Documentos de Académico
Documentos de Profesional
Documentos de Cultura
00400041EB
Revision History
Date
2007.09
Revision Contents
Basic CRS content omitted, March 2007 model CRS content added. Items added
are as per the following:
Applicable Vehicles and Product Information
Main Components and Sensors
Exhaust Gas Control System (DPF System)
Engine ECU Diagnostic Trouble Codes (DTC)
Engine ECU External Wiring Diagram and Connector Terminal Layout
2010.05
March 2010 model CRS content added. Items added are as per the following:
Applicable Vehicles and Product Information
CRS Outline (Diagram)
Supply Pump
Rail
Injector
Engine ECU
Selective Catalytic Reduction (SCR) System
Engine ECU Diagnostic Trouble Codes (DTC)
Engine ECU External Wiring Diagrams and Connector Terminal Layout
Table of Contents
Operation Section
1. APPLICABLE VEHICLE AND PRODUCT INFORMATION
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2
1.3
3. SUPPLY PUMP
3.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
3.2
3.3
4. RAIL
4.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
5. INJECTOR
5.1
Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
6. CONTROL SYSTEM
6.1
6.2
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
7.2
7.3
9. ATTACHED MATERIALS
9.1
9.2
Operation Section
1 1
Vehicle Model
Engine Model
Engine
Displacement
Release Date
HINO145
HINO165
J05D
4.73 L
HINO185
Medium Truck
April 2004
HINO238
HINO268
HINO308
HINO338
J08E
7.68 L
Operation Section
1 2
2007 model
Vehicle Type
Vehicle Model
Engine Model
Engine
Release Date
Displacement
HINO145
HINO165
J05D
4.73 L
HINO185
Medium Truck
March 2007
HINO238
HINO258
J08E
HINO268
7.68 L
HINO338
2010 model
Vehicle Type
Vehicle Model
Engine Model
Engine
Release Date
Displacement
HINO238
Medium Truck
HINO258
J08E
HINO268
7.68 L
June 2010
HINO338
Manufacturer
Remarks
Part Number
294000-025#
S2273-01321
J05D, HP3
294050-001#
S2273-01311
J08E, HP4
095440-053#
S2276-01221
J05D
095440-048#
S2276-01181
J08E
095000-539#
S2391-01311
J05D, G2
095000-528#
S2391-01361
J08E, G2
Engine ECU
102758-301#
S8956-06540
198800-316#
S7801-E0010
071560-011#
S8342-01250
029600-057#
S8941-11280
949979-136#
S8941-01590
J08E
949979-131#
S8941-01570
J05D
079800-589#
S8939-01080
135000-707#
S1735-01210
135000-709#
S1735-01220
197400-200#
22204-21010
Supply Pump
Rail
Injector
J05D,
2004
Model
2004
Model
Only
J08E,
Only
For EGR Control
Operation Section
1 3
2007 model
Part Name
Supply Pump
Rail
Manufacturer
294000-065#
22100-E0110
J05D, HP3
294050-015#
22100-E0101
J08E, HP4
095440-125#
23810-E0130
J05E
095440-124#
23810-E0120
J08D
095000-692#
23670-E0231
095000-681#
23670-E0201
275800-422#
89661-E0030
Without Bracket
102758-422#
98660-E0100
With Bracket
198800-316#
S7801-E0010
949979-131#
S8941-01570
J05D
949979-136#
S8941-01590
J08E
029600-057#
S8941-11280
079800-589#
S8939-01080
104990-106#
S8939-01090
DPF
265600-060#
S8944-16511
Injector
Engine ECU
Accelerator Pedal Module
Crankshaft Position Sensor
Camshaft Position Sensor
Manifold
Absolute
Pressure
(MAP) Sensor
Differential Pressure Sensor
Exhaust
Gas
Temperature
Sensor
Remarks
Part Number
J05D, G2
Four Injectors
J08E, G2
Six Injectors
2010 model
Part Name
Manufacturer
Remarks
Part Number
Supply Pump
294050-036#
22100-E0351-B
Rail
095440-156#
23810-E0170
Injector
294050-023#
23670-E0400
G3
Engine ECU
112500-100#
89661-E0041
198800-316#
78010-E0010
029600-057#
S8941-11280-A
079800-941#
89421-E0050
104990-106#
S8939-01090-B
072800-040#
89424-E0030
Manifold
Absolute
Pressure
(MAP) Sensor
HP4
1 4
Operation Section
Operation Section
1 5
2010 model
The fuel flow path in the 2010 model year CRS has changed as per the figure below to inhibit air mixing.
