement criteria
• The value of parameters calculated from the measured EGR rate, predicted EGR rate, and EGR valve feed-
back quantity is at least 0.2 conditions continue for at least 30 seconds.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
 ENGINE (J05E)/TROUBLESHOOTING 2–481

5. 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
• Abnormal consumption of DEF solution

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Obstruction due to buildup of soot or foreign substances in inlet/outlet of EGR cooler gas passageway
• Obstruction due to buildup of soot or foreign substances in EGR valve.
• Malfunction of intake system
• Air flow meter failure
• Boost pressure sensor failure
• Intake manifold temperature sensor failure
• SCV failure
• Injector failure
2–482 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0401

1 Inspect the air cleaner element

1. Check the air cleaner element for dirt, clogging, or damage.

2. Make sure the element is a Hino genuine part.

Was any failure found?

YES NO

Clean or replace the air cleaner element. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–483

4 Check the boost pressure sensor output signal

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Start the engine.

4. Select [Engine].

5. Select [Actual boost pressure] from the [Data monitor and Active
test].

6. Race the engine from idle to NMR and verify that the boost pres-
SHTS021270300440
sure output signal varies.

Standard values

There is no abnormal change in the sensor output signal.

(The pressure sensor signal response changes according
to the engine speed)

Was there no abnormal change in the sensor output signal?

YES NO

Go to step 5. Replace the boost pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 6.

If damaged, replace the intake manifold tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–484 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300441 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–485

7 Inspect the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
SHTS021270300442
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the EGR valve.

Perform "After-inspection work" of INFOR-
MATION section.
2–486 ENGINE (J05E)/TROUBLESHOOTING

8 Inspect the EGR cooler

1. Check if soot is obstructing the inlet/outlet of the EGR cooler gas

passageway.

2. Check if there are foreign substances stuck to the EGR cooler

coolant passageway.

3. Check the EGR cooler coolant passageway for obstruction due to

deformation or other damage.

4. Check if coolant is leaking from the EGR cooler.

Was any failure found?

YES NO

Remove the soot in the inlet/outlet of the gas Go to step 9.

passageway, or repair or replace the faulty
part.
Perform "After-inspection work" of INFOR-
MATION section.

9 Inspect the EGR valve

1. Check the EGR valve for damage due to incursion of foreign sub-
stances.

2. Check if the inlet/outlet of the exhaust gas passageway is

obstructed by soot.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 10.

passageway.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–487

10 Inspect the SCV

1. 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?

YES NO

Repair or replace the faulty part. Go to step 11.

Perform "After-inspection work" of INFOR-
MATION section.
2–488 ENGINE (J05E)/TROUBLESHOOTING

11 Inspect the injector

Check the injection quantity and the rotational fluctuation.

1. Start the engine.

2. Select [Injection quantity] from [Data monitor and Active test] on

HINO DX Ⅱ and measure the fuel injection quantity.

SHTS021270300443

NE Rotational fluctuation 3. Select [Engine revolution] from [Data monitor and Active test] on
@1,500 r/min (measurement by HINO DXII) HINO DX Ⅱ and measure the engine speed fluctuation.

Measurement conditions
Ne (r/min)

Engine speed: 1,500 r/min

No-load, Neutral, A/C off and Air compressor un-operating
Engine coolant temperature: more than 80 C {176 F}
Engine

Standard values

SHTS021270300444

Type of Q (mm3/st)

AT 5.0q

Do the measurements meet the standard values? (Are both injection quantity and engine speed
fluctuation within the standard values?)

YES NO

Go to step 12. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–489

12 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0401 has been detected.

SHTS021270300446

Has DTC P0401 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–490 ENGINE (J05E)/TROUBLESHOOTING

SCV FREE ACCELERATION TEST

1 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. Control the engine revolution by means of operating Cruise Control
system.

Engine speed pattern

2500 r/min - Measure each engine

Engine speed

speed for 20 seconds.

2000 r/min
1500 r/min
1000 r/min
750r/min
Time

SHTS021270300447

<Acceleration 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. Check that actual common rail pressure following target.

Acceleration pattern
At least three times, repeating the Wide-Open Throttle

100%
opening
Throttle

20sec 20sec

0%

Time

SHTS021270300448
 ENGINE (J05E)/TROUBLESHOOTING 2–491

2 Types of HINO DX Ⅱ data to be measured

SHTS021270300449

3 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

Common rail pressure

Actual common rail pressure

a: Pressure is reduced by 5
MPa or more continually for Target common rail pressure
5 seconds or more.

Time

SHTS021270300450
2–492 ENGINE (J05E)/TROUBLESHOOTING

b. Pressure is increased by 5 MPa or more continually for 5 seconds or

more.  Replace the SCV.

Engine speed pattern

Common rail pressure

Actual common rail pressure

Pressure is increased by 5
MPa or more continually for Target common rail pressure
5 seconds or more.

Time

SHTS021270300451

c. The maximum common rail pressure exceeds 222 MPa for even a
moment during pressure increase.  Replace the SCV.

Accelerator pattern
Common rail pressure

222 MPa

Actual common rail pressure

Target common rail pressure

Time

SHTS021270300452

d. After the maximum common rail pressure exceeds 222 MPa during
pressure increase, the actual rail pressure falls below the target rail
pressure.  Replace the SCV.

Accelerator pattern
Common rail pressure

222 MPa

Actual common rail pressure

Target common rail pressure

Time

SHTS021270300453
 ENGINE (J05E)/TROUBLESHOOTING 2–493

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
Common rail pressure

222 MPa

Actual common rail pressure

Target common rail pressure

Time

SHTS021270300454

f. The maximum common rail pressure exceeds 222 MPa during pres-
sure drop.  Check the return pipe.

Accelerator pattern
Common rail pressure

222 MPa

Actual common rail pressure

Target common rail pressure

Time

SHTS021270300455

g. The pressure is disturbed at a given speed and the pressure

decreases at higher speed.  Replace the supply pump.

Engine speed pattern

Common rail pressure

The pressure is disturbed

at a given speed and the Actual common rail pressure
10 MPa or more pressure decreases at
higher speed. Target common rail pressure

Remains for 5 seconds or longer.

Time

SHTS021270300456
2–494 ENGINE (J05E)/TROUBLESHOOTING

h. Hunting remains within 10 MPa or more for more than 5 seconds. 

Replace the SCV.

Engine speed pattern

Common rail pressure

㪩㪸㫅㪾㪼㩷㫉㪼㫄㪸㫀㫅㫊㩷㫎㫀㫋㪿㫀㫅㩷㪈㪇 Actual common rail pressure

10 MPa or more 㪤㪧㪸㩷㫆㫉㩷㫄㫆㫉㪼㩷㪽㫆㫉㩷㫄㫆㫉㪼
Target common rail pressure
㫋㪿㪸㫅㩷㪌㩷㫊㪼㪺㫆㫅㪻㫊㪅
Remains for 5 seconds or longer.

Time

SHTS021270300457

i. The engine stops during pressure relief.  Replace the SCV.

Accelerator pattern
Common rail pressure

222 MPa

Actual common rail pressure

Target common rail pressure

Time

SHTS021270300458
 ENGINE (J05E)/TROUBLESHOOTING 2–495

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. A/C, Head lights are off.
4. All other devices turned off. (PTO, Refrigeration compressor. etc)
5. Engine speed: 750 r/min

Criteria

Average current
FINAL VALUE OF 1740  40 mA
value
PUMP CURRENT
TARGET Fluctuation in cur-
< 80 mA
rent value
Current value [mA]

Target current value

Average current value (30sec)

Fluctuation in current value

Time [sec]

SHTS021270300459
2–496 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0402
EN01H02127030602016075

P0402: EGR high flow

INFORMATION

Engine ECU

DCU
(ETHW)

YM5 (CAN+)
(PCR1)

(PCR2)

YWC (ETHA)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
(THW)

XZJ (THIA)

XMH (EVG)

X82 (THA)
(EP1)

(EP2)

YKE (EPA)

X2U (VAF)
X0G (PIM)

X4K (VG)
X28
YKC
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW
X66 (THW)

Actuator power
(VC) J0M

(E) Z6R
(PIM) J0L

(CANH)

(CANH)
relay

(CANL)

(CANL)
Z5G (E)
Coolant temperature

XCV
XCT
EBM

#XG
EBH
EBN

NFA

NFA
EBK

(THA) X0Q

#XV
X71
(E2) Z7G

Z65
EBL

X72
EBJ
sensor 1

(L)
X36
(FC)
(E2G)
(+B)
(E2)
(THA)
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

VNT EGR
controller actuator
Boost pressure

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
sensor
Y2E Y4J Z90
Common rail Intake manifold Intake air
Body earth pressure sensor temperature temperature sensor L2J #E1 #ET
sensor (air flow sensor built in)

SHTS021270300460

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when coolant temperature is low (≤ 40 C {104 F}).
• Engine ECU calculates the actual EGR rate based on information from the boost pressure sensor, engine speed
sensor, intake manifold temperature sensor, and air flow meter.
• Engine ECU compares the actual EGR rate and the theoretical EGR rate stored in the ECU memory.

<Description of malfunction>
• EGR rate may be over-applied.
 ENGINE (J05E)/TROUBLESHOOTING 2–497

2. DTC set condition

(1) 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.
• Exhaust brake is not actuated.

Otherwise, the following conditions continue for at least 30 seconds.

• Starter key "ON".
• Engine coolant temperature is 55 C {131 F} or more.
• Engine speed of 750 r/min or less.
• Fuel injection rate 80 mm3/st. cyl.
• Exhaust brake is not actuated.
• EGR valve opening is 0%.
(2) Judgement criteria
• When EGR feedback (value of theoretical EGR rate - actual EGR rate) stays above the threshold value for at
least 30 seconds.
• Above criterion is determined from the boost pressure, intake manifold temperature, air intake quantity, fuel
injection rate, and engine speed.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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.

<Symptoms on the vehicle due to malfunction>

• Faulty engine revving (engine hesitation)
• Insufficient output or engine stall because of DPF clogging due to faulty catalyst regeneration

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–498 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

• Intake manifold temperature sensor failure
• Air flow meter failure
• Boost pressure sensor failure
• Injector failure
• EGR valve failure
• Clogged intake system
• VNT controller failure
 ENGINE (J05E)/TROUBLESHOOTING 2–499

INSPECTION PROCEDURE: P0402

1 Check the response delay of the EGR valve

1. Set the starter key to the "LOCK" position.

(1)
2. Connect the vehicle to HINO DX Ⅱ .
(3)
(2)
3. Set the starter key to the "ON" position.
(4)
(5) 4. 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.
SHTS021270300461

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 2. Replace the EGR valve.

Perform "After-inspection work" of INFOR-
MATION section.
2–500 ENGINE (J05E)/TROUBLESHOOTING

2 Check the response delay of the VNT controller

1. Select [Inspection Menu] from the menu, then inspect the

(1) response delay at the Target VNT position and Actual VNT posi-
tion.
(3)
! CAUTION
(2) Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Select [Start inspection].
(4) Select [VNT UP]:
SHTS021270300462
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target VNT position to the Actual VNT position,

the response delay should be within 3 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the turbocharger.

Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the air cleaner element

1. Check the air cleaner element for dirt, clogging, or damage.

2. Make sure the element is a Hino genuine part.

Was any failure found?

YES NO

Clean or replace the air cleaner element. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–501

4 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 5.

If damaged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the air flow meter connector

1. Check the connection of the air flow meter connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 6.

Perform "After-inspection work" of INFOR-
MATION section.

6 Check the air intake system

1. Check the air intake system (between air flow meter and diesel
throttle) for dirt, clogging, or damage.

Was any failure found?

YES NO

Clean or replace parts as needed. Go to step 7.

Perform "After-inspection work" of INFOR-
MATION section.
2–502 ENGINE (J05E)/TROUBLESHOOTING

7 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 8.

If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the intake manifold temperature sensor connector

1. Check the connection of the intake manifold temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 9.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–503

9 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 10.

If damaged, replace the intake manifold tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300463 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 11. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–504 ENGINE (J05E)/TROUBLESHOOTING

11 Inspect the EGR valve

1. Check the EGR valve for damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 12.

valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–505

12 Inspect the injector

Check the injection quantity and the rotational fluctuation.

1. Start the engine

SHTS021270300464

2. 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)
3. Select [Engine revolution] from the [Data monitor and Active test]
and measure the rotational fluctuation.
Ne (r/min)

Measurement conditions

Engine speed: 1,500 r/min No-load,

T/M shift lever: Neutral position,
A/C off and Air compressor un-operating.
Engine

Engine coolant temperature: more than 80 C {176 F}

Standard values
SHTS021270300465

Type of Q (mm3/st)

AT 5.0q

Do the measurements meet the standard value?

(Both the injection quantity and the rotational fluctuation are within the standard values)

YES NO

Go to step 13. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
2–506 ENGINE (J05E)/TROUBLESHOOTING

13 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0402 has been detected.

SHTS021270300467

Has DTC P0402 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–507

DTC: P0404
EN01H02127030602016076

P0404: Valve position control failure - DC motor out of range, functional

(EGR valve stick failure)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300468

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• Wiping operation from "fully open  fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.

<Description of malfunction>
• Failure message is received from EGR controller.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• A target EGR valve opening is 10 C {50 F} or more.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The intercooler temperature sensor is -15 C {5 F} or more.
(2) Judgement criteria
• The condition that Duty is 40% or more during motor control mode remains for 3 seconds or more.
The above content is judged if any of the following conditions is met:
• When 600 seconds elapses if the intercooler temperature sensor is -15 C {5 F}.
• When 360 seconds elapses if the intercooler temperature sensor is 0 C {32 F}.
• Instant if the intercooler temperature sensor is higher than 0 C {32 F}.
2–508 ENGINE (J05E)/TROUBLESHOOTING

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection limit

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe function)>

• Insufficient engine output

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• EGR valve ring parts are damaged due to incursion of foreign substances
• Soot adhesion to EGR valve sealing face and gas passageway, and motor abnormal heat rise due to damage
caused by hard foreign substances. (Hardened carbon may peel off from EGR cooler upstream of EGR valve.)
*1. If there is no problem with the above, foreign substance damage occurred when the MIL was ON, but at present
the foreign substances are thought to have dropped off and normal operation restored.
*2. This DTC may be detected because there is freezing inside the EGR valve when the outside temperature is low.
When the interior thaws, however, normal operation will be restored.
 ENGINE (J05E)/TROUBLESHOOTING 2–509

INSPECTION PROCEDURE: P0404

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0404 has been detected.

SHTS021270300469

Has a DTC other than P0404 been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the EGR valve

1. Check if the link joining the actuator and valve unit is disconnected
or damaged due to incursion of foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 3.

valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–510 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B GND 2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300470 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – GND

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the wire harness (actuator power sup-

ply and ground) and battery voltage.
Repair or replace if needed.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–511

5 Check the response delay of the EGR valve

1. Select [Inspection Menu] and check the time lag (following charac-
(1) teristics) of the target EGR valve opening and actual EGR valve
opening.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid
(4)
engine damages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
SHTS021270300471
• Check each step from 0% – 90% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
(5) Select [EGR opening DOWN]:
• Check each step from 90% – 0% of the time lag (following character-
istics) of the target EGR valve opening and actual EGR valve open-
ing.
HINT
In EGR openings from 0% – 90%, 1 step corresponds to a 10%
change.

Standard values

The response delay should be less than 5 seconds.

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace the EGR valve.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–512 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0405 and P0406

EN01H02127030602016077

P0405: EGR valve controller position sensor signal too low

(EGR actuator position sensor signal too low)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)

relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300472

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the angle difference between the position sensor input and the hole IC is ±5 or more
remains for 1 second or more.

3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection limit
 ENGINE (J05E)/TROUBLESHOOTING 2–513

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
2–514 ENGINE (J05E)/TROUBLESHOOTING

P0406: Valve position sensor magnet lost (EGR actuator position sensor signal too high)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300473

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the magnetic flux of the position sensor is less than 35kA/m remains for 1 second or more.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection limit
 ENGINE (J05E)/TROUBLESHOOTING 2–515

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
• Damaged output shaft magneto inside EGR valve actuator
2–516 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0405 and P0406

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than (P0405 or P0406)
has been detected.

SHTS021270300474

Has any DTC other than (P0405 or P0406) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–517

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B GND 2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300475 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – GND

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, and go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if the DTC (P0405 or P0406) has been
detected.

SHTS021270300476

Has DTC (P0405 or P0406) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–518 ENGINE (J05E)/TROUBLESHOOTING

DTC: P041B
EN01H02127030602016078

P041B: EGR gas temperature sensor - rationality

INFORMATION [at engine start]

Engine ECU
DCU

XSW (THAO)

YM5 (CAN+)
(PCR1)

(PCR2)

YWC (ETHA)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
XZJ (THIA)

X4A (THG)
(EP1)

(EP2)

YKE (EPA)
X0G (PIM)
ZXS (E07)
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW

Actuator power

(CANH)

(CANH)
relay

(CANL)

(CANL)
EBM
EBH
EBN

(E2) E7Q
EBK

EBL

(THG) X7U

(THG) E7P
EBJ

(E2) Z2N

#XG
NFA

NFA

#XV
(E2) Z7G
(THA) X0Q
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

(VC) J0M

(E) Z6R
(PIM) J0L

(L)
X36
VNT EGR
controller actuator

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
L2J #E1 #ET
Intake manifold Boost pressure
temperature sensor sensor

SHTS021270300477

1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.

<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition

The conditions described below remain for 20 seconds or more.

• The engine speed is 1000 r/min or less.
• Fuel injection quantity is 35 mm3/st.cyl or less.
• Engine coolant temperature is in the range of -30 to 30 C {-22 to 86 F}.
• The battery voltage is in the range of 10 to 16 V.
• Exhaust brake not actuated
• EGR valve opening is fully open.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Judged when the average EGR gas temperature is 70 C {158 F} or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–519

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
• Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply or internal circuit failure
2–520 ENGINE (J05E)/TROUBLESHOOTING

P041B: EGR gas temperature sensor - rationality

INFORMATION [at engine running 1]

Engine ECU
DCU

XSW (THAO)

YM5 (CAN+)
(PCR1)

(PCR2)

YWC (ETHA)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
XZJ (THIA)

X4A (THG)
(EP1)

(EP2)

YKE (EPA)
X0G (PIM)
ZXS (E07)
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW

Actuator power

(CANH)

(CANH)
relay

(CANL)

(CANL)
EBM
EBH
EBN

(E2) E7Q
EBK

EBL

(THG) X7U

(THG) E7P
EBJ

(E2) Z2N

#XG
NFA

NFA

#XV
(E2) Z7G
(THA) X0Q
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

(VC) J0M

(E) Z6R
(PIM) J0L

(L)
X36
VNT EGR
controller actuator

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
L2J #E1 #ET
Intake manifold Boost pressure
temperature sensor sensor

SHTS021270300478

1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.

<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.

2. DTC set condition

(1) 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.

• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st. cyl or more.
• The EGR gas flow rate is 36 kg/h or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mph or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow meter) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
(2) Judgement criteria
• Judged when the calculated EGR cooler efficiency based on engine speed, fuel injection quantity and EGR
gas outlet temperature are as follows: If the EGR gas flow rate is 144 kg/h: The efficiency is higher than 105%.
If the EGR gas flow rate is 100 kg/h: the efficiency is higher than 115%.
 ENGINE (J05E)/TROUBLESHOOTING 2–521

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Malfunction of intercooler outlet temperature sensor
• Malfunction of intake manifold temperature sensor
• Malfunction of boost pressure sensor
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
- Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply
2–522 ENGINE (J05E)/TROUBLESHOOTING

P041B: EGR gas temperature sensor - rationality

INFORMATION [at engine running 2]

Engine ECU
DCU

XSW (THAO)

YM5 (CAN+)
(PCR1)

(PCR2)

YWC (ETHA)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
XZJ (THIA)

X4A (THG)
(EP1)

(EP2)

YKE (EPA)
X0G (PIM)
ZXS (E07)
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW

Actuator power

(CANH)

(CANH)
relay

(CANL)

(CANL)
EBM
EBH
EBN

(E2) E7Q
EBK

EBL

(THG) X7U

(THG) E7P
EBJ

(E2) Z2N

#XG
NFA

NFA

#XV
(E2) Z7G
(THA) X0Q
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

(VC) J0M

(E) Z6R
(PIM) J0L

(L)
X36
VNT EGR
controller actuator

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
Common rail EGR cooler outlet Intercooler outlet Y2E Y4J Z90
pressure sensor temperature sensor temperature sensor
L2J #E1 #ET
Intake manifold Boost pressure
temperature sensor sensor

SHTS021270300479

1. Technical description
• The EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler.

<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.

2. DTC set condition

(1) 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.

• The engine speed is 1500 r/min or more.
• Fuel injection quantity is 40 mm3/st. cyl or more.
• The EGR gas flow rate is 36 kg/h or more.
• A change in the engine speed is 156 r/min/sec or less.
• A change in fuel injection quantity is 78 mm3/st.cyl.sec or less.
• Atmospheric pressure is higher than 75 kPa.
• Vehicle speed is 13 mile/h or more.
• Intake air quantity is 45 g/sec or more.
• Intake air temperature sensor (built-in air flow meter) is -10 C {14 F} or more.
• Exhaust brake and DPR are not actuated.
 ENGINE (J05E)/TROUBLESHOOTING 2–523

(2) 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. If the EGR rate is 60%: the difference is 60
C {140 F} or more. In addition;
• The calculated intercooler efficiencies are as follows. If the vehicle speed is 13 mile/h: the efficiency is higher
than 30%. If the vehicle speed is 25 mile/h: the efficiency is higher than 50%.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Malfunction of intercooler outlet temperature sensor
• Malfunction of intake manifold temperature sensor
• Malfunction of boost pressure sensor
- Loose/disconnected sensor or failure in sensing area (contamination, clogging or damage)
- Abnormal resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply
2–524 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P041B

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P041B (for example, P0401, P0402,

P0404, P0234, P0299, P22D3, turbocharger, EGR system DTC)
has been detected.
HINT
Intercooler outlet temperature sensor characteristic abnormality
SHTS021270300480
judgement is performed based on the boost pressure and EGR
rate data.
If EGR system or Turbo DTC are detected, perform another failure
diagnosis starting from the first DTC associated with the malfunc-
tion.

Has a DTC other than P041B been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR cooler outlet temperature sensor connector

1. Check the connection of the EGR cooler outlet temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–525

3 Inspect the EGR cooler outlet temperature sensor

1. Check the installation of the EGR cooler outlet temperature sen-

sor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the EGR cooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the EGR cooler outlet
temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR cooler outlet temperature sensor unit

1. Set the starter key to the "LOCK" position.

THG E2 2. Disconnect the EGR cooler outlet temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the EGR cooler outlet temperature sensor.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
EGR cooler outlet 13.7 – 29.8 k
SHTS021270300481 temperature sen- 50 C {122 F}:
Starter key: LOCK
sor 7.13 – 13.7 k
THG – E2 80 C {176 F}:
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the EGR cooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–526 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the EGR cooler outlet temperature sensor power supply

1. Set the starter key to the "ON" position.

E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the EGR cooler outlet temperature sensor vehicle side con-
nector.

Measurement Tester
Standard values
conditions connections

EGR cooler outlet

temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300482 connector
THG – E2

Do the measurements meet the standard value?

YES NO

Go to step 8. Go to step 6.

6 Inspect for short-circuit of the EGR cooler outlet temperature sensor harness

1. Set the starter key to the "LOCK" position.

E45 D F M56
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the EGR cooler outlet temperature sensor and
ground.

Measurement Tester
Standard values
conditions connections

SHTS021270300483 Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK THG (E45) – 
Ground
E07 (M56) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–527

7 Inspect disconnection of the EGR cooler outlet temperature sensor harness

1. Connect the EGR cooler outlet temperature sensor connector.

E45 D F M56 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Engine ECU (sig-
15.4 – 25.9 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.9 – 12.2 k
THG (E45) –
SHTS021270300484 80 C {176 F}:
E07 (M56)
4.5 – 6.5 k

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.

8 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 9.

If damaged, replace the intake manifold tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–528 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2 2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300485 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 10. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the intercooler outlet temperature sensor

1. Check the installation of the intercooler outlet temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intercooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 11.

If damaged, replace the intercooler outlet
temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–529

11 Inspect the intercooler outlet temperature sensor unit

1. Disconnect the intercooler outlet temperature sensor connector.

THG E2 2. Use the electrical tester to measure the resistance between the
terminals of the intercooler outlet temperature sensor.

Measurement Tester
Standard values
conditions connections

Intercooler outlet 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
sor 50 C {122 F}:
THG – E2 2.435 – 1.994 k
SHTS021270300486

Do the measurements meet the standard value?

YES NO

Go to step 12. Replace the intercooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.

12 Inspect the boost pressure sensor hose

1. Make sure the boost pressure sensor hose is not clogged, rup-
tured, or cracked.

2. Make sure the pipe on the intake manifold side is not clogged.

Was any failure found?

YES NO

Replace the boost pressure sensor hose. Go to step 13.

Clean the intake manifold pipe.
Perform "After-inspection work" of INFOR-
MATION section.
2–530 ENGINE (J05E)/TROUBLESHOOTING

13 Inspect the boost pressure sensor power supply system

1. Disconnect the boost pressure sensor connector.

E
2. Set the starter key to the "ON" position.
VC

3. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections

Boost pressure
sensor vehicle
Starter key: ON 4.75 – 5.25 V
SHTS021270300487 side connector
VC – E

Do the measurements meet the standard value?

YES NO

Go to step 14. Inspect the sensor power supply outlet volt-

age of the wire harness and engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.

14 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P041B has been detected.

SHTS021270300488

Has DTC P041B been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–531

DTC: P041C and P041D

EN01H02127030602016079

P041C: EGR gas temperature sensor - out of range (Out of range low)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

(THG) X7U X4A (THG)

EGR cooler outlet
temperature sensor (E2) Z2N ZXS (E07)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

SHTS021270300489

1. Technical description
• The installed EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR
cooler.

<Description of malfunction>
• EGR cooler outlet temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key is "ON".
• The condition that fuel injection quantity is 40 mm3/sc.cyl or less remains for 10 seconds or more.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.

(2) Judgement criteria

• Output of the sensor remains at 0.19 V or less (740 C {1,364 F} or higher) for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–532 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Short-circuit in the sensor.
• Disconnection or short-circuit of the harness.
• Malfunction of sensor power supply in the engine ECU.
 ENGINE (J05E)/TROUBLESHOOTING 2–533

P041D: EGR gas temperature sensor - out of range (Out of range high)
INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)

(THG) X7U X4A (THG)

EGR cooler outlet
temperature sensor (E2) Z2N ZXS (E07)

(VC) J0M YKF (VCPA)

Boost pressure sensor (PIM) J0L X0G (PIM)
(E) Z6R YKE (EPA)

SHTS021270300490

1. Technical description
• The installed EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR
cooler.

<Description of malfunction>
• The EGR cooler outlet temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Intake air temperature is -20 C {-4 F} or more.

(2) Judgement criteria

• Output of the sensor remains at 4.97 V or higher (-40 C {-40 F} or lower) for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–534 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor.
• Short-circuit in the sensor.
• Malfunction of the sensor power supply in the engine ECU.
• Disconnect and short-circuit of the harness.
• Irregular contact of the connector.
 ENGINE (J05E)/TROUBLESHOOTING 2–535

INSPECTION PROCEDURE: P041C and P041D

1 Inspect the EGR cooler outlet temperature sensor connector

1. Check the connection of the EGR cooler outlet temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the EGR cooler outlet temperature sensor

1. Check the installation of the EGR cooler outlet temperature sen-

sor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the EGR cooler outlet temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the EGR cooler outlet
temperature sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–536 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR cooler outlet temperature sensor

1. Set the starter key to the "LOCK" position.

THG E2 2. Disconnect the EGR cooler outlet temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the EGR cooler outlet temperature sensor.

Measurement Tester
Standard values
conditions connections

50 C {122 F}:
EGR cooler outlet 7.4 – 19.6 k
SHTS021270300491 temperature sen- 100 C {212 F}:
Starter key: LOCK
sor 3.0 – 6.2 k
THG – E2 150 C {302 F}:
1.5 – 2.6 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the EGR cooler outlet temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR cooler outlet temperature sensor power supply

1. Set the starter key to the "ON" position.

E2 THG 2. Use the electrical tester to measure the voltage between the termi-
nals of the EGR cooler outlet temperature sensor vehicle side con-
nector.

Measurement Tester
Standard values
conditions connections

EGR cooler outlet

temperature sen-
Starter key: ON sor vehicle side 4.5 – 5.5 V
SHTS021270300492 connector
THG – E2

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.
 ENGINE (J05E)/TROUBLESHOOTING 2–537

5 Check for short-circuit in wire harness of EGR cooler outlet temperature sensor

1. Set the starter key to the "LOCK" position.

E45 D F M56
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

EGR cooler outlet temperature sensor terminals and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300493 nal check har-
ness)
Starter key: LOCK THG (E45) – 
Ground
E07 (M56) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–538 ENGINE (J05E)/TROUBLESHOOTING

6 Check for disconnection in wire harness of EGR cooler outlet temperature sensor

1. Connect the EGR cooler outlet temperature sensor connector.

E45 D F M56 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

50 C {122 F}:
Engine ECU (sig-
7.4 – 19.6 k
nal check har-
100 C {212 F}:
Starter key: LOCK ness)
3.0 – 6.2 k
THG (E45) –
SHTS021270300494 150 C {302 F}:
E07 (M56)
1.5 – 2.6 k

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Warm up the Engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P041C or P041D) has been
detected.

SHTS021270300495

Has DTC (P041C or P041D) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–539

DTC: P0420
EN01H02127030602016080

P0420: Tentative determination of ATC deterioration

INFORMATION

1. 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).

2. DTC set condition

(1) DTC detection condition
• –
(2) Judgement criteria
• –

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• P0420
2–540 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0420

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine] and check

DTC P0420.

SHTS021270300496

Has DTC P0420 been detected?

YES NO

Perform DTC-specific troubleshooting for. Procedure completed.

• P0148
• P0421
 ENGINE (J05E)/TROUBLESHOOTING 2–541

DTC: P0421
EN01H02127030602016081

P0421: Determination of ATC deterioration

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• During DPR active regeneration
• Conditions below active continue for 35 sec
- Engine speed: 700 r/min or higher, 1,025 r/min or lower
- Fuel injection quantity: 10 mm3/st. or higher, 40 mm3/st. or lower
- Engine speed fluctuation: 156 r/min/sec or lower
- Fuel injection quantity fluctuation: 39 mm3/st./sec or less
- Post-injection quantity: 17.5 mm3/st. or more
- Exhaust gas mass flow ≤ 210 kg/h
- ATC inlet temperature: 300 C {572 F} or higher
- Post-injection does not have malfunction
(2) Judgement criteria
• ATC outlet temperature – ATC inlet temperature is below the specified value.

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• ATC deterioration caused by use of low-grade fuel
• Improper adjustment of exhaust brake valve
• Leak of exhaust gas from the pipe
• Exhaust temperature sensor No.0 malfunction
• Exhaust temperature sensor No.1 malfunction
2–542 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0421

1 Check the engine ECU

1. Set the starter key to the "LOCK" position.

2. Check the engine ECU software part number (ECU part number)
by HINO DX Ⅱ .
Confirm the latest part number with Hino national service man-
ager.

Does the engine ECU have the latest software number?

YES NO

Go to step 2. Reprogram the engine ECU by using HINO

DX Ⅱ and then go to step 2.

2 Inspect the exhaust leaks from the exhaust pipe between exhaust temperature sensor No.0
and the exhaust temperature sensor No.1

1. Check that the exhaust pipe has no looseness of flange or pipe

breakage.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–543

3 Inspect the exhaust brake valve [HINO DX Ⅱ ]

1. Warm up the engine. (Coolant temperature: 80 C {176 F} or

more)

2. Turn OFF the devices that place load on the engine, such as the
air conditioner.
<Inspection procedure>
(1) Select [Engine] on the screen of HINO DX Ⅱ .
(2) Select [Data monitor Setting] and [Active test Setting].
(3) Select [Target rpm] from [Active test Setting] and set the
engine revolution to 980 r/min.
(4) Select [Injection quantity] from [Data monitor Setting].
(5) Turn ON/OFF the exhaust brake switch, and check the differ-
SHTS021270300497
ence between the injection quantity of the injector while the
exhaust brake is working and the injection quantity when the
exhaust brake is not actuated.

Measurement conditions Standard values

• Engine revolution: 980 r/

min
• Engine coolant tempera-
ture: 80 C {176 F} or
more 10 – 14 mm3/st
• Turn OFF the air condi-
tioner, and other devices
that place load on the
engine.

Do the measurements meet the standard value? (There shall be a change in the injection quantity
between while the exhaust brake is working and when it is not actuated.)

YES NO

Go to step 4. Adjust the butterfly opening of the exhaust

brake.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect fuel

1. Open the fuel cap and check fuel for abnormality (in color is yellow
or green).

Was any failure found?

YES NO

Replace the fuel with good quality fuel. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.
2–544 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the exhaust temperature sensor No.1connector

1. Check the connection of the exhaust temperature sensor No.1

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 6.

Go to step 6.

6 Inspect the exhaust temperature sensor No.1

1. Check the installation of the exhaust temperature sensor No.1.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the exhaust temperature sensor No.1.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 7.

If damaged, replace the exhaust temperature
sensor No.1.
Go to step 7.
 ENGINE (J05E)/TROUBLESHOOTING 2–545

7 Inspect the exhaust temperature sensor No.1 unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the exhaust temperature sensor No.1 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the exhaust temperature sensor No.1.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Exhaust tempera- 13.7 – 29.8 k
SHTS021270300498 ture sensor No.1 50 C {122 F}:
Starter key: LOCK
1st terminal – 2nd 7.13 – 13.7 k
terminal 80 C {176 F}:
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the exhaust temperature sensor

No.1.
Go to step 8.
2–546 ENGINE (J05E)/TROUBLESHOOTING

8 Inspect the exhaust temperature sensor No.1 power supply

1. Set the starter key to the "ON" position.

2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust temperature sensor No.1 vehicle-side connec-
tor.

Measurement Tester
Standard values
conditions connections

Exhaust tempera-
ture sensor No.1
vehicle-side con-
Starter key: ON 4.5 – 5.5 V
SHTS021270300499 nector
1st terminal – 2nd
terminal

Do the measurements meet the standard value?

YES NO

Go to step 11. Go to step 9.

If any failure was found at the step 5 - 7, per-
form "After-inspection work" of INFORMA-
TION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–547

9 Inspect for short-circuit of the exhaust temperature sensor No.1 harness

1. Set the starter key to the "LOCK" position.

M50
F D E58
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU and ground.

Measurement Tester
Standard values
conditions connections

SHTS021270300500
Engine ECU (sig-
nal check har-
ness)
Starter key: LOCK THO (M50) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 10. Repair or replace the harness.

Go to step 10.
2–548 ENGINE (J05E)/TROUBLESHOOTING

10 Inspect disconnection of the exhaust temperature sensor No.1harness

1. Connect the exhaust temperature sensor No.1 connector.

M50
F D 2. Use the electrical tester to measure the resistance between the
E58 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
THO (M50) –
SHTS021270300501 80 C {176 F}:
ETHW (E58)
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 11. Repair or replace the harness.

If any failure was found at the step 5 - 9, per- Perform "After-inspection work" of INFOR-
form "After-inspection work" of INFORMA- MATION section.
TION section.

11 Inspect the exhaust temperature sensor No.0 connector

1. Check the connection of the exhaust temperature sensor No.0

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 12.

Go to step 12.
 ENGINE (J05E)/TROUBLESHOOTING 2–549

12 Inspect the exhaust temperature sensor No.0

1. Check the installation of the exhaust temperature sensor No.0.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the exhaust temperature sensor No.0.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 13.

If damaged, replace the exhaust temperature
sensor No.0.
Go to step 13.

13 Inspect the exhaust temperature sensor No.0 unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the exhaust temperature sensor No.0 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the exhaust temperature sensor No.0.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Exhaust tempera- 13.7 – 29.8 k
SHTS021270300502 ture sensor No.0 50 C {122 F}:
Starter key: LOCK
1st terminal – 2nd 7.13 – 13.7 k
terminal 80 C {176 F}:
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 14. Replace the exhaust temperature sensor

No.0.
Go to step 14.
2–550 ENGINE (J05E)/TROUBLESHOOTING

14 Inspect the exhaust temperature sensor No.0 power supply

1. Set the starter key to the "ON" position.

2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust temperature sensor No.0 vehicle-side connec-
tor.

Measurement Tester
Standard values
conditions connections

Exhaust tempera-
ture sensor No.0
vehicle-side con-
Starter key: ON 4.5 – 5.5 V
SHTS021270300503 nector
1st terminal – 2nd
terminal

Do the measurements meet the standard value?

YES NO

Go to step 17. Go to step 15.

If any failure was found at the step 11 - 13,
perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–551

15 Inspect for short-circuit of the exhaust temperature sensor No.0 harness

1. Set the starter key to the "LOCK" position.

E43 D E58
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

3. 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-

SHTS021270300504 nal check har-
ness)
Starter key: LOCK THO1 (E43) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 16. Repair or replace the harness.

Go to step 16.
2–552 ENGINE (J05E)/TROUBLESHOOTING

16 Inspect disconnection of the exhaust temperature sensor No.0 harness

1. Connect the exhaust temperature sensor No.0 connector.

E43 D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
THO1 (E43) –
SHTS021270300505 80 C {176 F}:
ETHW (E58)
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 17. Repair or replace the harness.

If any failure was found at the step 11 - 15, Perform "After-inspection work" of INFOR-
perform "After-inspection work" of INFOR- MATION section.
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–553

17 Test drive

1. Set the starter key to the "ON" position.

2. Change the [DPR soot amount] using the HINO DX Ⅱ .

3. Set the starter key to the "LOCK" position.

4. Monitor the [DPR mode] set.

5. Start the test drive.

6. Once the [DPR mode] reads any of "6, 7, 15, 23, 24, 27 or 28",
bring vehicle speed to "0" and keep idling for 60 seconds.

Measurement conditions Standard values

During the DPR automatic Vehicle interdiction  Vehi-

regeneration cle start

Has DTC P0421 been detected?

YES NO

Replace the ATC. Procedure completed. (Temporary loose con-

nection.)
2–554 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0422
EN01H02127030602016082

P0422: DOC deterioration

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• Determined during completion of DPR regeneration with the engine running.
• The exhaust gas flow rate is 150 kg/h or more.H9
• The engine revolution is 1000 r/min or more.
• The fuel injection quantity is 30 mm3/st or more.
And, the conditions described below remain for 3 seconds.
• A change in the engine revolution is 625 r/min/sec or less.
• A change in the fuel injection quantity is 625 mm3/sec/st or less.
• The vehicle speed is 18.8 mile/h or more.
And, the conditions described below remain for 10 seconds.
• The predicted detection temperature of the exhaust temperature sensor No.3 calculated by the engine ECU is
450 C {842 F} or more.
(2) Judgement criteria
• The temperature detected at the exhaust temperature sensor No.3 remains 385 C {725 F} or less for 30 sec-
onds.

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• DOC deterioration caused by use of low-grade fuel
• Contamination in the sensing area of the exhaust temperature sensor No.3, improper installation of sensors
 ENGINE (J05E)/TROUBLESHOOTING 2–555

INSPECTION PROCEDURE: P0422

1 Inspect fuel

1. Open the fuel cap and check fuel for abnormality (in color and
smell).

Was any failure found?

YES NO

Replace the fuel with good quality fuel and Go to step 3.

then go to Step 2.

2 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. Perform DPR manual regeneration.

5. After completion of regeneration, on the screen of the diagnostic

system, select [Engine] and check DTC P0422.

SHTS021270300506

Has DTC P0422 been detected?

YES NO

Go to step 3. Procedure completed.

3 Inspect the exhaust temperature sensor No.3 connector

1. Inspect the exhaust temperature sensor No.3 connector for

improper connection (improper fitting and defective contact).

Was any failure found?

YES NO

Connect securely, repair if necessary. Go to step 4.

2–556 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the exhaust temperature sensor No.3

1. Inspect the exhaust temperature sensor No.3 for improper installa-

tion.

2. Check the sensing area of the exhaust temperature sensor No.3

for dirt, clogging, and damage.

Was any failure found?

YES NO

Clean the sensing area and install the sensor Replace the DPR.
properly.
If damage is found, replace the sensor.
 ENGINE (J05E)/TROUBLESHOOTING 2–557

DTC: P0489 and P0490

EN01H02127030602016083

P0489: EGR valve controller motor (open circuit) (EGR actuator motor open circuit)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300507

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria.
• The condition that the actual current applied to the motor built-in the EGR actuator is 0.6 A or less remains for
2 seconds or more.

3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".
2–558 ENGINE (J05E)/TROUBLESHOOTING

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection limit

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged EGR actuator motor
 ENGINE (J05E)/TROUBLESHOOTING 2–559

P0490: EGR valve controller motor (short circuit) (EGR actuator motor short circuit)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6
Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
Y2E Y4J Z90
L2J #E1 #ET

SHTS021270300508

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key is turned "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the actual current applied to the motor built-in the EGR actuator is 70 A or more remains for
2 seconds or more.

3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection limit
2–560 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged EGR actuator motor
• Abnormal battery voltage
 ENGINE (J05E)/TROUBLESHOOTING 2–561

INSPECTION PROCEDURE: P0489 and P0490

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than DTC of this
inspection has been detected.

SHTS021270300509

Has a DTC other than DTC of this inspection been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–562 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B GND 2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300510 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – GND

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, and go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if the DTC (P0489 or P0490) has been
detected.

SHTS021270300511

Has DTC (P0489 or P0490) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–563

DTC: P049D
EN01H02127030602016084

P049D: Position failure (EGR actuator wiping fault)

INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300512

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• Wiping operation from "fully open  fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.

<Description of malfunction>
• Failure message is received from EGR controller.

2. DTC set condition

(1) DTC detection condition
• The starter key is "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When wiping (valve opens and closes with key LOCK) results in valve moving 10 beyond the learned value in
the closing direction for more than 1 seconds.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
2–564 ENGINE (J05E)/TROUBLESHOOTING

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Fuel injection quantity is limited.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Disconnected or bent EGR valve link.
• Valve or valve seat has come off.
 ENGINE (J05E)/TROUBLESHOOTING 2–565

INSPECTION PROCEDURE: P049D

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P049D has been
detected

SHTS021270300513

Has a DTC other than P049D been detected?

YES NO

Go to the diagnosis procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve

1. Check if the link joining the actuator and valve unit is disconnected
or bent.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

3. Check if the valve or valve seat has come off.

4. Manually push the actuator-side lever and check if the valve opens
and closes.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 3.

EGR valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–566 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B GND 2. Disconnect the EGR valve.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300514 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – GND

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the wire harness (actuator power sup-

ply and ground) and battery voltage. If neces-
sary, repair or replace.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–567

5 Check the response delay of the EGR controller

1. Select [Inspection Menu] [EGR inspection] from the menu, and

(1) inspect the response delay at the Target EGR position and Actual
EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid
(4)
engine damages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP].
SHTS021270300515
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN].
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of 10% per step between 0 –
90%.

Standard values

The response delay should be less than 5 seconds.

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace the valve.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–568 ENGINE (J05E)/TROUBLESHOOTING

DTC: P04D5 and P04D6

EN01H02127030602016085

P04D5: Exhaust brake - circuit (Circuit low)

INFORMATION

F ENG-3 15A F ENG-2 30A

NAT %X7 X36 X35 N1B
(L ) (+ ) (L) (B) (L )

(SOL+)
Y1T Z23 N16
(-S) (+S)

Exhaust brake Actuator power relay

magnetic valve
(SOL-)
Y1U
(EXB) LDJ

Engine ECU

SHTS021270300516

1. Technical description
• –

<Description of malfunction>
• Exhaust brake magnetic valve is not working properly.
• Possible magnetic valve failure or GND short-circuit

2. DTC set condition

(1) DTC detection condition
• Exhaust brake inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• The condition that the exhaust brake magnetic valve circuit voltage is 2.8 V or less remains for 3 seconds or
more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• The auxiliary brake control is stopped.

5. 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>

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–569

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• GND short-circuit in exhaust brake drive signal line
• Malfunction of exhaust brake magnetic valve
• Malfunction of engine ECU
2–570 ENGINE (J05E)/TROUBLESHOOTING

P04D6: Exhaust brake - circuit (Circuit high)

INFORMATION

F ENG-3 15A F ENG-2 30A

NAT %X7 X36 X35 N1B
(L ) (+ ) (L) (B) (L )

(SOL+)
Z23 N16

Y1T
(-S) (+S)

Exhaust brake Actuator power relay

magnetic valve

(SOL-)
Y1U
(EXB) LDJ

Engine ECU

SHTS021270300517

1. Technical description
• –

<Description of malfunction>
• Exhaust brake magnetic valve is not working properly.
• Possible magnetic valve failure or +B short-circuit or disconnection

2. DTC set condition

(1) DTC detection condition
• Exhaust brake inactivity request is in progress.
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• The condition that the exhaust brake magnetic valve circuit voltage is 3 V or more remains for 3 seconds or
more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Exhaust brake operates at all times (or does not operate when operation request is received).