1 6
Operation Section
3. SUPPLY PUMP
3.1 Outline
The HP3 and HP4 supply pumps have the same construction and operational characteristics as the
conventional supply pumps. Supply pumps place fuel suctioned from the fuel tank under high pressure for
delivery to the rail.
A feed pump outlet, and pump inlet have been added to the 2010 model supply pump to inhibit air mixing.
As a result of this change, the fuel flow has been altered to travel through the following path: main filter, feed
pump, bubble separator, pump unit.
HP3 (294000-025#)
HP4 (294050-001#)
Operation Section
HP3 (294000-065#)
HP4 (294050-015#)
HP4 (294050-036#)
1 7
1 8
Operation Section
Operation Section
1 9
1 10
Operation Section
Operation Section
1 11
4. RAIL
4.1 Outline
The construction and operational characteristics of the rail equipped with the J05D/J08E engines are
identical to the conventional rail. The rail distributes fuel delivered from the supply pump to each injector.
The rail detailed herein is equipped with both a pressure limiter and pressure sensor.
In the 2010 model CRS, the rail pressure sensor and flow damper have changed.
1 12
Operation Section
Operation Section
1 13
1 14
Operation Section
5. INJECTOR
5.1 Outline
The 2004 and 2007 model year CRSs use G2 injectors. The construction and operational characteristics of
the G2 injectors are identical to the conventional injector. The G2 injector injects fuel into the engine
combustion chamber in accordance with signals from the engine ECU.
As of the 2007 model year CRS, the injectors use a mutli-hole filter.
The 2010 model year CRS uses G3 injectors. G3 injectors are compliant with a pressure of 200 MPa, and
show improved responsiveness, as well as an increased resistance to foreign material adherence.
Operation Section
1 15
1 16
Operation Section
Operation Section
1 17
1 18
Operation Section
6. CONTROL SYSTEM
6.1 Engine ECU
2004, 2007 model
The construction and operational characteristics of the engine ECU equipped with the J05D/J08E engines
are identical to the conventional engine ECU. The engine ECU determines engine status based on signals
from each sensor. The engine ECU then controls various actuators so that the engine runs under optimal
conditions.
Operation Section
2010 model
The 2010 model year engine ECU mounts directly to the engine (direct mount type.)
1 19
1 20
Operation Section
6.2 Sensors
(1) Crankshaft position sensor and camshaft position sensor
The construction and operational characteristics of both the crankshaft position sensor and camshaft
position sensor equipped with the J05D/J08E engines are identical to the conventional sensors.
Crankshaft position sensor
A Magnetic Pick Up (MPU) type sensor is attached to the flywheel housing. Pulses are detected when
the signal holes established on the side of the flywheel pass the sensor.
Signal holes are established every 6 on the side of the flywheel. However, there are no signal holes in
four locations. As a result, there are 56 signal holes on the outer diameter of the flywheel, resulting in
the detection of 112 pulses for every two revolutions of the flywheel.
Operation Section
Pulse Chart
1 21
1 22
Operation Section
Operation Section
1 23
1 24
Operation Section
Operation Section
1 25
The MAF meter is installed to the rear of the air cleaner, and consists of a heater, thermometer, intake air
temperature sensor, and control circuit (base). The MAF meter diverts a portion of the air from the cleaner,
and measures the intake air flow at the hot-wire measuring section.