6. Pre-inspection work
• Check the battery voltage and make sure it is okay.
 ENGINE (J05E)/TROUBLESHOOTING 2–571

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• +B short-circuit or disconnection in exhaust brake drive signal line.
• Malfunction of exhaust brake magnetic valve.
• Malfunction of engine ECU.
2–572 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P04D5 and P04D6

1 Inspect the exhaust brake magnetic valve connector

1. Check the connection of the exhaust brake magnetic valve con-

nector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the exhaust brake magnetic valve

1. Check the installation of the exhaust brake magnetic valve.

Was any failure found?

YES NO

Install the exhaust brake magnetic valve cor- Go to step 3.

rectly.
Replace the exhaust brake magnetic valve if
it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–573

3 Inspect the exhaust brake magnetic valve unit

1. Set the starter key to the "LOCK" position.

SOL- SOL+
2. Disconnect the exhaust brake magnetic valve connector.

3. Use the electrical tester to measure the resistance between the

terminals of the exhaust brake magnetic valve.

Measurement Tester
Standard values
conditions connections

Exhaust brake
Starter key: LOCK magnetic valve 8.3 – 18.3 
SHTS021270300518 SOL+ – SOL-

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the exhaust brake magnetic valve.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect for power – circuit of the exhaust brake magnetic valve

1. Set the starter key to the "ON" position.

SOL+ 2. Using the electrical tester, measure the voltage between the
exhaust brake magnetic valve vehicle side connector SOL+ termi-
nal and ground.

Measurement Tester
Standard values
conditions connections

Exhaust brake
magnetic valve
Starter key: ON vehicle side con- 10 – 16 V
SHTS021270300519 nector
SOL+ – Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the wire harness between

the fuse (ECU3) and the magnetic valve.
2–574 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect for short-circuit of the exhaust brake magnetic valve harness

1. Disconnect the engine ECU connector.

SOL-
2. 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
conditions connections

Exhaust brake
magnetic valve
Starter key: LOCK vehicle side con- 
SHTS021270300520 nector
SOL- – Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect disconnection of the exhaust brake magnetic valve harness

1. Connect the signal check harness to the engine ECU.

E3 C 2. Use the electrical tester to measure the resistance between the

SOL-
terminals of the exhaust brake magnetic valve vehicle side con-
nector and the engine ECU.

Measurement Tester
Standard values
conditions connections

Exhaust brake
magnetic valve
vehicle side con-
SHTS021270300521 Starter key: LOCK nector – Engine 1  or less
ECU (signal check
harness)
SOL- – EXB (E3)

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–575

7 Check the DTC detected (Engine ECU)

1. Stop the engine and set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if the DTC (P04D5 or P04D6) has been
detected.

SHTS021270300522

Has DTC (P04D5 or P04D6) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–576 ENGINE (J05E)/TROUBLESHOOTING

DTC: P04DA
EN01H02127030602016086

P04DA: EGR feedback failure

INFORMATION

Engine ECU

DCU
(ETHW)

YM5 (CAN+)
(PCR1)

(PCR2)

YWC (ETHA)
(PC1S)

(VCP1)

(VCP2)
(PC2S)

YKF (VCPA)

YM6 (CAN-)
(THW)

XZJ (THIA)

XMH (EVG)

X82 (THA)
(EP1)

(EP2)

YKE (EPA)

X2U (VAF)
X0G (PIM)

X4K (VG)
X28
YKC
$XV
YWL
XZG
YWK
YWM
XZH
YWH
$XW
X66 (THW)

Actuator power
(VC) J0M

(E) Z6R
(PIM) J0L

(CANH)

(CANH)
relay

(CANL)

(CANL)
Z5G (E)
Coolant temperature

XCV
XCT
EBM

#XG
EBH
EBN

NFA

NFA
EBK

(THA) X0Q

#XV
X71
(E2) Z7G

Z65
EBL

X72
EBJ
sensor 1

(L)
X36
(FC)
(E2G)
(+B)
(E2)
(THA)
(E1)
(PCR1)
(VC1)
(E2)
(PCR2)
(VC2)

VNT EGR
controller actuator
Boost pressure

(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
sensor
Y2E Y4J Z90
Common rail Intake manifold Intake air
Body earth pressure sensor temperature temperature sensor L2J #E1 #ET
sensor (air flow sensor built in)

SHTS021270300523

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when coolant temperature is low (≤ 40 C {104 F}).
• Engine ECU calculates the actual EGR rate based on information from the boost pressure sensor, engine speed
sensor, intake manifold temperature sensor, and air flow meter.
• Engine ECU compares the actual EGR rate and the theoretical EGR rate stored in the ECU memory.

<Description of malfunction>
• EGR rate may be over-applied.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• DPR auto-regeneration is inactive.
• Engine coolant temperature is 30 C {86 F} or more.
• Engine speed of 500 r/min or more.
• Exhaust brake is not actuated.
• EGR valve opening is more than 0%.
• Atmospheric pressure is 75 kPa or more.
(2) Judgement criteria
• The threshold value of EGR feedback amount continues for 30 seconds or more.
 ENGINE (J05E)/TROUBLESHOOTING 2–577

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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.

<Symptoms on the vehicle due to malfunction>

• Faulty engine revving (engine hesitation)
• Insufficient output or engine stall because of DPF clogging due to faulty catalyst regeneration

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Intake manifold temperature sensor failure
• Air flow meter failure
• Boost pressure sensor failure
• Injector failure
• EGR valve failure
• Clogged intake system
• VNT controller failure
2–578 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P04DA

1 Check the response delay of the EGR valve

1. Set the starter key to the "LOCK" position.

(1)
2. Connect the vehicle to HINO DX Ⅱ .
(3)
(2)
3. Set the starter key to the "ON" position.
(4)
(5) 4. 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.
SHTS021270300524

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 2. Replace the EGR valve.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–579

2 Check the response delay of the VNT controller

1. Select [Inspection Menu] from the menu, then inspect the

(1) response delay at the Target VNT position and Actual VNT posi-
tion.
(3)

(2)
! CAUTION
(4)
Perform the inspection while the engine is stopped to avoid dam-
(5) ages.

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Select [Start inspection].
SHTS021270300525
(4) Select [VNT UP]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target VNT position to the Actual VNT position,

the response delay should be within 3 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the turbocharger.

Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the air cleaner element

1. Check the air cleaner element for dirt, clogging, or damage.

2. Make sure the element is a Hino genuine part.

Was any failure found?

YES NO

Clean or replace the air cleaner element. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.
2–580 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 5.

If damaged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect the air flow meter connector

1. Check the connection of the air flow meter connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 6.

Perform "After-inspection work" of INFOR-
MATION section.

6 Check the air intake system

1. Check the air intake system (between air flow meter and diesel
throttle) for dirt, clogging, or damage.

Was any failure found?

YES NO

Clean or replace parts as needed. Go to step 7.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–581

7 Inspect the boost pressure sensor

1. Check the installation of the boost pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the boost pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 8.

If damaged, replace the boost pressure sen-
sor.
Perform "After-inspection work" of INFOR-
MATION section.

8 Inspect the intake manifold temperature sensor connector

1. Check the connection of the intake manifold temperature sensor

connector (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 9.

Perform "After-inspection work" of INFOR-
MATION section.
2–582 ENGINE (J05E)/TROUBLESHOOTING

9 Inspect the intake manifold temperature sensor

1. Check the installation of the intake manifold temperature sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the intake manifold temperature sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 10.

If damaged, replace the intake manifold tem-
perature sensor.
Perform "After-inspection work" of INFOR-
MATION section.

10 Inspect the intake manifold temperature sensor unit

1. Set the starter key to the "LOCK" position.

THA E2
2. Disconnect the intake manifold temperature sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the intake manifold temperature sensor.

Measurement Tester
Standard values
conditions connections

Intake manifold 20 C {68 F}:

temperature sen- 7.336 – 5.794 k
Starter key: LOCK
SHTS021270300526 sor 50 C {122 F}:
THA – E2 2.435 – 1.994 k

Do the measurements meet the standard value?

YES NO

Go to step 11. Replace the intake manifold temperature

sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–583

11 Inspect the EGR valve

1. Check the EGR valve for damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 12.

valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–584 ENGINE (J05E)/TROUBLESHOOTING

12 Inspect the injector

Check the injection quantity and the rotational fluctuation.

1. Start the engine

SHTS021270300527

NE Rotational fluctuation 2. Select [Injection quantity] from the [Data monitor and Active test]
@1,500 r/min (measurement by HINO DX II) and measure the amount of fuel injection.

3. Select [Engine revolution] from the [Data monitor and Active test]
and measure the rotational fluctuation.
Ne (r/min)

Measurement conditions

Engine revolution: 1,500 r/min No-load,

Engine

T/M shift lever: Neutral position,

A/C off and Air compressor un-operating.
Engine coolant temperature: more than 80 C {176 F}

SHTS021270300528
Standard values

Type of Q (mm3/st)

AT 5.0q

Do the measurements meet the standard value?

(Both the injection quantity and the rotational fluctuation are within the standard values)

YES NO

Go to step 13. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–585

13 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P04DA has been detected.

SHTS021270300530

Has DTC P04DA been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–586 ENGINE (J05E)/TROUBLESHOOTING

DTC: P04DB
EN01H02127030602016087

P04DB: Crankcase ventilation system - disconnection between the CV valve and the
intake manifold
INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300531

1. Technical description
• The closed breather circuit is malfunctioning and the air flow meter detects trouble when air enters through the mal-
functioning part.

<Description of malfunction>
• Closed breather malfunction is detected.

2. DTC set condition

(1) DTC detection condition
• The engine speed is in the range of 720 to 960 r/min.
• A change in the engine speed is 234.4 r/min/sec or less.
• The fuel injection quantity is in the range of 0 mm3/st. cyl to 80 mm3/st. cyl.
• A change in fuel injection quantity is 78.1 mm3/st. cyl/sec or less.
• Engine coolant temperature is 55 C {131 F} or less.
• A target EGR valve opening is 0% or less.
• Exhaust brake not actuated
(2) Judgement criteria
• Theoretical air quantity calculated from boost pressure and atmospheric pressure and actual air quantity are
compared for at least 10 seconds, and the ratio of theoretical air quantity to actual air quantity is at least 1.12.
And:
• Difference between DCY value prior to above result and current DCY value is 0.10 or less; and
• When prior DCY the starter key is turned "LOCK" and engine is stopped, (boost pressure - atmospheric pres-
sure) ≥ 18 kPa, and that condition did not continue for 3 seconds or more.

3. Reset condition
• After normal operation is restored

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–587

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Sensor is disconnected from measuring site or sensing unit is malfunctioning (due to dirt, clogging, damage, etc.).
• EGR valve failure.
• Diesel throttle valve (intake throttle valve) failure.
• Intercooler failure (due to dirt, clogging, etc.).
• Engine ECU sensor power supply (air flow meter dedicated 12 V power supply) failure or internal circuit failure.
2–588 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P04DB

1 Inspect the air cleaner element

1. Check the air cleaner element for dirt, clogging, or damage.

2. Make sure the element is a Hino genuine part.

Was any failure found?

YES NO

Clean or replace the air cleaner element. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Check the air intake system

1. Check the intake hose and verify that there are no disconnections,
clogging, punctures, or cracks.

2. Check the breather hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.

3. Check the intercooler hose and verify that there are no disconnec-
tions, clogging, punctures, or cracks.

Was any failure found?

YES NO

Repair or replace the intake system hoses. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the air flow meter.

Was any failure found?

YES NO

Replace the air flow meter if the sensing unit Go to step 4.

is dirty, clogged, or damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–589

4 Inspect for short-circuit of the air flow meter harness

1. Set the starter key to the "LOCK" position.

C D
E12 2. Disconnect the air flow meter connector.

3. Connect the signal check harness to the engine ECU. (Do not con-
E74 E78 nect harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300532
Engine ECU (sig-
nal check har-
ness)
VAF (E12) –
Starter key: LOCK 
Ground
VG (E74) – Ground
EVG (E78) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–590 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect disconnection of the air flow meter harness

1. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and air flow
C meter vehicle side connector.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (sig-
D
FC nal check har-
ness) – Air flow
meter vehicle side
E74 E78
Starter key: LOCK Less than 1 
connector
VAF (E12) – +B
VG (E74) – FC
EVG (E78) – E2G

SHTS021270300533

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

6 Inspect the EGR valve

1. Check the EGR valve for damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 7.

valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–591

7 Check the response delay of the EGR valve [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

(1)
2. Select [Inspection Menu] and then [EGR inspection] from the
(3)
(2)
menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(4)
(5) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.

<Inspection procedure>
(1) Select [Inspection Menu].
SHTS021270300534
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the EGR valve.

Perform "After-inspection work" of INFOR-
MATION section.
2–592 ENGINE (J05E)/TROUBLESHOOTING

8 Inspect the intake throttle valve

1. Stop the engine.

2. Check the operating status of the intake throttle valve (for incorrect
opening or sticky valve).

Was any failure found?

YES NO

Replace the intake throttle valve. Go to step 9.

Perform "After-inspection work" of INFOR-
MATION section.

9 Inspect the intercooler

1. Check if there is an obstruction due to clogging inside the inter-

cooler.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 10.

intercooler.
Replace the intercooler if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–593

10 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P04DB has been detected.

SHTS021270300535

Has DTC P04DB been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–594 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0500 and P0501

EN01H02127030602016088

P0500: Vehicle speed sensor - low

INFORMATION

Engine ECU
Combination meter
(SP1) U27 EJE (SP02)

SHTS021270300536

1. Technical description
• The engine ECU consistently measures pulses from the vehicle speed sensor through combination meter.

<Description of malfunction>
• Pulses from the vehicle speed sensor cannot be sensed.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".

The conditions described below remain for 5 seconds or longer.

• Engine speed is 1,200 r/min or more.
• Gear position: Other than neutral.
• The fuel injection quantity is 60 mm3/st. cyl or more.
• Engine coolant temperature is 50 C {122 F} or higher.
• Battery voltage is in the range of 10 to 16 V.
• PTO is not actuated.
(2) Judgement criteria
• Output of the vehicle speed sensor remains at a vehicle speed of 0 km/h for 5 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–595

8. 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)
2–596 ENGINE (J05E)/TROUBLESHOOTING

P0501: Vehicle speed sensor - high

INFORMATION

Engine ECU
Combination meter
(SP1) U27 EJE (SP02)

SHTS021270300537

1. Technical description
• The Engine ECU consistently measures pulses from the vehicle speed sensor.

<Description of malfunction>
• Pulses from the vehicle speed sensor are improper.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Engine speed is 0 r/min or more.
• The fuel injection quantity is 0 mm3/st. cyl or less.
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• Vehicle speed pulse frequency remains at 256 Hz or higher (112 miles/h) for 5 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Malfunction of pulse modulator
• Harness disconnection or short-circuit
• Irregular contact (disconnection or poor fit of connector)
• Noise
 ENGINE (J05E)/TROUBLESHOOTING 2–597

INSPECTION PROCEDURE: P0500 and P0501

1 Inspect the combination meter

1. Drive the vehicle and confirm that the combination meter (speed-
ometer) is working properly.

Was any failure found?

YES NO

Check the combination meter (vehicle speed Go to step 2.

signal system).
Perform "After-inspection work" of INFOR-
MATION section.

2 Check the DTC detected (vehicle control ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [VCS] and check if the DTC (P0500 or P0501) has been
detected.

SHTS021270300538

Has DTC (P0500 or P0501) been detected?

YES NO

Go to step 3. Go to step 5.
2–598 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect for short-circuits in wire harness of vehicle speed signal circuit

1. Set the starter key to the "LOCK" position.

V14 A 2. Disconnect the combination meter connector.

GROUND

3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300539
Engine ECU (sig-
nal check har-
Starter key: LOCK ness) – Ground 
V14 (SP1) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–599

4 Inspect for disconnection in wire harness of vehicle speed signal circuit

1. Use the electrical tester to measure the resistance between the

combination meter vehicle side connector terminal and engine
V14 A ECU (signal check harness) terminal.

Measurement Tester
Standard values
conditions connections
SP02
Combination
meter vehicle side
connector –
Starter key: LOCK engine ECU (sig- Less than 1 
nal check har-
SHTS021270300540 ness)
SP02 – V14 (SP1)

Do the measurements meet the standard value?

YES NO

Replace the combination meter. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–600 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect for disconnection in wire harness of vehicle speed signal circuit

1. Set the starter key to the "LOCK" position.

V14 A 2. Disconnect the combination meter connector.

3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
SP02
4. 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
SHTS021270300541 Standard values
conditions connections

Combination
meter vehicle side
connector –
Starter key: LOCK engine ECU (sig- Less than 1 
nal check har-
ness)
SP02 – V14 (SP1)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–601

DTC: P0504
EN01H02127030602016089

P0504: Brake Switch Correlation

INFORMATION

Engine ECU
Brake switch
(ST1-) J4K EKE (NC-)

SHTS021270300542

1. Technical description
• The brake switch detects brake input during deceleration.

<Description of malfunction>
• Malfunction of the brake switch caused by disconnection has been detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• Absence of input of the brake switch is detected during deceleration.
(2) Judgement criteria
• Absence of input of the brake switch remains for 3 seconds or longer during deceleration.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
• Cruise control function is not available.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Brake switch failure (stuck switch)
• Irregular contact (disconnection or poor fit of connector)
• Harness disconnection or short-circuit
• CAN signal: Noise
2–602 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0504

1 Inspect the brake switch connector

1. Check the connection of the brake switch connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the brake switch

1. Check the installation of the brake switch.

2. Check if the brake switch is properly adjusted.

Was any failure found?

YES NO

Adjust the brake switch so that it is correctly Go to step 3.

installed.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–603

3 Inspect the brake switch unit

1. Set the starter key to the "LOCK" position.

NC+ NC- 2. Disconnect the brake switch connector.

3. Use the electrical tester to measure the resistance between the

terminals of the brake switch.

Measurement Tester
Standard values
conditions connections

• Depress brake
Brake switch pedal:  
Starter key: LOCK
SHTS021270300543 NC+ – NC- • Release brake
pedal: 2  max.

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the brake switch.

Perform "After-inspection work" of INFOR-
MATION section.

4 Check the brake switch power supply

1. Set the starter key to the "ON" position.

NC+ 2. Use the electrical circuit to measure the voltage between the NC+
terminal in the brake switch vehicle side connector and ground.

Measurement Tester
Standard values
conditions connections

Brake switch vehi-

Starter key: ON cle side connector More than 10 V
NC+ – Ground

SHTS021270300544

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the brake switch power

supply circuit (fuse, wire harness).
Perform "After-inspection work" of INFOR-
MATION section.
2–604 ENGINE (J05E)/TROUBLESHOOTING

5 Check the brake switch signal

1. Set the starter key to the "LOCK" position.

B 2. Connect the brake switch connector.
V75
V80
3. Connect the signal check harness to the engine ECU.

4. Set the starter key to the "ON" position.

5. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

Measurement Tester
SHTS021270300545 Standard values
conditions connections

Engine ECU (sig- • Depress brake

nal check har- pedal: 0 V
Starter key: ON ness) • Release brake
ST1- (V75) – pedal: 10 V or
E4 (V80) more

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the wire harness between

the brake switch and the engine ECU.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–605

6 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0504 have been detected.

SHTS021270300546

Has DTC P0504 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–606 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0506
EN01H02127030602016090

P0506: Idle speed control system

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".

The conditions described below remain for 10 seconds or longer.

• Accelerator pedal opening = 0% (pedal not depressed)
• Engine coolant temperature is 60C {140 F} or higher.
• The target idling speed is within the range of 745 to 755 r/min.
• Vehicle speed is 0 mile/h.
• The monitor disable DTC table can be referred to.
(2) Judgement criteria
• Actual speed remains at 725 r/min or lower for 15 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Extremely large load applied to engine while it is idling
• Fuel injection rate abnormality

6. Pre-inspection work
• Perform diagnosis system check to confirm there is no abnormality.
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Injector injection rate abnormality
• Dragging/interference with transmission
• Failure in air compressor
• Failure in power steering pump
 ENGINE (J05E)/TROUBLESHOOTING 2–607

INSPECTION PROCEDURE: P0506

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0506 has been
detected.

SHTS021270300547

Has a DTC other than P0506 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.
2–608 ENGINE (J05E)/TROUBLESHOOTING

2 Check the injector fuel injection quantity [HINO DX Ⅱ ]

1. Start the engine.

2. Select [Injection quantity] from [Data monitor and Active test] in

HINO DX Ⅱ and measure the fuel injection quantity.

3. Select [Engine revolution] from [Data monitor and Active test] on

HINO DX Ⅱ , and measure the engine speed.

Measurement conditions Standard values

Engine revolution:
1,500 r/min (no load) AT model:
Engine coolant temperature: 12 mm3/st maximum
NE Engine speed 80 C {176 F} minimum
@1,500 r/min (measurement by HINO-DX II)

Standard values
Ne (r/min)

Q (mm3/st)
Engine

Type of

AT 5.0q

SHTS021270300548

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–609

3 Inspect the air compressor

1. Check the air compressor for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the power steering pump

1. Check the power steering pump for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.

5 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0506 has been detected.

SHTS021270300550

Has DTC P0506 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–610 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0507
EN01H02127030602016091

P0507: Idle speed control system

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".

The conditions described below remain for 10 seconds or longer.

• Accelerator pedal opening = 0% (pedal not depressed)
• Engine coolant temperature is 60C {140 F} or higher.
• The target idling speed is within the range of 745 to 755 r/min.
• Vehicle speed is 0 mile/h.
• The monitor disable DTC table can be referred to.
(2) Judgement criteria
• Actual speed remains at 775 r/min or higher for 15 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Extremely large load applied to engine while it is idling
• Fuel injection rate abnormality

6. Pre-inspection work
• Perform diagnosis system check to confirm there is no abnormality.
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Injector injection rate abnormality
• Dragging/interference with transmission
• Failure in air compressor
• Failure in power steering pump
 ENGINE (J05E)/TROUBLESHOOTING 2–611

INSPECTION PROCEDURE: P0507

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0507 has been
detected.

SHTS021270300551

Has a DTC other than P0507 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.
2–612 ENGINE (J05E)/TROUBLESHOOTING

2 Check the injector fuel injection quantity [HINO DX Ⅱ ]

1. Start the engine.

2. Select [Injection quantity] from [Data monitor and Active test] in

HINO DX Ⅱ and measure the fuel injection quantity.

3. Select [Engine revolution] from [Data monitor and Active test] on

HINO DX Ⅱ , and measure the engine speed.

Measurement conditions Standard values

Engine revolution:
1,500 r/min (no load) AT model:
Engine coolant temperature: 12 mm3/st maximum
NE Engine speed
80 C {176 F} minimum
@1,500 r/min (measurement by HINO-DX II)

Standard values
Ne (r/min)
Engine

Type of Q (mm3/st)

AT 5.0q

SHTS021270300552

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–613

3 Inspect the air compressor

1. Check the air compressor for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the power steering pump

1. Check the power steering pump for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.

5 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P0507 has been detected.

SHTS021270300554

Has DTC P0507 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–614 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0521
EN01H02127030602016092

P0521: Malfunction of oil pressure switch (High)

INFORMATION

Engine ECU
Oil pressure switch
H26 GCP (OSW)
Body earth
(S)

SHTS021270300555

1. Technical description
• A rise in engine oil pressure is sensed by the oil pressure switch.

<Description of malfunction>
• Abnormality (high-pressure) in engine oil pressure is detected.

2. DTC set condition

(1) DTC detection condition
• The engine stopped.
• Engine coolant temperature of 30 C {86 F} or more.
(2) Judgement criteria
• The oil pressure switch continues to be OFF (high-pressure detection) for more than 3 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Insufficient oil pan oil quantity.
• Malfunction of oil pressure switch.
• +B short-circuit of disconnection harness.
• Engine oil viscosity is high.
 ENGINE (J05E)/TROUBLESHOOTING 2–615

INSPECTION PROCEDURE: P0521

1 Check the engine oil level

1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the stipulated value.

2. Check the engine oil condition (dirt, viscosity).

Rivet Oil level gauge

FULL ADD

Preferred level

Gauge end

SHTS021270300556

Was any failure found?

YES NO

Adjust the engine oil quantity so that it is Go to step 2.

within the stipulated value.
Change the oil if it is dirty.
Perform "After-inspection work" of INFOR-
MATION section.

2 Check for engine oil leaks

1. Make sure there is no oil leaking from the engine unit or from
around the oil pressure switch.

Was any failure found?

YES NO

Repair the faulty part. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–616 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the oil pressure switch connector

1. Check the connection of the oil pressure switch connector (loose-

ness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the oil pressure switch unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the oil pressure switch connector.

3. Use the electrical tester to measure the resistance between the

terminals of the oil pressure switch and ground.

Measurement conditions Standard values

• Stop the engine (OFF) With engine stopped:

Less than 1 
• Start the engine (ON) With engine running:  
SHTS021270300557

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the oil pressure switch.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–617

5 Inspect for short-circuit of the oil pressure switch harness

1. Set the starter key to the "LOCK" position.

E41 D 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Disconnect the oil pressure switch connector.

4. Use the electrical tester to measure the resistance between the

OSW (E41) terminal in the engine ECU (signal check harness)
and ground.

Measurement Tester
SHTS021270300558 Standard values
conditions connections

Engine ECU (sig-

nal check har-
Starter key: LOCK ness) 
OSW (E41) –
Ground

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–618 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0524
EN01H02127030602016093

P0524: Engine oil pressure Too Low

INFORMATION

Engine ECU
Oil pressure switch
H26 GCP (OSW)
Body earth
(S)

SHTS021270300559

1. Technical description
• A drop in engine oil pressure is sensed by the oil pressure switch.

<Description of malfunction>
• Drop in engine oil pressure is detected.

2. DTC set condition

(1) DTC detection condition
• While the engine is in operation - Always
(2) Judgement criteria
• The oil pressure switch continues to be ON for more than 30 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON
• Cruise control is not available.
• After fixed time, engine stopped.

5. 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.
• After fixed time, engine stopped.

<Symptoms on the vehicle due to malfunction>

• Drop in engine oil pressure

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Drop in oil pan oil quantity: Drop in pressure due to air suction
• Malfunction of oil pressure circuit: Drop in pressure due to oil leakage
• Malfunction of oil pressure switch: Correct oil pressure cannot be sensed.
• GND short-circuit of harness: The sensing result of the oil pressure switch becomes invalid.
 ENGINE (J05E)/TROUBLESHOOTING 2–619

INSPECTION PROCEDURE: P0524

1 Check the engine oil level

1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the stipulated value.

2. Check the engine oil condition (dirt, viscosity).

Rivet Oil level gauge

FULL ADD

Preferred level

Gauge end

SHTS021270300560

Was any failure found?

YES NO

Adjust the engine oil quantity so that it is Go to step 2.

within the stipulated value.
Change the oil if it is dirty.
Perform "After-inspection work" of INFOR-
MATION section.

2 Check for engine oil leaks

1. Make sure there is no oil leaking from the engine unit or from
around the oil pressure switch.

Was any failure found?

YES NO

Repair the faulty part. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–620 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the oil pressure switch connector

1. Check the connection of the oil pressure switch connector (loose-

ness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the oil pressure switch unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the oil pressure switch connector.

3. Use the electrical tester to measure the resistance between the

terminals of the oil pressure switch and ground.

Measurement conditions Standard values

• Stop the engine (OFF) With engine stopped:

Less than 1 
• Start the engine (ON) With engine running:  
SHTS021270300561

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the oil pressure switch.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–621

5 Inspect for short-circuit of the oil pressure switch harness

1. Set the starter key to the "LOCK" position.

E41 D 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Disconnect the oil pressure switch connector.

4. Use the electrical tester to measure the resistance between the

OSW (E41) terminal in the engine ECU (signal check harness)
and ground.

Measurement Tester
SHTS021270300562 Standard values
conditions connections

Engine ECU (sig-

nal check har-
Starter key: LOCK ness) 
OSW (E41) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Replace or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–622 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect disconnection of the oil pressure switch harness

1. Use the electrical tester to measure the resistance between the

terminals of the engine ECU and oil pressure switch vehicle side
E41 D connector.
OIL+
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness) – Oil
Starter key: LOCK pressure switch Less than 1 
vehicle side con-
SHTS021270300563 nector
OSW (E41) – OIL+

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–623

DTC: P0545 and P0546

EN01H02127030602016094

P0545: Exhaust temperature sensor No.1 - out of range (Out of range low)
INFORMATION

Engine ECU

Exhaust temperature (TOIL) VKF XMK (THO)

sensor No.1 (GND) ZKT YKC (ETHW)

SHTS021270300564

1. Technical description
• The exhaust temperature sensor No.1 consistently detects exhaust gas temperature.
• A reading taken by the exhaust temperature sensor No.1 is used to control DPR regeneration.

<Description of malfunction>
• Exhaust gas temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• Voltage of the exhaust temperature sensor No.1 remains less than 0.063 V (1,165 C {2,219 F}) for 3 sec-
onds.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–624 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

Exhaust temperature sensor No.1:

• 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
• Irregular contact (disconnection or poor fit of connector)
 ENGINE (J05E)/TROUBLESHOOTING 2–625

P0546: Exhaust temperature sensor No.1 - out of range (Out of range high)
INFORMATION

Engine ECU

Exhaust temperature (TOIL) VKF XMK (THO)

sensor No.1 (GND) ZKT YKC (ETHW)

SHTS021270300565

1. Technical description
• The exhaust temperature sensor No.1 consistently detects exhaust gas temperature.
• A reading taken by the exhaust temperature sensor No.1 is used to control DPR regeneration.

<Description of malfunction>
• Exhaust gas temperature cannot be correctly recognized.

2. DTC set condition

(1) DTC detection condition
• Intake air temperature is -20 C {-4 F} or higher.
• Battery voltage is in the range of 10 to 16 V.
• The engine speed remains at 690 r/min or more for 5 seconds or more.
(2) Judgement criteria
• Voltage of the exhaust temperature sensor No.1 remains at 4.958 V or higher (-46 C {-50.8 F} or lower) for 3
seconds.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
2–626 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

Exhaust temperature sensor No.1:

• 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
• Irregular contact (disconnection or poor fit of connector)
 ENGINE (J05E)/TROUBLESHOOTING 2–627

INSPECTION PROCEDURE: P0545 and P0546

1 Inspect the exhaust temperature sensor No.1 connector

1. Check the connection of the exhaust temperature sensor No.1

connector (looseness or poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the exhaust temperature sensor No.1

1. Check the installation of the exhaust temperature sensor No.1.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the exhaust temperature sensor No.1.

Was any failure found?

YES NO

Clean the sensing unit and connect the sen- Go to step 3.

sor securely.
If damaged, replace the exhaust temperature
sensor No.1.
Perform "After-inspection work" of INFOR-
MATION section.
2–628 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the exhaust temperature sensor No.1 unit

1. Set the starter key to the "LOCK" position.

TOIL GND
2. Disconnect the exhaust temperature sensor No.1 connector.

3. Use the electrical tester to measure the resistance between the

terminals of the exhaust temperature sensor No.1.

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
13.7 – 29.8 k
Exhaust tempera-
SHTS021270300566 50 C {122 F}:
Starter key: LOCK ture sensor No.1
7.13 – 13.7 k
TOIL – GND
80 C {176 F}:
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the exhaust temperature sensor

No.1.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–629

4 Inspect the sensor power supply

1. Set the starter key to the "ON" position.

GND TOIL
2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust temperature sensor No.1.

Measurement Tester
Standard values
conditions connections

Exhaust tempera-
ture sensor No.1
Starter key: ON vehicle side con- 4.5 – 5.5 V
nector
SHTS021270300567 TOIL – GND

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 5.

5 Check short-circuit in wire harness of exhaust temperature sensor No.1

1. Set the starter key to the "LOCK" position.

M50
F D E58 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) terminals and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300568 nal check har-
ness)
Starter key: LOCK THO (M50) – 
Ground
ETHW (E58) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–630 ENGINE (J05E)/TROUBLESHOOTING

6 Check disconnection in wire harness of exhaust temperature sensor No.1

1. Connect the exhaust temperature sensor No.1 connector.

M50
F D E58 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

20 C {68 F}:
Engine ECU (sig-
13.7 – 29.8 k
nal check har-
50 C {122 F}:
Starter key: LOCK ness)
7.13 – 13.7 k
THO (M50) –
SHTS021270300569 80 C {176 F}:
ETHW (E58)
4.1 – 7.13 k

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0545 or P0546) has been
detected.

SHTS021270300570

Has DTC (P0545 or P0546) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–631

DTC: P054E
EN01H02127030602016095

P054E: Idling injection rate abnormality (Low)

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".

The conditions described below remain for 10 seconds or longer.

• Accelerator pedal opening = 0% (pedal not depressed)
• Engine coolant temperature is 71 C {159.8 F} or higher.
• The target idling speed is within the range of 745 to 755 r/min.
• Vehicle speed is 0 mile/h.
• The monitor disable DTC table can be referred to.
(2) Judgement criteria
• The fuel injection quantity is 2 mm3/st. cyl or less for 15 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Extremely large load applied to engine while it is idling
• Fuel injection rate abnormality

6. Pre-inspection work
• Perform diagnosis system check to confirm there is no abnormality.
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Injector injection rate abnormality
• Dragging/interference with transmission
• Failure in air compressor
• Failure in power steering pump
2–632 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P054E

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P054E has been
detected.

SHTS021270300571

Has a DTC other than P054E been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.
 ENGINE (J05E)/TROUBLESHOOTING 2–633

2 Check the injector fuel injection quantity [HINO DX Ⅱ ]

1. Start the engine.

2. Select [Injection quantity] from [Data monitor and Active test] in

HINO DX Ⅱ and measure the fuel injection quantity.

3. Select [Engine revolution] from [Data monitor and Active test] on

HINO DX Ⅱ , and measure the engine speed.

Measurement conditions Standard values

Engine revolution:
1,500 r/min (no load) AT model:
Engine coolant temperature: 12 mm3/st maximum
NE Engine speed 80 C {176 F} minimum
@1,500 r/min (measurement by HINO-DX II)

Standard values
Ne (r/min)

Q (mm3/st)
Engine

Type of

AT 5.0q

SHTS021270300572

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
2–634 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the air compressor

1. Check the air compressor for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the power steering pump

1. Check the power steering pump for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.

5 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 60 C {140

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P054E has been detected.

SHTS021270300574

Has DTC P054E been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–635

DTC: P054F
EN01H02127030602016096

P054F: Idling injection rate abnormality (High)

INFORMATION

1. 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.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".

The conditions described below remain for 10 seconds or longer.

• Accelerator pedal opening = 0% (pedal not depressed)
• Engine coolant temperature is 71 C {159.8 F} or higher.
• The target idling speed is within the range of 745 to 755 r/min.
• Vehicle speed is 0 mile/h.
• The monitor disable DTC table can be referred to.
(2) Judgement criteria
• The fuel injection quantity is 52.5 mm3/st. cyl or more for 15 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• Extremely large load applied to engine while it is idling
• Fuel injection rate abnormality

6. Pre-inspection work
• Perform diagnosis system check to confirm there is no abnormality.
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Injector injection rate abnormality
• Dragging/interference with transmission
• Failure in air compressor
• Failure in power steering pump
2–636 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P054F

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P054F has been
detected.

SHTS021270300575

Has a DTC other than P054F been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.
 ENGINE (J05E)/TROUBLESHOOTING 2–637

2 Check the injector fuel injection quantity [HINO DX Ⅱ ]

1. Start the engine.

2. Select [Injection quantity] from [Data monitor and Active test] in

HINO DX Ⅱ and measure the fuel injection quantity.

3. Select [Engine revolution] from [Data monitor and Active test] on

HINO DX Ⅱ , and measure the engine speed.

Measurement conditions Standard values

Engine revolution:
1,500 r/min (no load) AT model:
Engine coolant temperature: 12 mm3/st maximum
NE Engine speed 80 C {176 F} minimum
@1,500 r/min (measurement by HINO-DX II)

Standard values
Ne (r/min)

Q (mm3/st)
Engine

Type of

AT 5.0q

SHTS021270300576

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the injector.

Perform "After-inspection work" of INFOR-
MATION section.
2–638 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the air compressor

1. Check the air compressor for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the power steering pump

1. Check the power steering pump for failure.

Was any failure found?

YES NO

Repair or replace the faulty part. Go to step 5.

Perform "After-inspection work" of INFOR-
MATION section.

5 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 60 C {140

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P054F has been detected.

SHTS021270300578

Has DTC P054F been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–639

DTC: P0562 and P0563

EN01H02127030602016097

P0562: Battery voltage - out of range (Out of range low)

INFORMATION

Engine ECU

(+BM) JFZ
(+B2) XAU
(+B1) X0D
(+B) X21

To EDU relay

SHTS021270300579

1. Technical description
• –

<Description of malfunction>
• Excessive low voltage has been detected in the ECU power supply.

2. DTC set condition

(1) DTC detection condition
• Engine speed of 0 r/min or more.
(2) Judgement criteria
• Engine ECU power supply voltage is 9 V or less for 2 seconds or less.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Fusible Link, FUSE: Fusing, irregular contact, partial engagement
• Connectors, harnesses and terminals: Disconnection, irregular contact, looseness
• Battery: Over discharge, service life
• Alternator: Power generation failure
• ECU: Malfunction
2–640 ENGINE (J05E)/TROUBLESHOOTING

P0563: Battery voltage - out of range (Out of range high)

INFORMATION

Engine ECU

(+BM) JFZ
(+B2) XAU
(+B1) X0D
(+B) X21

To EDU relay

SHTS021270300580

1. Technical description
• –

<Description of malfunction>
• Excessively high voltage has been detected in the ECU power supply.

2. DTC set condition

(1) DTC detection condition
• Engine speed of 0 r/min or more.
(2) Judgement criteria
• Engine ECU power supply voltage is 17 V or more for 2 seconds or more.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Fusible Link, FUSE: Fusing, irregular contact, partial engagement
• Alternator failure (abnormal voltage or requires adjustment)
• ECU: Malfunction
 ENGINE (J05E)/TROUBLESHOOTING 2–641

INSPECTION PROCEDURE: P0562 and P0563

1 Inspect the fuse or fusible link

1. Check for fusing or improper fit.

Was any failure found?

YES NO

Connect the fusible link properly or replace. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the connection of the battery cable

1. Check if the battery cable is properly installed (tightly fastened).

• Each battery terminal
• Alternator terminal

Was any failure found?

YES NO

Connect properly. If necessary, repair the Go to step 3.

cable.
Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the alternator

1. Start the engine.

2. Use the electrical tester to measure the voltage between the alter-
nator B terminal and ground.

Measurement Tester
Standard values
conditions connections

Alternator B –
Engine idling 13.5 V or more
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the alternator.

Perform "After-inspection work" of INFOR-
MATION section.
2–642 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the engine ECU power supply

1. Set the starter key to the "LOCK" position.

A V18 B V58 2. Connect the signal check harness to the engine ECU.
V59

3. Start the engine.

V39 V80
V38 V79 4. Use the electrical tester to measure the voltage between the termi-
V78
nals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300581 Engine ECU (sig-

nal check har-
ness)
(+) – (-)
+B (V18) – E1
(V39)
Engine idling 10 – 16 V
+B1 (V38) – E2
(V59)
+B2 (V58) – E3
(V79)
+BM (V78) – E4
(V80)

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the engine ECU wire harness (power

supply circuit).
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–643

5 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P0562 or P0563) has been
detected.

SHTS021270300582

Has DTC (P0562 or P0563) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–644 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0603
EN01H02127030602016098

P0603: Controller store data error (Engine ECU EEPROM error)

INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300583

1. Technical description
• Write the same QR correction value in 3 EEPROM areas in engine ECU. Judge EEPROM malfunction if stored data
does not match.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16V.
(2) Judgement criteria

Item Details (Reference)

1. EEPROM failure Data saved in the 3 EEPROM sectors do not match.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–645

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Engine ECU malfunction
2–646 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0603

1 Check the injector replaced record

1. Check the injector replaced record.

Has the injector been replaced in the past?

YES NO

(Replacement history exists or is unclear.) (No replacement history)

Go to step 3. Go to step 2.

2 Check the QR CODE 1 [HINO DX Ⅱ ]

1. Re-input the registration QR code date of the service server.

2. Erase the DTC memory, and check again DTC code. Check that
DTC code P0603 is not displayed.

SHTS021270300584

Has DTC P0603 been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–647

3 Check the QR CODE 2 [HINO DX Ⅱ ]

1. Read the QR code date of the injectors using HINO DX Ⅱ , re-input

QR code date.

2. Erase the DTC memory, and check again DTC code. Check that
DTC code P0603 is not displayed.

SHTS021270300585

Has DTC P0603 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–648 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0605
EN01H02127030602016099

P0605: Flash ROM error

INFORMATION

1. Technical description
• Engine ECU flash ROM failure is detected.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
(2) Judgement criteria
• Flash ROM check sum error
• Failure determination time ≥ 96 msec

3. Reset condition
• After restoration to normal condition and starter key "OFF"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.
• PTO is not available

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.
• PTO cannot be used.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
 ENGINE (J05E)/TROUBLESHOOTING 2–649

INSPECTION PROCEDURE: P0605

1 Inspect the engine ECU circuit [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check the communication between HINO DX Ⅱ

and the engine ECU.

4. Erase the trouble history.

5. Set the starter key to the "LOCK" position.

When communication with the engine ECU is
interrupted while the engine ECU is connected to 6. Make sure the engine ECU main relay is OFF in HINO DX Ⅱ . (This
the HINO DXⅡ, the connection symbol at the left cuts off the communication between HINO DX Ⅱ and the engine
bottom of the HINO DXⅡ screen (the figure below) ECU.)
becomes disconnected.

7. Set the starter key to the "ON" position.

8. Select [Engine] and check if P0605 has been detected.

SHTS021270300586

Has DTC P0605 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
2–650 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0606
EN01H02127030602016100

P0606: Control module processor

INFORMATION

1. Technical description
• Engine ECU internal failure is detected.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
(2) Judgement criteria
• IC for monitoring microcomputer failure inside ECU is detected.
• Failure determination time ≥ 96 msec

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON
• Engine is stopped.

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe function)>

• Engine is stopped.

<Symptoms on the vehicle due to malfunction>

• Engine is stalled.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
 ENGINE (J05E)/TROUBLESHOOTING 2–651

INSPECTION PROCEDURE: P0606

1 Inspect the engine ECU circuit [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] in HINO DX Ⅱ and check the communication

between HINO DX Ⅱ and the engine ECU.

4. Erase the trouble history.

5. Set the starter key to the "LOCK" position.

When communication with the engine ECU is
interrupted while the engine ECU is connected to 6. Make sure the engine ECU main relay is OFF in HINO DX Ⅱ . (This
the HINO DXⅡ, the connection symbol at the left cuts off the communication between HINO DX Ⅱ and the engine
bottom of the HINO DXⅡ screen (the figure below) ECU.)
becomes disconnected.

7. Set the starter key to the "ON" position.

8. Select [Engine] and check if P0606 has been detected.

SHTS021270300587

Has DTC P0606 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
2–652 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0607
EN01H02127030602016101

P0607: Control module performance

INFORMATION

1. Technical description
• Engine ECU internal failure is detected.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
(2) Judgement criteria
• Failure of IC for monitoring inside engine ECU is detected.
• Failure determination time ≥ 96 msec

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.
• PTO is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.
• PTO cannot be used.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Malfunction of engine ECU circuit.
• Temporary malfunction caused by radio frequency interference or noise.
 ENGINE (J05E)/TROUBLESHOOTING 2–653

INSPECTION PROCEDURE: P0607

1 Inspect the engine ECU circuit [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] in HINO DX Ⅱ and check the communication

between HINO DX Ⅱ and the engine ECU.

4. Erase the trouble history.

5. Set the starter key to the "LOCK" position.

When communication with the engine ECU is
interrupted while the engine ECU is connected to 6. Make sure the engine ECU main relay is OFF in HINO DX Ⅱ . (This
the HINO DXⅡ, the connection symbol at the left cuts off the communication between HINO DX Ⅱ and the engine
bottom of the HINO DXⅡ screen (the figure below) ECU.)
becomes disconnected.

7. Set the starter key to the "ON" position.

8. Select [Engine] and check if P0607 has been detected.

SHTS021270300588

Has DTC P0607 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
2–654 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0610
EN01H02127030602016102

P0610: VIN data error

INFORMATION

<Vehicle control ECU> <Engine ECU>

CAN communication
䌑䌒

SHTS021270300589

1. Technical description
• Receipt of vehicle information (VIN) is detected.

<Description of malfunction>
• Vehicle information is not received or the wrong vehicle information is received.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
HINT
This DTC is detected when replacing the engine ECU and the VIN information from the vehicle control ECU has
not been received.
(2) Judgement criteria
• Engine ECU can not receive VIN information from the vehicle control ECU.

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON
• Cruise control function is not available.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Vehicle control ECU failure
• Engine ECU failure
• Malfunction of vehicle power supply (noise)
• CAN circuit failure (noise)
 ENGINE (J05E)/TROUBLESHOOTING 2–655

INSPECTION PROCEDURE: P0610

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0610 (for exam-
ple, U1001, U110A) has been detected.

SHTS021270300590

Has a DTC other than P0610 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the vehicle Information [HINO DX Ⅱ ]

1. Select [VCS] and read the vehicle information (VIN) written in the
Vehicle control ECU at system fix.

2. Compare the data with the vehicle's VIN LABEL, and check if the
vehicle information (VIN) that has been written to the Vehicle con-
trol ECU is correct.

SHTS021270300591

Is the vehicle Information (VIN) in the vehicle control ECU correct?

YES NO

Go to step 4. Go to step 3.
2–656 ENGINE (J05E)/TROUBLESHOOTING

3 Reprogram the vehicle control ECU [HINO DX Ⅱ ]

1. Use HINO DX Ⅱ , and perform [Reprograming] from vehicle control

ECU.

2. Select [Engine] from the HINO DX Ⅱ and read the DTC that has
been detected.

SHTS021270300592

Has DTC P0610 been detected?

YES NO

Replace the vehicle control ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.

4 Reprogram the Engine ECU [HINO DX Ⅱ ]

1. Use HINO DX Ⅱ , and perform [Reprograming] from engine ECU.

2. Select [Engine] from the HINO DX Ⅱ , and read the DTC that has
been detected.

SHTS021270300593

Has DTC P0610 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–657

DTC: P0611
EN01H02127030602016103

P0611: Fuel injector driver charge circuit - circuit (circuit low)

INFORMATION

1. Technical description
• –

<Description of malfunction>
• Low voltage failure of injector actuation charging circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• With the injector not operating
(2) Judgement criteria
• Injector driver charge circuit voltage remains at 55 V or less for 0.096 seconds or more.

3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• Vehicle start control is not available.
• PTO is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.
• Vehicle start control does not work.
• PTO cannot be used.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Engine ECU failure
• Temporary operating error due to radio wave interference or noise.
2–658 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0611

1 Inspect the engine ECU circuit [HINO DX Ⅱ ]

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] in HINO DX Ⅱ and check the communication

between HINO DX Ⅱ and the engine ECU.

4. Erase the trouble history.

5. Set the starter key to the "LOCK" position.

When communication with the engine ECU is
interrupted while the engine ECU is connected to 6. Make sure the engine ECU main relay is OFF in HINO DX Ⅱ . (This
the HINO DXⅡ, the connection symbol at the left cuts off the communication between HINO DX Ⅱ and the engine
bottom of the HINO DXⅡ screen (the figure below) ECU.)
becomes disconnected.

7. Set the starter key to the "ON" position.

8. Select [Engine] and check if P0611 has been detected.

SHTS021270300594

Has DTC P0611 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- (Temporary operating error due to radio
MATION section. wave interference or noise.)
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–659

DTC: P0617
EN01H02127030602016104

P0617: Starter key - rationality

INFORMATION

+B
Starter relay
Fuse
To starter

+B
+ST
+B ST1 STA Engine STCR
ST ECU Starter cut relay
Ignition switch Neutral start switch

SHTS021270300595

1. Technical description
- Engine ECU detects the starter signal while the engine is running (START position signal).

<Description of malfunction>
- +B short-circuit has occurred in the starter key.

2. DTC set condition

(1) DTC detection condition
- Battery voltage is in the range of 10 to 16 V
- Engine speed is 1,100 r/min or more.
(2) Judgement criteria
• The starter key remains ON for 30 seconds or longer.

3. Reset condition
• After normal operation is restored and engine is restarted after engine stall.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Malfunction of starter key.
• Harness disconnection or short-circuit.
2–660 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0617

1 Inspect the starter key connector

1. Check the connection of the starter key connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair or replace if Go to step 2.

needed.

2 Inspect the starter key "Start" signal

1. Set the shift lever to the "N" position.

V12 A B 2. Set the starter key to the "LOCK" position.

V80
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

4. Use the electrical tester to measure the voltage between the

engine ECU (signal check harness) terminals first with the starter
key to the "LOCK" position and then with the starter key in the
"START" position.

SHTS021270300596 Measurement Tester

Standard values
conditions connections

Engine ECU (sig-

Starter key
nal check har-
Starter key: "LOCK": 0 V
ness)
START/LOCK Starter key
STA (V12) – E4
"START": 12 V
(V80)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–661

3 Inspect for short-circuit of the wire harness of the starter key "Start" signal

1. Set the starter key to the "LOCK" position.

A 2. Disconnect the neutral start switch.

V12

3. Use the electrical tester to measure the resistance between the

engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
SHTS021270300597 Starter key: LOCK ness) 
STA (V12) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

(Engine ECU – Neutral start switch)
Perform "After-inspection work" of INFOR-
MATION section.
2–662 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect disconnection of the wire harness of the starter key "Start" signal

1. Set the starter key to the "LOCK" position.

A 2. Use the electrical tester to measure the resistance between the
V12
engine ECU (signal check harness) and the #6 terminals in neutral
start switch vehicle side connector.
#6
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness) – Neutral
Starter key: LOCK Less than 1 
SHTS021270300598 start switch vehi-
cle side connector
STA (V12) – #6

Do the measurements meet the standard value?

YES NO

Inspect the starter key "Start" circuit. Repair or replace the harness.
(Neutral start switch – starter key) (Engine ECU – Neutral start switch)
Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–663

DTC: P0628 and P0629

EN01H02127030602016105

P0628: Suction control valve for fuel supply pump - circuit (Circuit low)
INFORMATION

Engine ECU
XZC (PCV+)
(SCV+) EBS %X0 (PV+S)
Suction control valve $XZ
(SCV-) EBT (PV-S)
XZD (PCV-)

SHTS021270300599

1. Technical description
• The supply pump controls a fuel delivery rate to control common rail pressure.

<Description of malfunction>
• Abnormal voltage of supply pump magnetic valve (suction control valve) is detected. Possible disconnection or
GND short-circuit.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The injectors and injector driver circuits have started running.
(2) Judgement criteria
• SCV (suction control valve) drive current remains less than 500 mA for 2.1 seconds.

3. Reset condition
• After restoration to normal condition and starter key "OFF"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
• DPR regeneration stop.

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe function)>

• Engine output is insufficient.
• DPR can not be regenerated.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–664 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit
• Looseness or poor contact of connector
• Supply pump (SCV) unit failure
• Engine ECU malfunction
 ENGINE (J05E)/TROUBLESHOOTING 2–665

P0629: Suction control valve for fuel supply pump - circuit (Circuit high)
INFORMATION

Engine ECU
XZC (PCV+)
(SCV+) EBS %X0 (PV+S)
Suction control valve $XZ
(SCV-) EBT (PV-S)
XZD (PCV-)

SHTS021270300600

1. Technical description
• The supply pump controls a fuel delivery rate to control common rail pressure.

<Description of malfunction>
• Abnormal voltage of supply pump magnetic valve (suction control valve) is detected. Possible +B short.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The injectors and injector driver circuits have started running.
(2) Judgement criteria
• SCV (suction control valve) drive current remains less than 1,900 mA for 2.1 seconds.

3. Reset condition
• After restoration to normal condition and starter key "OFF"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
• Cruise control function is not available.
• HINO STOP&START SYSTEM is not available.
• PTO is not available.
• DPR regeneration stop.

5. 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.
• HINO STOP&START SYSTEM does not work.
• PTO cannot be used.
• DPR cannot be regenerated.

<Symptoms on the vehicle due to malfunction>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–666 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit
• Looseness or poor contact of connector
• Supply pump (SCV) unit failure
• Engine ECU malfunction
 ENGINE (J05E)/TROUBLESHOOTING 2–667

INSPECTION PROCEDURE: P0628 and P0629

1 Inspect the suction control valve (SCV) connector

1. Check the connection of the suction control valve (SCV) connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the suction control valve (SCV) unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the SCV connector.

SCV- SCV+

3. Use the electrical tester to measure the resistance between the

terminals of the suction control valve.

4. Use the electrical tester to measure the resistance between the

suction control valve terminal and ground.

Measurement Tester
Standard values
conditions connections
SCV- SCV+
Suction control (1) 20 C {68 F}:
valve 1.6 – 2.6 
Starter key: LOCK (1) SCV+ – SCV- (2), (3) 20 C {68
(2) SCV+ – Ground F}:
(3) SCV- – Ground 100 M or more

SHTS021270300601

Do the measurements meet the standard value?

YES NO

Go to step 3. Replace the SCV.

Perform "After-inspection work" of INFOR-
MATION section.
2–668 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect for short-circuit in wire harness of suction control valve

1. Set the starter key to the "LOCK" position.

SCV+
SCV- 2. Disconnect the engine ECU connector.

3. Use the electrical tester to measure the resistance between the

suction control valve vehicle side connector terminals and ground.

Measurement Tester
Standard values
conditions connections

Suction control
valve vehicle side
SHTS021270300602 Starter key: LOCK connector 
SCV+ – Ground
SCV- – Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–669

4 Inspect for disconnection in wire harness of suction control valve

1. Connect the SCV connector.

E9
C E10 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

E30 3. Use the electrical tester to measure the resistance between the
E29 terminals of the engine ECU (signal check harness) terminals.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300603 nal check har-
ness)
PCV+ (E9) – PV-S
(E30)
20 C {68 F}:
Starter key: LOCK PCV+ (E9) – PCV-
1.6 – 2.6 
(E10)
PV+S (E29) – PV-S
(E30)
PV+S (E29) – PCV-
(E10)

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–670 ENGINE (J05E)/TROUBLESHOOTING

5 Check the DTC detected (Engine ECU)

1. Warm up the engine. (engine coolant temperature: 80 C {176 F}

or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if the DTC (P0628 or P0629) has been
detected.

SHTS021270300604

Has DTC (P0628 or P0629) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–671

DTC: P062F
EN01H02127030602016106

P062F: Controller store data error (VNT actuator EEPROM error)

INFORMATION

LEA

POWER
(12V) Power
supply block Motor driver I/F block DC Brushless
GND High side motor
MOTOR (U)
Low side FET
MOTOR (V)
CAN-H CAN I/F Micro
computer MOTOR (W)
CAN-L block

Target position Over current Position sensor

information and protection block (Hall IC)
P/S (POWER)
diagnosis result data
communication P/S (U, V, and W)
terminal EEPROM Position sensor
I/F block P/S (U+, V+, and W+)

P/S (GND)

SHTS021270300605

1. Technical description
• The VNT actuator steplessly operates the nozzle via the LEA (Linear Electric Actuator) and controls turbine speed
and boost pressure.
• The VNT actuator (LEA) has a position sensor and constantly monitors the target opening and the actual opening.
• Wiping operation is carried out when the engine is stopped and the soot, oil, and other impurities accumulated in
the vane working range are removed. Also, the turbocharger mechanical working range is checked for trouble.

<Description of malfunction>
• –

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria

Item Details (Reference)

1. EEPROM failure Data saved in the 3 EEPROM sectors do not match.

3. Reset condition
• After normal operation is restored and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–672 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• EEPROM failure inside controller
 ENGINE (J05E)/TROUBLESHOOTING 2–673

INSPECTION PROCEDURE: P062F

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if any DTC other than P062F (for exam-
ple, U010C) has been detected.

SHTS021270300606

Has a DTC other than P062F been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 3.

DTC.
After the repair, go to step 2.

2 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P062F has been detected.

SHTS021270300607

Has DTC P062F been detected?

YES NO

Go to step 3. Procedure completed.

Perform "After-inspection work" of INFOR-
MATION section.
2–674 ENGINE (J05E)/TROUBLESHOOTING

3 Check operation of VNT controller [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history using HINO DX Ⅱ .

3. Set the starter key to the "OFF" position.

4. Set the starter key to the "ON" position again.

5. Select [Engine] and check if P062F has been detected.

HINT
Set the starter key "LOCK" and "ON" verifies the wiping operation
of the VNT actuator (DC motor).
SHTS021270300608

Measurement conditions

Starter key: LOCK  ON

Has DTC P062F been detected?

YES NO

Replace the VNT controller. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–675

DTC: P0630
EN01H02127030602016107

P0630: VIN Not Programmed or Mismatch

INFORMATION

<Engine ECU>
<Vehicle control ECU>
CAN communication
䌑䌒

SHTS021270300609

1. Technical description
• Reception of vehicle information (VIN) is detected.

<Description of malfunction>
• Vehicle information is not received or may be faulty.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.

(2) Judgement criteria

• Vehicle information is not written.
• Vehicle information was upgraded.
• Vehicle information is not valid (did not use a code)

3. Reset condition
• After restoration to normal condition and starter key "LOCK"

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–676 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

• Vehicle control ECU failure
• Engine ECU failure
• Vehicle power supply failure (noise)
• CAN circuit failure (noise)
 ENGINE (J05E)/TROUBLESHOOTING 2–677

INSPECTION PROCEDURE: P0630

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P0630 (for exam-
ple U1001, U110A) has been detected.

SHTS021270300610

Has a DTC other than P0630 detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Check the vehicle information [HINO DX Ⅱ ]

1. Select [VCS] and read the vehicle information (VIN) written in the
Vehicle control ECU at system fix.

2. Compare the data with the vehicle's VIN LABEL, and check if the
vehicle information (VIN) that has been written to the Vehicle con-
trol ECU is correct.

SHTS021270300611

Is the vehicle Information (VIN) in the vehicle control ECU correct?

YES NO

Replace the vehicle control ECU. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–678 ENGINE (J05E)/TROUBLESHOOTING

3 Check the vehicle control ECU [HINO DX Ⅱ ]

1. After replacing the vehicle control ECU, check if it was previously

used in another vehicle.

Was the vehicle control ECU used in another vehicle?

YES NO

Replace the vehicle control ECU. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected (Engine ECU) [HINO DX Ⅱ ]

1. Set the starter key to the "ON" position.

2. Erase the trouble history and set the starter key to the "LOCK"
position.

3. Set the starter key to the "ON" position again.

4. Select [Engine] and check if P0630 has been detected.

SHTS021270300612

Has DTC P0630 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–679

DTC: P0642
EN01H02127030602016108

P0642: ECU sensor power supply 1 failure (Out of range low)

INFORMATION

Engine ECU

$XV (PC1S) (VPA) XQ4 JE5 (VPA1)

(E1) EBK YWL (EP1) (E01) Z68 Z6S (E1)
(PCR1) EBJ XZG (PCR1) (VC) X85 JE3 (VCP1) Accelerator
Common rail (VC1) EBH YWK (VCP1) (VPA2) XZL ZSQ (VPA2) sensor
pressure sensor (E2) EBN YWM (EP2) (E02) Z69 Z6T (E2)
(PCR2) EBM XZH (PCR2) (VC2) XG2 JE4 (VCP2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(G-) N44 X4Z (G-)
Engine speed sub (G1) N43 XZA (G+)
sensor
(VG) N45 EB5 (VCG)

SHTS021270300613

1. Technical description
• Power is supplied to the sensor power supply 1 circuit.
(Common rail pressure sensor (main), accelerator sensor 2, engine speed sub sensor (camshaft position sensor))

<Description of malfunction>
• Low voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor has a power supply voltage no greater than 3.5 V for at least 3 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–680 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (GND short-circuit in sensor power supply/GND circuit)
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–681

INSPECTION PROCEDURE: P0642

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Erase the trouble history and set the starter key to the "LOCK"
position.

3. Disconnect the common rail pressure sensor1 (main) connector.

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0642 has been detected.

SHTS021270300614

Has DTC P0642 been detected?

YES NO

Connect the connector, and go to step 2. Replace the common rail pressure sensor1
(main).
Perform "After-inspection work" of INFOR-
MATION section.

2 Check the DTC detected 2 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the accelerator sensor 2 connector.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0642 has been detected.

SHTS021270300615

Has DTC P0642 been detected?

YES NO

Connect the connector, and go to step 3. Replace the accelerator sensor 2.

Perform "After-inspection work" of INFOR-
MATION section.
2–682 ENGINE (J05E)/TROUBLESHOOTING

3 Check the DTC detected 5 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the engine speed sub sensor (camshaft position sen-

sor) connector.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0642 has been detected.

SHTS021270300616

Has DTC P0642 been detected?

YES NO

Connect the connector, and go to step 4. Replace the engine speed sub sensor (cam-
shaft position sensor).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–683

4 Check the wire harness of the sensor power supply

1. Set the starter key to the "LOCK" position.

B E33 C E53 D E56 2. Connect the signal check harness to the engine ECU vehicle side
V51 harness. (Do not connect harness to the ECU.)

3. 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-

SHTS021270300617 nal check har-
ness)
VCP2 (E33) – EP1
Starter key: LOCK (E56) 
VCG (E53) – EP1
(E56)
VC2 (V51) – EP1
(E56)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–684 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0643
EN01H02127030602016109

P0643: ECU sensor power supply 1 failure (Out of range high)

INFORMATION

Engine ECU

$XV (PC1S) (VPA) XQ4 JE5 (VPA1)

(E1) EBK YWL (EP1) (E01) Z68 Z6S (E1)
(PCR1) EBJ XZG (PCR1) (VC) X85 JE3 (VCP1) Accelerator
Common rail (VC1) EBH YWK (VCP1) (VPA2) XZL ZSQ (VPA2) sensor
pressure sensor (E2) EBN YWM (EP2) (E02) Z69 Z6T (E2)
(PCR2) EBM XZH (PCR2) (VC2) XG2 JE4 (VCP2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
(G-) N44 X4Z (G-)
Engine speed sub (G1) N43 XZA (G+)
sensor
(VG) N45 EB5 (VCG)

SHTS021270300618

1. Technical description
• Power is supplied to the sensor power supply 1 circuit.
(Common rail pressure sensor (main), accelerator sensor 2, engine speed sub sensor)

<Description of malfunction>
• High voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor has a power supply voltage no greater than 4.5 V for at least 3 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–685

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (short-circuit in battery power supply of sensor power supply circuit)
• Failure in engine ECU sensor power supply or internal circuit
2–686 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0643

1 Check the power supply of common rail pressure sensor 1

1. Set the starter key to the "LOCK" position.

VC2 E2
2. Disconnect the common rail pressure sensor 1 connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor 1 vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300619 Common rail pres-

sure sensor 1
Starter key: ON vehicle side con- 4.5 – 5.5 V
nector
VC2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 2. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–687

2 Check the power supply of accelerator sensor 2

1. Set the starter key to the "LOCK" position.

VCP2 E2
2. Disconnect the accelerator sensor 2 connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the accelerator sensor 2 vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300620 Accelerator sen-

sor 2 vehicle side
Starter key: ON 4.5 – 5.5 V
connector
VCP2 – E2

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–688 ENGINE (J05E)/TROUBLESHOOTING

3 Check the power supply of engine speed sub sensor (camshaft position sensor)

1. Set the starter key to the "LOCK" position.

2. Disconnect the engine speed sub sensor (camshaft position sen-

G- VG sor) connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the engine speed sub sensor (camshaft position sensor)
vehicle side connector.

Measurement Tester
SHTS021270300621 Standard values
conditions connections

Engine speed sub

sensor (camshaft
position sensor)
Starter key: ON 4.5 – 5.5 V
vehicle side con-
nector
VG – G-

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–689

4 Check the power supply of all sensors

1. Set the starter key to the "LOCK" position.

B C E53 D E56
2. Connect the signal check harness to the engine ECU.
V51
3. Set the starter key to the "ON" position.

E33 4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300622 Engine ECU (sig-

nal check har-
ness)
(+) – (-)
VCP2 (E33) – EP1
Starter key: ON 4.9 – 5.1 V
(E56)
VCG (E53) – EP1
(E56)
VC2 (V51) – EP1
(E56)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–690 ENGINE (J05E)/TROUBLESHOOTING

DTC: P064C
EN01H02127030602016110

P064C: Glow controller - Battery for glow plug open, GND short Glow controller - Over
temperature
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300623

1. Technical description
• Controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• A disconnection or short-circuit has occurred in the GCU internal circuit.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter is not actuated.
(2) Judgement criteria
• The condition that the difference between the glow control power supply voltage and the glow operating volt-
age is 2 V or less remains at for 0.3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–691

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Blown fuse, faulty connection, or partial mating
• Harness disconnection or short-circuit
• Abnormal ground potential difference between engine ECU and GCU
• GCU failure
2–692 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P064C

1 Inspect the fuse (ENG-3), fusible link (GLOW)

1. Check if the fuse (ENG-3) and fusible link (GLOW) are blown and if
they are properly installed.

Was any failure found?

YES NO

Replace or correctly connect the fuse and Go to step 2.

fusible link.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the ground circuit of the glow control unit

1. Set the starter key to the "LOCK" position.

GND 2. Disconnect the GCU connector.

3. Use the electrical tester to measure the resistance between the

glow control unit GND terminal and ground.

Measurement Tester
Standard values
conditions connections

GCU vehicle side

Starter key: LOCK connector Less than 1 
SHTS021270300624 GND – Ground

Do the measurements meet the standard value?

YES NO

Go to step 3. Inspect the GCU ground circuit.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–693

3 Inspect the glow control unit power supply circuit

1. Set the starter key to the "ON" position.

GND
2. Use the electrical tester to measure the voltage between the termi-
nals of the GCU vehicle side connector.

BATT Measurement Tester

Standard values
conditions connections
+B
GCU vehicle side
connector
Starter key: ON 10 – 16 V
+B – GND
BATT – GND
SHTS021270300625

Do the measurements meet the standard value?

YES NO

Go to step 4. Inspect the GCU ground circuit.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the GCU harness

1. Set the starter key to the "LOCK" position.

V15
V35 A 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
Sl DI
3. Use the electrical tester to measure the resistance between the
terminals of the GCU vehicle side connector and engine ECU.

Measurement Tester
Standard values
conditions connections

GCU vehicle side

SHTS021270300626 connector –
Engine ECU (sig-
Starter key: LOCK nal check har- Less than 1 
ness)
DI – Dl (V35)
Sl – ST (V15)

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–694 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the ground circuit voltage

1. Set the starter key to the "ON" position.

A B 2. Use the electrical tester to measure the voltage between each ter-
minal in the engine ECU (signal check harness) and ground.
V59
V39 V80 3. Measure the voltage between the GND terminal in the glow control
V79 unit vehicle side connector and ground.

4. Check the difference in potential between the engine ECU and the
ground circuit of the glow control unit.

Measurement Tester
GND Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
E1(V39) – Ground
Potential differ-
E2(V59) – Ground
Starter key: ON ence:
E3(V79) – Ground
within 400 mV
E4(V80) – Ground
GCU vehicle side
connector
SHTS021270300627 GND – Ground

Do the measurements meet the standard value?

YES NO

Replace the GCU. Inspect the ground circuit.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–695

DTC: P0652
EN01H02127030602016111

P0652: ECU sensor power supply 2 failure (Out of range low)

INFORMATION

Engine ECU
Common rail
pressure sensor $XV (PC1S) (VPA) XQ4 JE5 (VPA1)
(E1) EBK YWL (EP1) (E01) Z68 Z6S (E1)
(PCR1) EBJ XZG (PCR1) (VC) X85 JE3 (VCP1) Accelerator
(VC1) EBH YWK (VCP1) (VPA2) XZL ZSQ (VPA2) sensor
(E2) EBN YWM (EP2) (E02) Z69 Z6T (E2)
(PCR2) EBM XZH (PCR2) (VC2) XG2 JE4 (VCP2)
(VC2) EBL YWH (VCP2) Aftertreatment fuel
$XW (PC2S) (FPR) X4T FFE (PR) injection line
pressure sensor

%8V (VCC) PTO accelerator

sensor

(VCPE) NVJ +QG ECE (VC)

DPR differential
(PEX) EB6 +Q6 ECF (PEX)
pressure sensor
(E03) 2AR +QF ECG (E2)

SHTS021270300628

1. Technical description
• Power is supplied to the sensor supply 2 circuit.
(Accelerator sensor1, common rail pressure sensor (sub), PTO accelerator sensor, DPR differential pressure sen-
sor (exhaust gas pressure sensor), aftertreatment fuel injection line pressure sensor)

<Description of malfunction>
• Excessively low voltage has been detected in the sensor power supply.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor has a power supply voltage no greater than 3.5 V for at least 3 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
2–696 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Individual sensors and harnesses (sensor power supply circuit GND short-circuit)
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–697

INSPECTION PROCEDURE: P0652

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Erase the trouble history and set the starter key to the "LOCK"
position.

3. Disconnect the common rail pressure sensor 2 (sub) connector.

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0652 has been detected.

SHTS021270300629

Has DTC P0652 been detected?

YES NO

After connecting the connector, go to step 2. Replace the common rail pressure sensor 2
(sub).
Perform "After-inspection work" of INFOR-
MATION section.

2 Check the DTC detected 2 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the accelerator sensor 1 connector.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0652 has been detected.

SHTS021270300630

Has DTC P0652 been detected?

YES NO

After connecting the connector, go to step 3. Replace the accelerator sensor 1.

Perform "After-inspection work" of INFOR-
MATION section.
2–698 ENGINE (J05E)/TROUBLESHOOTING

3 Check the DTC detected 3 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the differential pressure sensor connector.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0652 has been detected.

SHTS021270300631

Has DTC P0652 been detected?

YES NO

After connecting the connector, go to step 4. Replace the differential pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 4 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the PTO accelerator sensor connector.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0652 has been detected.

SHTS021270300632

Has DTC P0652 been detected?

YES NO

After connecting the connector, go to step 5. Replace the PTO accelerator sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–699

5 Check the DTC detected 5 (Engine ECU)

1. Erase the trouble history and set the starter key to the "LOCK"
position.

2. Disconnect the aftertreatment fuel injection line pressure sensor.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P0652 has been detected.

SHTS021270300633

Has DTC P0652 been detected?

YES NO

After connecting the connector, go to step 6. Replace the aftertreatment fuel injection line
pressure sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–700 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the wire harness of the sensor power supply

1. Set the starter key to the "LOCK" position.

V50
B C E56 D 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
V71
3. Use the electrical tester to measure the resistance between the
E13 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300634 nal check har-
ness)
VCP1 (E13) – EP1
Starter key: LOCK (E56) 
VC (V50) – EP1
(E56)
VCPE (V71) – EP1
(E56)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–701

DTC: P0653
EN01H02127030602016112

P0653: ECU sensor power supply 2 failure (Out of range high)

INFORMATION

Engine ECU
Common rail
pressure sensor $XV (PC1S) (VPA) XQ4 JE5 (VPA1)
(E1) EBK YWL (EP1) (E01) Z68 Z6S (E1)
(PCR1) EBJ XZG (PCR1) (VC) X85 JE3 (VCP1) Accelerator
(VC1) EBH YWK (VCP1) (VPA2) XZL ZSQ (VPA2) sensor
(E2) EBN YWM (EP2) (E02) Z69 Z6T (E2)
(PCR2) EBM XZH (PCR2) (VC2) XG2 JE4 (VCP2)
(VC2) EBL YWH (VCP2) Aftertreatment fuel
$XW (PC2S) (FPR) X4T FFE (PR) injection line
pressure sensor

%8V (VCC) PTO accelerator

sensor

(VCPE) NVJ +QG ECE (VC)

DPR differential
(PEX) EB6 +Q6 ECF (PEX)
pressure sensor
(E03) 2AR +QF ECG (E2)

SHTS021270300635

1. Technical description
• Power is supplied to the sensor supply 2 circuit.
(Accelerator sensor 1, common rail pressure sensor (sub), PTO accelerator sensor, DPR differential pressure sen-
sor, aftertreatment fuel injection line pressure sensor)

<Description of malfunction>
• Excessively high voltage has been detected in the sensor power supply.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor has a power supply voltage no greater than 3.5 V for at least 3 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
2–702 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (battery power supply short-circuit)
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–703

INSPECTION PROCEDURE: P0653

1 Inspect the power supply of common rail pressure sensor 2

1. Set the starter key to the "LOCK" position.

E1 VC1
2. Disconnect the common rail pressure sensor 2 connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the common rail pressure sensor 2 vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300636 Common rail pres-

sure sensor 2
Starter key: ON vehicle side con- 4.5 – 5.5 V
nector
VC1 – E1

Do the measurements meet the standard value?

YES NO

Go to step 2. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–704 ENGINE (J05E)/TROUBLESHOOTING

2 Inspect the power supply of accelerator sensor 1

1. Set the starter key to the "LOCK" position.

VCP1 E1
2. Disconnect the accelerator sensor 1 connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the accelerator sensor 1 vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300637 Accelerator sen-

sor 1 vehicle side
Starter key: ON 4.5 – 5.5 V
connector
VCP1 – E1

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the power supply of DPR differential pressure sensor

1. Set the starter key to the "LOCK" position.

E2 VC
2. Disconnect the DPR differential pressure sensor connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the DPR
differential pressure sensor terminals.

Measurement Tester
Standard values
conditions connections

SHTS021270300638 DPR differential

Starter key: ON pressure sensor 4.5 – 5.5 V
VC – E2

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–705

4 Inspect the power supply of the PTO accelerator sensor

1. Set the starter key to the "LOCK" position.

VCC
2. Disconnect the PTO accelerator sensor connector.

3. Set the starter key to the "ON" position.

GND 4. Use the electrical tester to measure the voltage between the termi-
nals of the PTO accelerator sensor vehicle side connector.

Measurement Tester
Standard values
conditions connections
SHTS021270300639 PTO accelerator
sensor vehicle
Starter key: ON 4.5 – 5.5 V
side connector
VCC – GND

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–706 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the power supply of aftertreatment fuel injection line pressure sensor

1. Set the starter key to the "LOCK" position.

E2 VC
2. Disconnect the aftertreatment fuel injection line pressure sensor.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the after-
treatment fuel injection line pressure sensor.

Measurement Tester
Standard values
conditions connections

SHTS021270300640 Aftertreatment
fuel injection line
Starter key: ON 4.5 – 5.5 V
pressure sensor
VC – E2

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–707

6 Inspect the power supply of all sensors

1. Set the starter key to the "LOCK" position.

V50
B C E56 D 2. Connect the signal check harness to the engine ECU.

V71 3. Set the starter key to the "ON" position.

E13 4. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300641 Engine ECU (sig-

nal check har-
ness)
(+) – (-)
VCP1 (E13) – EP1
Starter key: ON 4.9 – 5.1 V
(E56)
VC (V50) – EP1
(E56)
VCPE (V71) –
EP1(E56)

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–708 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0671 and P0672

EN01H02127030602016113

P0671: Glow plug (Circuit low) (#1cyl), Glow plug (Circuit high) (#1cyl)
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300642

1. Technical description
• Glow plug is controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• Circuit failure between the GCU and glow plug #1 is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key is "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter is not actuated.
(2) Judgement criteria
• The condition that the glow plug operating current is less than the range of 0.5 to 0.9 A remains for 0.3 sec-
onds or more, or the condition that the glow plug operating current is greater than the range of 21 to 36 A
remains for 0.3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–709

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit between GCU and glow plug #1
• Glow plug #1 unit is faulty.
2–710 ENGINE (J05E)/TROUBLESHOOTING

P0672: Glow plug (Circuit low) (#2cyl), Glow plug (Circuit high) (#2cyl)
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300643

1. Technical description
• Glow plug is controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• Circuit failure between the GCU and glow plug #2 is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key is "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter is not actuated.
(2) Judgement criteria
• The condition that the glow plug operating current is less than the range of 0.5 to 0.9 A remains for 0.3 sec-
onds or more, or the condition that the glow plug operating current is greater than the range of 21 to 36 A
remains for 0.3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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.
 ENGINE (J05E)/TROUBLESHOOTING 2–711

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit between GCU and glow plug #2
• Glow plug #2 unit is faulty.
2–712 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0671 and P0672

1 Inspect the fusible link (GLOW)

1. Check for fusing and improper fit.

Was any failure found?

YES NO

Connect the fusible link correctly or replace Go to step 2.

it.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the power supply wire harness of the glow control unit (GCU)

1. Set the starter key to the "LOCK" position.

GND
2. Disconnect the GCU connector.

3. Use the electrical tester to measure the voltage between the termi-
nals of the GCU vehicle side connector.

+B Measurement Tester
Standard values
conditions connections

GCU vehicle side

Starter key: LOCK connector 10 – 16 V
SHTS021270300644 +B – GND

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the wire harness in the

glow control unit power supply circuit
(between the fusible link and the control
unit).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–713

3 Inspect the wire harness of the glow plug

1. Disconnect the target's glow plug terminal.

GLW1
GL2 GL1 2. Use the electrical tester to measure the resistance between the
GLW2 glow control unit vehicle side connector and the target's glow plug
terminal.

Measurement Tester
Standard values
conditions connections

GCU vehicle side

connector – Tar-
get's glow plug
SHTS021270300645 Starter key: LOCK #1 Glow plug: Less than 1 
GL1 – GLW1
#2 Glow plug:
GL2 – GLW2

Do the measurements meet the standard value?

YES NO

Replace the target's glow plug. Repair or replace the harness.

Go to step 4. Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if DTC (P0671, P0672) has been

detected.

SHTS021270300646

Has DTC (P0671, P0672) been detected?

YES NO

Replace the GCU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–714 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0673 and P0674

EN01H02127030602016114

P0673: Glow plug (Circuit low) (#3cyl), Glow plug (Circuit high) (#3cyl)
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300647

1. Technical description
• Glow plug is controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• Circuit failure between the GCU and glow plug #3 is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key is "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter is not actuated.
(2) Judgement criteria
• The condition that the glow plug operating current is less than the range of 0.5 to 0.9 A remains for 0.3 sec-
onds or more, or the condition that the glow plug operating current is greater than the range of 21 to 36 A
remains for 0.3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–715

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit between GCU and glow plug #3
• Glow plug #3 unit is faulty.
2–716 ENGINE (J05E)/TROUBLESHOOTING

P0674: Glow plug (Circuit low) (#4cyl), Glow plug (Circuit high) (#4cyl)
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300648

1. Technical description
• Glow plug is controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• Circuit failure between the GCU and glow plug #4 is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key is "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter is not actuated.
(2) Judgement criteria
• The condition that the glow plug operating current is less than the range of 0.5 to 0.9 A remains for 0.3 sec-
onds or more, or the condition that the glow plug operating current is greater than the range of 21 to 36 A
remains for 0.3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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.
 ENGINE (J05E)/TROUBLESHOOTING 2–717

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit between GCU and glow plug #4
• Glow plug #4 unit is faulty.
2–718 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0673 and P0674

1 Inspect the fusible link (GLOW)

1. Check for fusing and improper fit.

Was any failure found?

YES NO

Connect the fusible link correctly or replace Go to step 2.

it.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the power supply wire harness of the glow control unit (GCU)

1. Set the starter key to the "LOCK" position.

GND
2. Disconnect the GCU connector.

3. Use the electrical tester to measure the voltage between the termi-
nals of the GCU vehicle side connector.

+B Measurement Tester
Standard values
conditions connections

GCU vehicle side

Starter key: LOCK connector 10 – 16 V
SHTS021270300649 +B – GND

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the wire harness in the

glow control unit power supply circuit
(between the fusible link and the control
unit).
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–719

3 Inspect the wire harness of the glow plug

1. Disconnect the target's glow plug terminal.

GL4
GLW3 GL3 2. Use the electrical tester to measure the resistance between the
GLW4 glow control unit vehicle side connector and the target's glow plug
terminal.

Measurement Tester
Standard values
conditions connections

GCU vehicle side

connector – Tar-
get's glow plug
SHTS021270300650 Starter key: LOCK #3 Glow plug: Less than 1 
GL3 – GLW3
#4 Glow plug:
GL4 – GLW4

Do the measurements meet the standard value?

YES NO

Replace the target's glow plug. Repair or replace the harness.

Go to step 4. Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if DTC (P0673, P0674) has been

detected.

SHTS021270300651

Has DTC (P0673, P0674) been detected?

YES NO

Replace the GCU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–720 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0683
EN01H02127030602016115

P0683: Glow controller - Battery for glow controller open, GND short Glow controller -
Glow control signal Glow controller - Diagnosis signal
INFORMATION

Actuator power relay

ENG2 ENG1
+B

ENG3

ECU GCU Glow

+B
BATT
+B GL1 GLW1 Glow Plug 1 #1cyl
+B ST SI GL2 GLW2 Glow Plug 2 #2cyl
Control signal
+B1
+B2 +B GL3 GLW3 Glow Plug 3 #3cyl
+BM DI DI GL4 GLW4 Glow Plug 4 #4cyl
Diagnosis signal

SHTS021270300652

1. Technical description
• Controlled by GCU.
• The indicator in the meter lights up when a failure (malfunction caused by short-circuit or disconnection) occurs in
the glow system.

<Description of malfunction>
• Detection of the GCU communication error.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The engine ECU instructs glow discharge.

The conditions described below remain for 1 second or more.

- The battery voltage is in the range of 10 to 16 V.
- Starter not actuated.
(2) Judgement criteria
• The condition that GCU is not actuated (or no response) remains for 4.4 seconds or more.

3. Reset condition
• Just after restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–721

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Blown, improperly connected, or half-connected fuse
• Harness disconnection or short-circuit
• Abnormal ground potential difference between engine ECU and GCU
• GCU failure
2–722 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0683

1 Inspect the fuse and fusible link

1. Check the fuse (GCU (M)) and fusible link (GLOW) for fusing or
improper fit.

Was any failure found?

YES NO

Connect the fuse and fusible link properly or Go to step 2.

replace.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the GCU circuit

1. Set the starter key to the "LOCK" position.

GND 2. Disconnect the GCU connector.

3. Use the electrical tester to measure the resistance between the

GCU vehicle side connector GND terminal and ground.

Measurement Tester
Standard values
conditions connections

GCU chassis vehi-

Starter key: LOCK cle side connector Less than 1 
SHTS021270300653 GND – Ground

Do the measurements meet the standard value?

YES NO

Go to step 3. Check the GCU ground circuit.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–723

3 Inspect the GCU power supply circuit

1. Set the starter key to the "ON" position.

GND
2. Use the electrical tester to measure the voltage between the termi-
nals of the GCU vehicle side connector.

BATT Measurement Tester

Standard values
conditions connections
+B
GCU vehicle side
connector termi-
Starter key: ON nal – GND 10 – 16 V
+B – GND
SHTS021270300654 BATT – GND

Do the measurements meet the standard value?

YES NO

Go to step 4. Inspect the GCU power supply circuit.

Perform "After-inspection work" of INFOR-
MATION section.
2–724 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the harness of the GCU

1. Set the starter key to the "LOCK" position.

V15
V35 A 2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)
Sl DI
3. Use the electrical tester to measure the resistance between the
GCU vehicle side connector terminals and engine ECU (signal
check harness) terminals.

Measurement Tester
Standard values
conditions connections

SHTS021270300655 GCU vehicle side

connector termi-
nals – engine ECU
Starter key: LOCK (signal check har- 1  or less
ness) terminals
DI – Dl (V35)
Sl – ST (V15)

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–725

5 Check the ground circuit voltage

1. Set the starter key to the "ON" position.

A B
2. Use the electrical tester to measure the voltage between each ter-
minal in the engine ECU (signal check harness) and ground.
V59
V39 V80 3. Measure the voltage between the GCU vehicle side connector
V79 GND terminal and ground.

4. Check the ground circuit potential difference between the engine

ECU and the glow control unit.

Measurement Tester
GND Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
E1 (V39) – Ground
Potential defer-
E2 (V59) – Ground
Starter key: ON ence:
E3 (V79) – Ground
400 mV or less
E4 (V80) – Ground
GCU vehicle side
connector
SHTS021270300656 GND – Ground

Do the measurements meet the standard value?

YES NO

Replace the GCU. Check the ground circuit.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–726 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0686
EN01H02127030602016116

P0686: ECM/PCM Power Relay Control Circuit high

INFORMATION

YRC YRA ENG1

X04
(INJ) (B) (L )
YRD YRB
(IREL) (B2)
EDU relay
XAU
X0D

(MRL2) $XT
X21

(MREL) X64
JFZ
(+BM)
(+B2)
(+B1)
(+B)

Engine ECU

SHTS021270300657

1. Technical description
• The main relay (EDU relay) supplies power from the battery to the ECU.

<Description of malfunction>
• The main relay cannot be turned OFF.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• With the main relay in OFF position, 8 V or higher power supply voltage remains for 60 seconds.

3. Reset condition
• After restoration to normal condition.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: ON

5. 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.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–727

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit
• Looseness or poor contact of connector
• Main relay failure
• Engine ECU failure
2–728 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0686

1 Inspect the main (EDU) relay

1. Check the connection of the main relay (EDU relay) (inside chassis
relay block B) (looseness or poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the main relay unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the main relay.

3. Use the electrical tester to measure the resistance between the

terminals of the main relay.

Tester connections Standard values

1 in the figure: 167 

Main relay terminals
2 in the figure:  
 
SHTS021270300658

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the main relay.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–729

3 Inspect the main relay power supply circuit

1. Set the starter key to the "ON" position.

EDU RELAY
B
B2
2. Use the electrical tester to measure the voltage between each ter-
B

B2
minal in the main relay vehicle side connector (inside chassis relay
block B) and ground.

Measurement Tester
Standard values
conditions connections

Main relay vehicle

side connector
Starter key: ON 10 V or more
B – Ground
SHTS021270300659 B2 – Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the main relay power sup-

ply circuit.
Perform "After-inspection work" of INFOR-
MATION section.
2–730 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the main relay power supply

1. Set the starter key to the "LOCK" position.

V3 㧭 2. Connect the main relay.

V23
3. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

4. Set the starter key to the "ON" position.

5. Use the electrical tester to measure the voltage between the

engine ECU (signal check harness) terminals and ground.

SHTS021270300660
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: ON MREL (V3) – 10 V or more
Ground
MRL2 (V23) –
Ground

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–731

DTC: P0698
EN01H02127030602016117

P0698: ECU sensor power supply 3 failure (Out of range low)

INFORMATION

Engine ECU
(VC) J0M YKE (VCPA)
Boost pressure (PIM) J0L X0G (PIM)
sensor
(E) Z6R YKE (EPA)

SHTS021270300661

1. Technical description
• Power is supplied to the sensor power supply 3 circuit.
(Boost pressure sensor)

<Description of malfunction>
• Low voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor power supply voltage remains at 3.5 V or less for 3 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–732 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (GND short-circuit in sensor power supply/GND circuit)
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–733

INSPECTION PROCEDURE: P0698

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Erase the trouble history and set the starter key to the "LOCK"
position.

3. Disconnect the boost pressure sensor connector.

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P0698 has been detected.

SHTS021270300662

Has DTC P0698 been detected?

YES NO

Replace the engine ECU. Replace the boost pressure sensor.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–734 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0699
EN01H02127030602016118

P0699: ECU sensor power supply 3 failure (Out of range high)

INFORMATION

Engine ECU
(VC) J0M YKE (VCPA)
Boost pressure (PIM) J0L X0G (PIM)
sensor
(E) Z6R YKE (EPA)

SHTS021270300663

1. Technical description
• Power is supplied to the sensor power supply 3 circuit.
(Boost pressure sensor)

<Description of malfunction>
• High voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor power supply voltage remains at 4.5 V or more for 3 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–735

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (short-circuit in battery power supply of sensor power supply circuit)
• Failure in engine ECU sensor power supply or internal circuit
2–736 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P0699

1 Check the power supply of boost pressure sensor

1. Set the starter key to the "LOCK" position.

2. Disconnect the boost pressure sensor connector.

E VC

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the boost pressure sensor connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300664 Boost pressure

sensor vehicle
Starter key: ON 4.5 – 5.5 V
side connector
VC – E

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–737

DTC: P06A4
EN01H02127030602016119

P06A4: ECU sensor power supply 4 failure (Out of range low)

INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300665

1. Technical description
• Power is supplied to the sensor power supply 4 circuit.
(Diesel throttle (intake throttle valve) position sensor 1 and 2)

<Description of malfunction>
• Low voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor power supply voltage remains at 3.5 V or less for 3 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–738 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (GND short-circuit in sensor power supply/GND circuit)
• Failure in engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–739

INSPECTION PROCEDURE: P06A4

1 Check the DTC detected 1 (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Erase the trouble history and set the starter key to the "LOCK"
position.

3. Disconnect the diesel throttle (intake throttle valve) position sensor

1, 2 connector.

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P06A4 has been detected.

SHTS021270300666

Has DTC P06A4 been detected?

YES NO

Replace the engine ECU. Replace the diesel throttle (intake throttle
Perform "After-inspection work" of INFOR- valve) position sensor.
MATION section. Perform "After-inspection work" of INFOR-
MATION section.
2–740 ENGINE (J05E)/TROUBLESHOOTING

DTC: P06A5
EN01H02127030602016120

P06A5: ECU sensor power supply 4 failure (Out of range high)

INFORMATION

Engine ECU

(E2R) XFD XQT (M-)

(VCR) XFC XQS (M+)
(E2) Z8P
Diesel throttle XSR X3V (VTA2)
(VTA2)
(VC) X0N ZTV (VCTA)
(VTA) X3U XK3 (VTA1)

(E) Z6R YKE (EPA)

Boost pressure
sensor (PIM) J0L Y0G (PIM)
(VC) J0M YKF (VCPA)

SHTS021270300667

1. Technical description
• Power is supplied to the sensor power supply 4 circuit.
(Diesel throttle (intake throttle valve) position sensor 1, diesel throttle (intake throttle valve) position sensor 2)

<Description of malfunction>
• High voltage failure of sensor power supply circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• The AC/DC converter input sensor power supply voltage remains at 3.5 V or more for 3 seconds or longer.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–741

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (short-circuit in battery power supply of sensor power supply circuit)
• Failure in engine ECU sensor power supply or internal circuit
2–742 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P06A5

1 Check the power supply of diesel throttle (intake throttle valve) position sensor

1. Set the starter key to the "LOCK" position.

2. Disconnect the diesel throttle (intake throttle valve) position sensor

E2 VC connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the diesel throttle (intake throttle valve) position sensor
connector.

Measurement Tester
SHTS021270300668 Standard values
conditions connections

Diesel throttle
(intake throttle
valve) position
Starter key: ON 4.5 – 5.5 V
sensor vehicle
side connector
VC – E2

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Repair or replace the harness.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–743

DTC: P06D3 and P06D4

EN01H02127030602016121

P06D3: Air flow meter power supply failure Short to GND

INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300669

1. Technical description
• The air flow meter installed to the air cleaner consistently measures an intake air volume.
• The engine ECU supplies power to the air flow meter.

<Description of malfunction>
• Excessively low voltage has been detected in the air flow meter power supply.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
Voltage of the air flow meter power supply circuit remains at 5.6 V or lower for 1 sec.

3. Reset condition
• Normal operation instantly restored once values deviate from judgment criteria.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
2–744 ENGINE (J05E)/TROUBLESHOOTING

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Harness disconnection or short-circuit
• Air flow meter failure
• Engine ECU failure
 ENGINE (J05E)/TROUBLESHOOTING 2–745

P06D4: Air flow meter power supply failure (High)

INFORMATION

Coolant temperature sensor 1 Engine ECU

X66 (THW) X28 (THW)

Body earth
Z5G (E) YKC
(ETHW)

X71 X4K (VG)

(FC)
XCV XMH (EVG)
Intake air (E2G)
temperature sensor XCT X2U (VAF)
(+B)
(air flow sensor built in) Z65
(E2)
X72 X82 (THA)
(THA)

SHTS021270300670

1. Technical description
• The air flow meter installed to the air cleaner consistently measures an intake air volume.
• The engine ECU supplies power to the air flow meter.

<Description of malfunction>
• Excessively low voltage has been detected in the air flow meter power supply.

2. DTC set condition

(1) DTC detection condition
• Key is ON and starter is OFF.
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
Voltage of air flow meter power supply circuit ≥ 20 V for 1 second.

3. Reset condition
• Normal operation instantly restored once values deviate from judgment criteria.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
2–746 ENGINE (J05E)/TROUBLESHOOTING

8. Estimated failure factors

• Harness disconnection or short-circuit
• Air flow meter failure
• Engine ECU failure
 ENGINE (J05E)/TROUBLESHOOTING 2–747

INSPECTION PROCEDURE: P06D3 and P06D4

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than (P06D3 or

P06D4) (for example P0642, P0643, P0652, P0653) have been
detected.

SHTS021270300671

Has a DTC other than P06D3 or P06D4 (for example P0642, P0643, P0652, P0653) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the air flow meter connector

1. Check the connection of the air flow meter connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–748 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the air flow meter

1. Check the installation of the air flow meter.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of air flow meter.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the air flow meter.
Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect for short-circuit in wire harness or air flow meter

1. Set the starter key to the "LOCK" position.

E12
C D E74
2. Connect the signal check harness to the engine ECU vehicle side
harness. (Do not connect the harness to the ECU.)

E78 3. Disconnect the air flow meter connector.

4. Use the electrical tester to measure the resistance between the

terminals of engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300672
Engine ECU
(the signal check
harness)
VG (E74) – Ground
Starter key: LOCK 
EVG (E78)–
Ground
VAF (E12)–
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–749

5 Inspect for disconnection in wire harness or air flow meter

1. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and the air
C flow meter vehicle side connector terminals.
E12
Measurement Tester
Standard values
conditions connections
+B E2G Engine ECU (the
D
FC signal check har-
ness) – Air flow
meter vehicle side
E74 E78 Starter key: LOCK connector termi- Less than 1 
nals
VG (E74) – FC
EVG (E78) – E2G
VAF (E12) – +B

SHTS021270300673

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–750 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect the air flow meter power supply

1. Connect the signal check harness to engine ECU.

B+
E2G
2. Set the starter key to the "ON" position.

3. Use the electrical tester to measure the voltage between the termi-
nals of the air flow meter vehicle side connector.

Measurement Tester
Standard values
conditions connections

Air flow meter

vehicle side con-
Starter key: ON 11.5 – 13.5 V
SHTS021270300674 nector terminals
+B – E2G

Do the measurements meet the standard value?

YES NO

Go to step 7. Replace the engine ECU.

7 Inspect the air flow meter signal unit

1. Set the starter key to the "LOCK" position.

E74 E78
D 2. Connect the air flow meter connector.

3. Start the engine.

4. Use an oscilloscope to measure the signal voltage between the

terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300675 Engine ECU

After warm up, the (the signal check
engine idling con- harness) 5 – 6 kHz
dition VG (E74) –
EVG (E78)

Do the measurements meet the standard value?

YES NO

Go to step 8. Replace the air flow meter.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–751

8 Check the DTC detected (Engine ECU)

1. Warm up the engine (engine coolant temperature: 80 C {176 F}

or more)

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if the DTC (P06D3 or P06D4) has been
detected.

SHTS021270300676

Has DTC (P06D3 or P06D4) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–752 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0700
EN01H02127030602016122

P0700: HV clutch system failure

INFORMATION

1. Technical description

<Description of malfunction>
• The engine ECU detected malfunction in the HV clutch system.

2. DTC set condition

(1) DTC detection condition
• –
(2) Judgement criteria
• –

3. Reset condition
• Immediately after normal status is resumed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–753

INSPECTION PROCEDURE: P0700

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and read

the detected DTC.

SHTS021270300677

Has DTC P0700 been detected?

YES NO

Go to DTC-specific troubleshooting for the Procedure completed.

hybrid system (HV ECU).
2–754 ENGINE (J05E)/TROUBLESHOOTING

DTC: P073D
EN01H02127030602016123

P073D: Transmission information - rationality

INFORMATION

Engine ECU
Neutral switch
(NSW) X2M M16 (L )
Neutral signal

SHTS021270300678

1. Technical description
• Transmission information is transferred through CAN communication.

<Description of malfunction>
• Information sent from the transmission ECU (AT) is incorrect.
• Information from transmission ECU (AT) and neutral switch information are abnormal.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• The PTO is deactivated.
(2) Judgement criteria

Detected at one of the following conditions:

• The condition that there is an abnormality (communication blackout between the vehicle ECU and transmis-
sion ECU) in the lock up information provided by the vehicle control ECU remains for 5 seconds or more.
• The condition that there is an abnormality in the HV front clutch information provided by the vehicle control
ECU remains for 5 seconds or more.
• The condition that the neutral switch is positioned at the neutral position even though the neutral information
provided by the vehicle control ECU recognizes the "non-neutral" state remains for 10 seconds or more.
• The condition that the neutral information provided by the vehicle control ECU recognizes the "neutral" state
even though the lock up information recognizes the "lock up" remains for 10 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.
 ENGINE (J05E)/TROUBLESHOOTING 2–755

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Neutral switch failure (stuck ON or faulty contact)
• Harness disconnection or short-circuit
• Harness/connector faulty contact or improper fit
• CAN communication blackout
• Transmission ECU failure
2–756 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P073D

1 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if no DTC other than P073D (CAN com-
munication failure, etc.) is detected.

SHTS021270300679

Has a DTC other than P073D been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the neutral switch [HINO DX Ⅱ ]

1. Select [Data monitor and Active test] and read the data output
from [Neutral switch] when the shift lever is in N range and when it
is in other ranges besides N range.

Measurement conditions Standard values

Shift lever in N range: 1

Starter key: ON
Shift lever in other range: 0

SHTS021270300680

Do the measurements meet the standard value?

YES NO

Go to step 3. Perform a failure diagnosis of the transmis-

sion ECU.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–757

3 Check the neutral switch signal

1. Set the starter key to the "LOCK" position.

A
V11 2. Connect the signal check harness to the engine ECU.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the NSW
(V11) terminal in the engine ECU (signal check harness) and
ground.

Measurement Tester
Standard values
conditions connections
SHTS021270300681
Engine ECU (sig-
Shift lever in N
nal check har-
range: ≥ 10 V
Starter key: ON ness)
Shift lever in other
NSW (V11) –
range: 0 V
Ground

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Inspect the neutral switch circuit.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–758 ENGINE (J05E)/TROUBLESHOOTING

DTC: P081A
EN01H02127030602016124

P081A: Starter Disable Circuit Low

INFORMATION

+B
Starter relay
Fuse
To starter

+B
+ST
+B ST1 STA Engine STCR
ST ECU Starter cut relay
Ignition switch Neutral start switch

SHTS021270300682

1. 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>
• Harness GND short-circuit or disconnection and relay unit failure are detected.

2. DTC set condition

(1) DTC detection condition
• Engine speed of 650 r/min or more. (Request starter cut relay operation)
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Output of the starter cut relay remains at 10 V or less for 3 seconds or longer.

3. Reset condition
• Just after restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• Starter operates even when the engine is running.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–759

8. Estimated failure factors

• Harness disconnection or short-circuit
• Looseness or poor contact of connector
• starter cut relay failure
• Engine ECU failure
2–760 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P081A

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Disconnect the starter cut relay.

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if P081A has been detected.

SHTS021270300683

Has DTC P081A been detected?

YES NO

Go to step 2. Replace the starter cut relay.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the starter cut relay connector

1. Check the connection of the starter cut relay connector (looseness

and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–761

3 Inspect for short-circuit in wire harness of starter cut relay signal circuit

1. Set the starter key to the "LOCK" position.

A 2. Remove the starter cut relay.

V2

3. Connect the signal check harness to the engine ECU.

(Do not connect the harness to the ECU.)

4. Use the electrical tester to measure the resistance between the

STCR (V2) terminals of the engine ECU (signal check harness)
and ground.

Measurement Tester
SHTS021270300684 Standard values
conditions connections

Engine ECU (sig-

nal check har-
Starter key: ON ness) 
STCR (V2) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 4. Repair or replace the harness.

(Engine ECU – starter cut relay)
Perform "After-inspection work" of INFOR-
MATION section.
2–762 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect for disconnection in wire harness of starter cut relay signal circuit

1. Use the electrical tester to measure the resistance between the

Starter cut relay terminals of the engine ECU (signal check harness) and starter cut
(Vehicle side connector) relay vehicle side connector terminals.
V2
A #1
Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness) –
Starter key: ON Starter cut relay Less than 1 
vehicle side con-
SHTS021270300685 nector terminals
STCR (V2) – #1

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

(Engine ECU – starter cut relay)
Perform "After-inspection work" of INFOR-
MATION section.

5 Inspect for disconnection in wire harness of starter cut relay (GND circuit)

1. Use the electrical tester to measure the resistance between the

Starter cut relay starter cut relay vehicle side connector #2 terminals and ground.
(Vehicle side connector)
Measurement Tester
Standard values
#2 conditions connections

Starter cut relay

vehicle side con-
Starter key: ON Less than 1 
nector terminals
#2 – Ground

SHTS021270300686

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

(Starter cut relay GND circuit)
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–763

6 Check the DTC detected (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P081A has been detected.

SHTS021270300687

Has DTC P081A been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–764 ENGINE (J05E)/TROUBLESHOOTING

DTC: P081B
EN01H02127030602016125

P081B: Starter Disable Circuit High

INFORMATION

+B
Starter relay
Fuse
To starter

+B
+ST
+B ST1 STA Engine STCR
ST ECU Starter cut relay
Ignition switch Neutral start switch

SHTS021270300688

1. Technical description
• The starter block relay prevents further rotations of the starter when the starter key is turned after start of the
engine.

<Description of malfunction>
• Harness +B short-circuit is detected.

2. DTC set condition

(1) DTC detection condition
• Request for deactivation of starter block is in progress (while engine is stopped).
• Starter key "ON".
• Battery voltage is 10 V – 16 V.
Above conditions continue for at least 5 seconds.
(2) Judgement criteria
• Output of the starter block relay remains at 10 V or more for 3 seconds or longer.

3. Reset condition
• After restoration to normal condition

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• Starter may not turn over. (If the starter turns over it will not interfere with engine operation.)

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.
 ENGINE (J05E)/TROUBLESHOOTING 2–765

8. Estimated failure factors

• Harness disconnection or short-circuit
• Looseness or poor contact of connector
• starter block relay failure
• Engine ECU failure
2–766 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P081B

1 Inspect the starter block relay connector

1. Check the connection of the starter block relay connector (loose-

ness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect for disconnection in wire harness of starter block relay

1. Set the starter key to the "LOCK" position.

A B 2. Connect the signal check harness to the engine ECU.

V2
V80 3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300689 Engine ECU (sig-

nal check har-
Starter key: ON ness) 3 V or less
STCR (V2) – E4
(V80)

Do the measurements meet the standard value?

YES NO

Go to step 3. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–767

3 Check the DTC detected (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P081B has been detected.

SHTS021270300690

Has DTC P081B been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–768 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0A7B
EN01H02127030602016126

P0A7B: HV BATTERY system failure

INFORMATION

1. Technical description

<Description of malfunction>
• The engine ECU detected malfunction in the HV battery system.

2. DTC set condition

(1) DTC detection condition
• –
(2) Judgement criteria
• –

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–769

INSPECTION PROCEDURE: P0A7B

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and read

the detected DTC.

SHTS021270300691

Has DTC P0A7B been detected?

YES NO

Go to DTC-specific troubleshooting for the Procedure completed.

hybrid system (HV ECU).
2–770 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0AC4
EN01H02127030602016127

P0AC4: HV system failure

INFORMATION

1. Technical description

<Description of malfunction>
• The engine ECU detected malfunction in the hybrid system.

2. DTC set condition

(1) DTC detection condition
• –
(2) Judgement criteria
• –

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–771

INSPECTION PROCEDURE: P0AC4

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and read

the detected DTC.

SHTS021270300692

Has DTC P0AC4 been detected?

YES NO

Go to DTC-specific troubleshooting for the Procedure completed.

hybrid system (HV ECU).
2–772 ENGINE (J05E)/TROUBLESHOOTING

DTC: P0CA1
EN01H02127030602016128

P0CA1: HV MOTOR system failure

INFORMATION

1. Technical description

<Description of malfunction>
• The engine ECU detected malfunction in the hybrid motor.

2. DTC set condition

(1) DTC detection condition
• –
(2) Judgement criteria
• –

3. Reset condition
• Immediately after normal status is resumed

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• –
 ENGINE (J05E)/TROUBLESHOOTING 2–773

INSPECTION PROCEDURE: P0CA1

1 Check the DTC detected [HINO DX Ⅱ ]

1. Set the starter key to the "LOCK" position.

2. Connect the diagnostic system (HINO DX Ⅱ ) to the vehicle.

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and read

the detected DTC.

SHTS021270300693

Has DTC P0CA1 been detected?

YES NO

Go to DTC-specific troubleshooting for the Procedure completed.

hybrid system (HV ECU).
2–774 ENGINE (J05E)/TROUBLESHOOTING

DTC: P1133
EN01H02127030602016129

P1133: PTO accelerator sensor (Hi)

INFORMATION

PTO accelerator sensor Engine ECU

(VCC) %8V
(SIG) %8W XZK (VPA1)
(GND) %8X

Differential pressure sensor

(E2) ECG ZAR (E03)

(PEX) ECF EB6 (PEX)
(VC) ECE NVJ (VCPE)

Accelerator sensor

(E1) Z6S Z68 (E01)

(VCP2) JE4 XG2 (VC2)
(E2) Z6T Z69 (E02)
(VPA2) XSQ XZL (VPA2)
(VCP1) JE3 X85 (VC)
(VPA1) JE5 XQ4 (VPA)

SHTS021270300694

1. 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>
• The operational accelerator sensor cannot correctly sense.
• +B short-circuit is likely to have occurred.

2. DTC set condition

(1) DTC detection condition
• Key is ON and starter is OFF.
• Battery voltage is in the range of 10 to 16 V.
The conditions described above remain for 5 seconds or longer.
(2) Judgement criteria
• Sensor voltage remains at 4.82 V or higher for 3 seconds or longer.

3. Reset condition
• After normal operation is restored and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: OFF
• SVS light: OFF
• Body mounting control is not available.
 ENGINE (J05E)/TROUBLESHOOTING 2–775

5. 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>

• Body mounting control is not working.

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Faulty harness (+B short-circuit)
• Malfunction of PTO accelerator sensor (operational accelerator sensor)
• Failure in engine ECU sensor power supply or internal circuit
2–776 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P1133

1 Inspect the PTO accelerator sensor connector

1. Check the connection of the PTO accelerator sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the PTO accelerator sensor

1. Check the installation of the PTO accelerator sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the PTO accelerator sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–777

3 Inspect the PTO accelerator sensor unit

1. Set the starter key to the "LOCK" position.

SIG VCC 2. Disconnect the PTO accelerator sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the PTO accelerator sensor.

Measurement Tester
Standard values
conditions connections

PTO accelerator
sensor
Starter key: LOCK More than 2 
SIG – VCC
SIG – GND
SIG
GND

SHTS021270300695

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the PTO accelerator sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–778 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect for short-circuit of the PTO accelerator sensor harness

1. Connect the signal check harness to the engine ECU. (Do not con-
V45 nect the harness to the ECU.)
V71
B
V68 2. Use the electrical tester to measure the resistance between the
terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
SHTS021270300696 VPA1 (V68) –
Starter key: LOCK Ground 
VCPE (V71) –
Ground
E01 (V45) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 5. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–779

5 Inspect disconnection of the PTO accelerator sensor harness

1. Connect the PTO accelerator sensor connector.

B
V71
V68 2. 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-
ness)
Starter key: LOCK VPA1 (V68) – More than 2 
V45 VCPE (V71)
B V68 VPA1 (V68) –
E01 (V45)

SHTS021270300697

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–780 ENGINE (J05E)/TROUBLESHOOTING

6 Check the DTC detected (Engine ECU)

1. Connect the vehicle to HINO DX Ⅱ .

2. Set the starter key to the "ON" position.

3. Select [Engine] and check if P1133 has been detected.

SHTS021270300698

Has DTC P1133 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–781

DTC: P119F
EN01H02127030602016130

P119F: Fuel rail pressure sensor - rationality

INFORMATION

Engine ECU
$XV (PC1S)
(E1) EBK YWL (EP1)
(PCR1) EBJ XZG (PCR1)
(VC1) EBH YWK (VCP1)
Common rail EBN YWM
pressure sensor (E2) (EP2)
(PCR2) EBM XZH (PCR2)
(VC2) EBL YWH (VCP2)
$XW (PC2S)
X4A

SHTS021270300699

1. Technical description
• The common rail pressure sensor consistently measures common rail pressure.

<Description of malfunction>
• Common rail pressure cannot be correctly sensed.
• Malfunction is likely to have occurred in the common rail pressure sensor.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Common rail pressure is 220 MPa or less.
(2) Judgement criteria
P119F is detected under the conditions described below. 1 and 2 represent the order of priority.
• The difference obtained by subtracting the common rail pressure sensor power (main) from the common rail
pressure sensor power (sub) continues to be more than 1.06 V for 3 seconds or more, or the difference
obtained by subtracting the common rail pressure sensor power (main) from the common rail pressure sensor
power (sub) continues to be less than 0.04 V for 3 seconds or more.

3. Reset condition
• After normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Cruise control is not available.
• HINO STOP&START SYSTEM is not available.

5. 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.
• HINO STOP&START SYSTEM does not work.

<Symptoms on the vehicle due to malfunction>

• –
2–782 ENGINE (J05E)/TROUBLESHOOTING

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Sensor disconnected from measuring site
• Harness disconnection or short-circuit
• Abnormal resistance of sensor (stuck)
• Malfunction of ECU
 ENGINE (J05E)/TROUBLESHOOTING 2–783

INSPECTION PROCEDURE: P119F

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P119F (for exam-
ple, P0192, P0193, P01A5, P01A6) have been detected.

SHTS021270300700

Has a DTC (P0192, P0193, P01A5, P01A6) other than P119F been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the common rail pressure sensor connector

1. Check the connection of the common rail pressure sensor connec-

tor (looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–784 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the sensor power supply

1. Set the starter key to the "LOCK" position.

E68
C E56 D E49
E13 2. Connect the signal check harness to the engine ECU.
E65
3. Disconnect the common rail pressure sensor connector.
E64
E33 E76 4. Set the starter key to the "ON" position.

5. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

Measurement Tester
SHTS021270300701 Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
VCP1 (E13) – EP1
(E56)
PCR1 (E49) – EP1
(E56)
Starter key: ON PC1S (E68) – EP1 4.5 – 5.5 V
(E56)
VCP2 (E33) – EP2
(E76)
PCR2 (E64) – EP2
(E76)
PC2S (E65) – EP2
(E76)

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the engine ECU.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–785

4 Inspect the signal of the common rail pressure sensor

1. Set the starter key to the "LOCK" position.

E65 D E49
2. Connect the common rail pressure sensor connector.
E64 E68

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

SHTS021270300702 Engine ECU (sig-

nal check har-
ness)
PCR1 (E49) –
PCR2 (E64)
Starter key: ON PCR1 (E49) – 0.3 – 0.7 V
PC2S (E65)
PC1S (E68) –
PCR2 (E64)
PC1S (E68) –
PC2S (E65)

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the common rail pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–786 ENGINE (J05E)/TROUBLESHOOTING

5 Check the DTC detected 2(Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "ON" position.

3. Select [Engine] and check if P119F has been detected.

SHTS021270300703

Has DTC P119F been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–787

DTC: P1426
EN01H02127030602016131

P1426: Differential pressure sensor - rationality

INFORMATION

+QG ECE (VC)

+Q6 ECF (PEX)
+QF ECG (E2)

DPR differential
pressure sensor

(E03) ZAR
(VCPE) NVJ
(PEX) EB6

Engine ECU

SHTS021270300704

1. 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.

<Description of malfunction>
• DPR differential pressure sensor is recognized as being stuck or in characteristics failure condition.

2. DTC set condition

(1) DTC detection condition
• Elapse of at least 2 seconds after engine stop
(2) Judgement criteria
• Differential pressure remains less than -2 kPa or higher than 2 kPa for 2 seconds.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF

5. 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>

• –
2–788 ENGINE (J05E)/TROUBLESHOOTING

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Loose/disconnected sensor and failure in sensing area (contamination or clogging)
• Abnormality in resistance of sensor (stuck)
• Malfunction of engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–789

INSPECTION PROCEDURE: P1426

1 Check the differential pressure hose and pipe

1. Check if the differential pressure hose and pipe are cracked, bent,
ruptured, or clogged.

Was any failure found?

YES NO

Clean or replace the differential pressure Go to step 2.

hose and pipe.
Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the differential pressure sensor connector

1. Check the connection of the differential pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.

3 Inspect the differential pressure sensor

1. Check the installation of the differential pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the differential pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 4.

If damaged, replace the differential pressure
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–790 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the differential pressure sensor unit

1. Set the starter key to the "LOCK" position.

VC E2
2. Disconnect the DPR differential pressure sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the differential pressure sensor.

Measurement Tester
Standard values
conditions connections

Differential pres-
sure sensor
Starter key: LOCK 2 – 15 k
PEX E2 VC – E2
PEX – E2

SHTS021270300705

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the differential pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–791

5 Inspect for short-circuit of the differential pressure sensor harness

1. Set the starter key to the "LOCK" position.

V46
B V70 2. Connect the signal check harness to the engine ECU vehicle side
V71 harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300706 nal check har-
ness)
VCPE (V71) –
Starter key: LOCK Ground 
PEX (V70) –
Ground
E03 (V46) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–792 ENGINE (J05E)/TROUBLESHOOTING

6 Inspect disconnection of the differential pressure sensor harness

1. Connect the differential pressure sensor connector.

B 2. Use the electrical tester to measure the resistance between the

V71 V70 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK VCPE (V71) – PEX 2 – 15 k
V46 (V70)
B V70 E03 (V46) – PEX
(V70)

SHTS021270300707

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–793

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P1426 has been detected.

SHTS021270300708

Has DTC P1426 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–794 ENGINE (J05E)/TROUBLESHOOTING

DTC: P1427
EN01H02127030602016132

P1427: Differential pressure sensor - out of range (Out of range low)

INFORMATION

+QG ECE (VC)

+Q6 ECF (PEX)
+QF ECG (E2)

DPR differential
(E03) ZAR pressure sensor
(VCPE) NVJ
(PEX) EB6

Engine ECU

SHTS021270300709

1. 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.

<Description of malfunction>
• Exhaust pressure cannot be correctly recognized.
• Possible DPR differential pressure sensor failure, harness disconnection, or GND short-circuit

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• Output of the DPR differential pressure sensor remains less than 0.59 V (-4.1 kPa) for 3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
 ENGINE (J05E)/TROUBLESHOOTING 2–795

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Harness disconnection or short-circuit
• Looseness or poor contact of connector.
• Malfunction of engine ECU sensor power supply or internal circuit.
2–796 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P1427

1 Inspect the differential pressure sensor connector

1. Check the connection of the differential pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the differential pressure sensor

1. Check the installation of the differential pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the differential pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the differential pressure
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–797

3 Inspect the differential pressure sensor unit

1. Set the starter key to the "LOCK" position.

2. Disconnect the DPR differential pressure sensor connector.
VC E2
3. Use the electrical tester to measure the resistance between the
terminals of the differential pressure sensor.

Measurement Tester
Standard values
conditions connections

Differential pres-
sure sensor
Starter key: LOCK 2 – 15 k
VC – E2
PEX – E2
PEX E2

SHTS021270300710

Do the measurements meet the standard value?

YES NO

Go to step 4. Replace the differential pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–798 ENGINE (J05E)/TROUBLESHOOTING

4 Inspect the power supply of the sensor

1. Set the starter key to the "ON" position.

E2 VC
2. 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-
sure sensor vehi-
Starter key: ON 4.5 – 5.5 V
cle side connector
VC – E2
SHTS021270300711

Do the measurements meet the standard value?

YES NO

Go to step 5. Go to step 7.

5 Inspect for short-circuit of the differential pressure sensor harness

1. Set the starter key to the "LOCK" position.

V46
B V70 2. Connect the signal check harness to the engine ECU vehicle side
V71 harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300712 nal check har-
ness)
VCPE (V71) –
Starter key: LOCK Ground 
PEX (V70) –
Ground
E03 (V46) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–799

6 Inspect disconnection of the differential pressure sensor harness

1. Connect the differential pressure sensor connector.

B 2. Use the electrical tester to measure the resistance between the

V71 V70 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK VCPE (V71) – 2 – 15 k
V46 PEX (V70)
B V70 E03 (V46) –
PEX (V70)

SHTS021270300713

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–800 ENGINE (J05E)/TROUBLESHOOTING

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P1427 have been detected.

SHTS021270300714

Has DTC P1427 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–801

DTC: P1428
EN01H02127030602016133

P1428: Differential pressure sensor - out of range (Out of range high)

INFORMATION

+QG ECE (VC)

+Q6 ECF (PEX)
+QF ECG (E2)

DPR differential
pressure sensor

(E03) ZAR
(VCPE) NVJ
(PEX) EB6

Engine ECU

SHTS021270300715

1. 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.

<Description of malfunction>
• Exhaust pressure cannot be correctly recognized.
• Possible DPR differential pressure sensor failure or harness +B short

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
(2) Judgement criteria
• Output of the DPR differential pressure sensor remains greater than 4.06 V (84.9 kPa) for 3 seconds or more.

3. Reset condition
• Immediately after normal operation is restored.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
2–802 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is stored after test drive.

8. Estimated failure factors

• Abnormal resistance of sensor
• Harness disconnection or short-circuit
• Looseness or poor contact of connector.
• Malfunction of engine ECU sensor power supply or internal circuit
 ENGINE (J05E)/TROUBLESHOOTING 2–803

INSPECTION PROCEDURE: P1428

1 Inspect the differential pressure sensor connector

1. Check the connection of the differential pressure sensor connector

(looseness and poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 2.

Perform "After-inspection work" of INFOR-
MATION section.

2 Inspect the differential pressure sensor

1. Check the installation of the differential pressure sensor.

2. Make sure there is no dirt, damage or clogging in the sensing unit

of the differential pressure sensor.

Was any failure found?

YES NO

Clean the sensing unit and install it properly. Go to step 3.

If damaged, replace the differential pressure
sensor.
Perform "After-inspection work" of INFOR-
MATION section.
2–804 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the sensor power supply

1. Set the starter key to the "ON" position.

E2 VC
2. 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-
sure sensor vehi-
Starter key: ON cle side connector 4.5 – 5.5 V
VC – E2
E2 PEX – E2
PEX

SHTS021270300716

Do the measurements meet the standard value?

YES NO

Go to step 7. Go to step 4.
 ENGINE (J05E)/TROUBLESHOOTING 2–805

4 Inspect the differential pressure sensor unit

1. Set the starter key to the "LOCK" position.

VC PEX
2. Disconnect the differential pressure sensor connector.

3. Use the electrical tester to measure the resistance between the

terminals of the differential pressure sensor.

Measurement Tester
Standard values
conditions connections

Differential pres-
sure sensor con-
PEX E2 Starter key: LOCK nector 2 – 15 k
VC – PEX
PEX – E2

SHTS021270300717

Do the measurements meet the standard value?

YES NO

Go to step 5. Replace the differential pressure sensor.

Perform "After-inspection work" of INFOR-
MATION section.
2–806 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect for short-circuit of the differential pressure sensor harness

1. Set the starter key to the "LOCK" position.

V46
B V70 2. Connect the signal check harness to the engine ECU vehicle side
V71 harness. (Do not connect the harness to the ECU.)

3. Use the electrical tester to measure the resistance between the

terminals of the engine ECU (signal check harness) and ground.

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

SHTS021270300718 nal check har-
ness)
VCPE (V71) –
Starter key: LOCK Ground 
PEX (V70) –
Ground
E03 (V46) –
Ground

Do the measurements meet the standard value?

YES NO

Go to step 6. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–807

6 Inspect disconnection of the differential pressure sensor harness

1. Connect the differential pressure sensor connector.

B 2. Use the electrical tester to measure the resistance between the

V71 V70 terminals of the engine ECU (signal check harness).

Measurement Tester
Standard values
conditions connections

Engine ECU (sig-

nal check har-
ness)
Starter key: LOCK VCPE (V71) – 2 – 15 k
V46 PEX (V70)
B V70 E03 (V46) –
PEX (V70)

SHTS021270300719

Do the measurements meet the standard value?

YES NO

Go to step 7. Repair or replace the harness.

Perform "After-inspection work" of INFOR-
MATION section.
2–808 ENGINE (J05E)/TROUBLESHOOTING

7 Check the DTC detected (Engine ECU)

1. Perform engine warm up. (engine coolant temperature: 80 C {176

F} or more)

2. Stop the engine and set the starter key to the "LOCK" position.

3. Connect the vehicle to HINO DX Ⅱ .

4. Set the starter key to the "ON" position.

5. Select [Engine] and check if P1428 has been detected.

SHTS021270300720

Has DTC P1428 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–809

DTC: P1458
EN01H02127030602016134

P1458: Valve position control failure - DC motor out of range, functional (EGR actuator
over temp warning level)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300721

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 8 to 16 V.
• There is no disconnection in harness connected to EGR valve.
• Starter key is turned "ON". (Not related to engine speed)
(2) Judgement criteria
• Actual actuator temperature is higher than 150 C {320 F} and lower than 165 C {329 F}, and this condition
continues for 1.6 sec.

3. Reset condition
• Normal operation is restored and accelerator is not being operated.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–810 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal engine room interior temperature
• Abnormal heat rise in motor or element inside EGR actuator.
• Soot adhesion and damage due to hard foreign substances on EGR valve sealing face and gas passageway.
(Hardened carbon may peel off from EGR cooler upstream of EGR valve.)
 ENGINE (J05E)/TROUBLESHOOTING 2–811

INSPECTION PROCEDURE: P1458

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P1458 have been
detected.

SHTS021270300722

Has a DTC other than P1458 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve

1. Check the valve sealing face and gas passageway for soot accu-
mulation and damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 3.

EGR valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
2–812 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300723 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the wire harness (actuator power sup-

ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–813

5 Inspect the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
SHTS021270300724
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace the EGR valve.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
2–814 ENGINE (J05E)/TROUBLESHOOTING

DTC: P1459
EN01H02127030602016135

P1459: Controller high temperature (EGR actuator over temp severe level)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH) relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300725

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F}).
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Battery voltage is in the range of 10 to 16 V.
• The engine stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• Starter key "ON".
(2) Judgement criteria
• Actual actuator temperature is 165 C {329 F}, and this condition continues for 1.6 sec.

3. Reset condition
• Normal operation is restored and accelerator is not being operated.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: ON
• Engine output is restricted.
 ENGINE (J05E)/TROUBLESHOOTING 2–815

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal engine room interior temperature.
• Abnormal heat rise in motor or element inside EGR actuator.
• Soot adhesion and damage due to hard foreign substances on EGR valve sealing face and gas passageway (Hard-
ened carbon may peel off from EGR cooler upstream of EGR valve.)
2–816 ENGINE (J05E)/TROUBLESHOOTING

INSPECTION PROCEDURE: P1459

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P1459 has been
detected.

SHTS021270300726

Has a DTC other than P1459 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve

1. Check the valve sealing face and gas passageway for soot accu-
mulation and damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Remove foreign substances and clean the Go to step 3.

EGR valve.
Replace the EGR valve if it is damaged.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–817

3 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Check the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300727 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the wire harness (actuator power sup-

ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
2–818 ENGINE (J05E)/TROUBLESHOOTING

5 Inspect the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
SHTS021270300728
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace the EGR valve.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–819

DTC: P14B0
EN01H02127030602016136

P14B0: Controller store data error (EGR actuator abnormal information reading)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300729

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• Battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that data stored on the actuator cannot be read occurs 3 times or more in 1 second.

3. Reset condition
• After normal status is resumed and the starter key is turned "LOCK".

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–820 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
 ENGINE (J05E)/TROUBLESHOOTING 2–821

INSPECTION PROCEDURE: P14B0

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P14B0 have been
detected.

SHTS021270300730

Has a DTC other than P14B0 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–822 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300731 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P14B0 have been detected.

SHTS021270300732

Has DTC P14B0 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–823

DTC: P14B2
EN01H02127030602016137

P14B2: EGR controller power supply open circuit

(EGR actuator power supply open circuit)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300733

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When difference in power supply voltage input with 2 systems is at least 1 V, and this condition continues for 2
second.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–824 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged substrate or element inside EGR valve actuator
• Abnormal battery voltage
• Faulty contact in EGR actuator connector
• Disconnection or short-circuit in sensor harness
 ENGINE (J05E)/TROUBLESHOOTING 2–825

INSPECTION PROCEDURE: P14B2

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P14B2 has been
detected.

SHTS021270300734

Has a DTC other than P14B2 been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–826 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300735 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if P14B2 has been detected.

SHTS021270300736

Has DTC P14B2 been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–827

DTC: P14B3 and P14B4

EN01H02127030602016138

P14B3: Battery voltage (high) (EGR actuator power supply too high)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300737

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• Wiping operation from "fully open  fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.

<Description of malfunction>
• Failure message is received from EGR controller.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the actuator power supply voltage is 37 V or more remains for 2 seconds or more.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–828 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal battery voltage.
• Faulty contact in EGR actuator connector.
• Harness disconnection or short-circuit.
 ENGINE (J05E)/TROUBLESHOOTING 2–829

P14B4: Battery voltage (low) (EGR actuator power supply too low)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6
Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E
Y2E Y4J Z90
L2J #E1 #ET

SHTS021270300738

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• Wiping operation from "fully open  fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.

<Description of malfunction>
• Failure message is received from EGR controller.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• The condition that the actuator power supply voltage is less than 7 V remains for 1.06 seconds or more.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–830 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Abnormal battery voltage.
• Faulty contact in EGR actuator connector.
• Disconnection or short-circuit in sensor harness.
 ENGINE (J05E)/TROUBLESHOOTING 2–831

INSPECTION PROCEDURE: P14B3 and P14B4

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than DTC (P14B3 or
P14B4) has been detected.

SHTS021270300739

Has a DTC other than DTC (P14B3 or P14B4) been detected?

YES NO

Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–832 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300740 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, and go to step 4. Check the wire harness (actuator power sup-
ply and ground).
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if the DTC (P14B3 or P14B4) has been
detected.

SHTS021270300741

Has DTC (P14B3 or P14B4) been detected?

YES NO

Replace the ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–833

DTC: P14B7 and P14B8

EN01H02127030602016139

P14B7: EGR valve controller temperature sensor 1 (Signal too low)

(EGR actuator temp. sensor 1 signal too low)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300742

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When temperature of temperature sensor 1 (FET side) inside actuator is -50 C {-58 F} or less, and this con-
dition continues for 2 second.

3. Reset condition
• Normal operation is restored and accelerator is not being operated.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–834 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
 ENGINE (J05E)/TROUBLESHOOTING 2–835

P14B8: EGR valve controller temperature sensor 1 (Signal too high)

(EGR actuator temp. sensor 1 signal too high)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300743

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When temperature of temperature sensor 1 (FET side) inside actuator is at least 200 C {392 F}, and this
condition continues for 2 second.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–836 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
 ENGINE (J05E)/TROUBLESHOOTING 2–837

INSPECTION PROCEDURE: P14B7 and P14B8

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than DTC (P14B7 or
P14B8) has been detected.

SHTS021270300744

Has a DTC other than DTC (P14B7 or P14B8) been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–838 ENGINE (J05E)/TROUBLESHOOTING

3 Check the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300745 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if the DTC (P14B7 or P14B8) has been
detected.

SHTS021270300746

Has DTC (P14B7 or P14B8) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–839

DTC: P14BC and P14BD

EN01H02127030602016140

P14BC: EGR valve controller temperature sensor 2 (Signal too low)

(EGR actuator temp. sensor 2 signal too low)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300747

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When temperature of temperature sensor 2 (CPU side) inside actuator is -50 C {-58 F} or less, and this con-
dition continues for 2 second.

3. Reset condition
• Normal operation is restored and accelerator is not being operated.
2–840 ENGINE (J05E)/TROUBLESHOOTING

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
 ENGINE (J05E)/TROUBLESHOOTING 2–841

P14BD: EGR valve controller temperature sensor 2 (Signal too high)

(EGR actuator temp. sensor 2 signal too high)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300748

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• DTC is issued when failure message is received from EGR actuator unit.

<Description of malfunction>
• EGR actuator system is malfunctioning.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
(2) Judgement criteria
• When temperature of temperature sensor 2 (CPU side) inside actuator is at least 200 C {392 F}, and this
condition continues for 2 second.

3. Reset condition
• Normal operation is restored and accelerator is not being operated.

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.
2–842 ENGINE (J05E)/TROUBLESHOOTING

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
 ENGINE (J05E)/TROUBLESHOOTING 2–843

INSPECTION PROCEDURE: P14BC and P14BD

1 Check the DTC detected 1 (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than DTC (P14BC or
P14BD) has been detected.

SHTS021270300749

Has a DTC other than DTC (P14BC or P14BD) been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.
2–844 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300750 EGR valve vehicle

Starter key: ON side connector 10 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Replace the EGR valve, go to step 4. Check the wire harness (actuator power sup-
ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.

4 Check the DTC detected 2 (Engine ECU)

1. Set the starter key to the "ON" position.

2. Select [Engine] and check if the DTC (P14BC or P14BD) has been
detected.

SHTS021270300751

Has DTC (P14BC or P14BD) been detected?

YES NO

Replace the engine ECU. Procedure completed.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–845

DTC: P14BF
EN01H02127030602016141

P14BF: EGR valve controller temperature sensor 1, 2 - rationality

(EGR actuator temp. sensor 1 performance invalid)
INFORMATION

Engine ECU DCU

(CAN+)

(CAN-)
YM5

YM6

Actuator power
(CANH)

(CANH)
relay
(CANL)

(CANL)
NFB

#XG
NFA

#XV

(L)
X36
VNT EGR
controller actuator
(GND)

(+B)

(E)

(+B)
Y4K

Y4J

Z90

Y2E

Y2E Y4J Z90

L2J #E1 #ET

SHTS021270300752

1. Technical description
• EGR valve is a butterfly type.
• EGR valve opening is controlled by engine speed and amount of intake air.
• EGR valve opening is adjusted by engine ECU and CAN communication.
• EGR valve will not operate when engine coolant temperature is low (≤ 40 C {104 F})
• Wiping operation from "fully open  fully closed" is conducted as an EGR valve surface cleaning operation when
the key is LOCK.

<Description of malfunction>
• Failure message is received from EGR controller.

2. DTC set condition

(1) DTC detection condition
• Starter key "ON".
• The temperature sensor in the actuator 1 (FET side) is in the range of -20 to 170 C {-4 to 338 F}.
• The battery voltage is in the range of 10 to 16 V.
• The engine is stopped, or the engine speed remains at 500 r/min or more for 5 seconds or more.
• The EGR motor drive duty is 3% or less.
(2) Judgement criteria
• The condition that the difference between the temperature sensor 1 in the actuator (FET side) and the tem-
perature sensor in the actuator 2 (CPU side) is 30 C {86 F} or more remains for 2 seconds or more.

3. Reset condition
• After normal status is resumed and accelerator opening is fully closed.
2–846 ENGINE (J05E)/TROUBLESHOOTING

4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

5. 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>

• –

6. Pre-inspection work
• Check that the battery voltage is in the normal range.

7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.

8. Estimated failure factors

• Damaged element inside EGR valve actuator
• Soot adhesion to EGR valve sealing face and gas passageway, and motor abnormal heat rise due to damage
caused by hard foreign substances (Hardened carbon may peel off from EGR cooler upstream of EGR valve.)
*1. If there is no problem with the above, foreign substance damage occurred when the MIL was ON, but at present
the foreign substances are thought to have dropped off and normal operation restored.
*2. This DTC may be detected because there is freezing inside the EGR valve when the outside temperature is low.
When the interior thaws, however, normal operation will be restored.
 ENGINE (J05E)/TROUBLESHOOTING 2–847

INSPECTION PROCEDURE: P14BF

1 Check the DTC detected (Engine ECU)

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX Ⅱ .

3. Set the starter key to the "ON" position.

4. Select [Engine] and check if any DTC other than P14BF has been
detected.

SHTS021270300753

Has a DTC other than P14BF been detected?

YES NO

Go to the diagnostic procedure of a related Go to step 2.

DTC.

2 Inspect the EGR valve

1. Check the valve sealing face and gas passageway for soot buildup
or damage due to foreign substances.

2. Check if there is soot obstructing the exhaust gas passageway

inlet or outlet.

Was any failure found?

YES NO

Removing foreign matter and clean. Go to step 3.

If damaged, replace the EGR valve.
Perform "After-inspection work" of INFOR-
MATION section.
2–848 ENGINE (J05E)/TROUBLESHOOTING

3 Inspect the EGR valve connector

1. Check the connection of the EGR valve connector (looseness and

poor contact).

Was any failure found?

YES NO

Connect securely, repair if needed. Go to step 4.

Perform "After-inspection work" of INFOR-
MATION section.

4 Inspect the EGR valve power supply

1. Set the starter key to the "LOCK" position.

+B E
2. Disconnect the EGR valve connector.

3. Set the starter key to the "ON" position.

4. Use the electrical tester to measure the voltage between the termi-
nals of the EGR valve vehicle side connector.

Measurement Tester
Standard values
conditions connections

SHTS021270300754 EGR valve vehicle

Starter key: ON side connector 8 – 16 V
+B – E

Do the measurements meet the standard value?

YES NO

Go to step 5. Check the wire harness (actuator power sup-

ply and ground) and battery voltage.
Repair or replace parts as needed.
Perform "After-inspection work" of INFOR-
MATION section.
 ENGINE (J05E)/TROUBLESHOOTING 2–849

5 Check the response delay of the EGR valve

1. Select [Inspection Menu] and then [EGR inspection] from the

(1) menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
(3)
(2) ! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)

<Inspection procedure>
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
SHTS021270300755
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.

Standard values

From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.

Do the measurements meet the standard value?

YES NO

Replace the engine ECU. Replace the EGR valve.

Perform "After-inspection work" of INFOR- Perform "After-inspection work" of INFOR-
MATION section. MATION section.
Hino Motors Sales U.S.A., Inc.
41180 Bridge Street, Novi, MI 48375
Telephone: (248) 699-9300
PRINTED IN JAPAN

Pub.No. S7-LXJE12A 1/5 '16. 10