1 26
Operation Section
Operation Section
1 27
(1) Control
In the DPF system regeneration mode, a post-injection is added to the normal injection pattern (pilotinjection, main-injection, after-injection). After-injection causes exhaust temperature to increase,
promoting PM oxidation. Catalyst temperature is increased to the self-ignition temperature for PM by the
post-injection, causing the PM accumulated in the filter to combust.
1 28
Operation Section
Operation Section
1 29
SCR
The SCR is a urea selective type reduction catalyst. Urea is used to chemically decompose and convert the
NOx contained in the exhaust gas into non-hazardous materials. Urea is added to the exhaust gas via
injection, causing NOx decomposition. The resulting non-hazardous water (H20) and nitrogen gas (N2) are
then discharged.
Operation Section
1 30
Detection Item
Code
P0045
Variable
Nozzle Turbo
Pressure
Control
Rail
P0088
High-Pressure
Abnormality
(Pressure
Continuously
Above
Standard Value or Pressure include faulty contacts in the rail pressure sensor
Momentarily
Abnormally High)
P0102
Remarks
Malfunction
Rail
P0087
DTC Description
P0103
P0108
detected.
Possible
causes
include
sensor
P0112
Intake
Air
Temperature detected.
Possible
causes
include
sensor
P0113
Intake
Air
Temperature detected.
Possible
causes
include
sensor
P0117
Possible
causes
include
sensor
Operation Section
DTC
Detection Item
Code
DTC Description
Remarks
Possible
causes
include
sensor
Malfunction (Hi)
wiring harness.
Electronic
P0122
Control
Throttle
P0123
Electronic
Control
Malfunction (Hi)
P0182
Fuel
Temperature
Malfunction (Lo)
Sensor detected.
Possible
causes
include
sensor
P0183
Fuel
Temperature
Malfunction (Hi)
Sensor detected.
Possible
causes
include
sensor
P0191
Rail Pressure Sensor Malfunction Issued when rail pressure cannot be correctly
(Abnormal
Sensor detected. Possibility of a sensor malfunction.
Characteristics)
Rail
Pressure
Malfunction (Lo)
Sensor detected.
Possible
causes
include
sensor
P0193
Rail
Pressure
Malfunction (Hi)
Sensor detected.
Possible
causes
include
sensor
P0200
Faulty Engine ECU Charge Issued when the injector activation voltage is too
Circuit (Hi)
P0201
P0202
P0203
P0204
1 31
Operation Section
1 32
DTC
Detection Item
Code
P0205
P0206
P0217
Overheat
P0219
Engine Overrun
P0234
Turbo Overboost
(MAP)
Sensor
Malfunction
(Lo)
Cylinder
P0263
DTC Description
Correction Error #1 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Cylinder
P0266
Correction Error #2 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Cylinder
P0269
Correction Error #3 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Cylinder
P0272
Correction Error #4 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Cylinder
P0275
Correction Error #5 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Cylinder
P0278
Correction Error #6 (Cylinder larger than the other cylinders. There is a possibility
Injection Quantity, Rotational that the flow damper is operating.
Fluctuation)
Crankshaft Position Sensor Issued when the pulse from the crankshaft position
P0335
and
Camshaft
Sensor Malfunction
Remarks
Operation Section
DTC
Detection Item
Code
P0336
P0340
P0341
DTC Description
Position
Sensor
Malfunction
Camshaft
1 33
Remarks
Position
Sensor
P0400
Excessive
Exhaust
Gas
P0400
P0501
Vehicle
Speed
Sensor
Malfunction (Lo)
Vehicle
Speed
Sensor
Malfunction (Hi)
P0504
P0510
P0524
Engine
Oil
Abnormality
Preheat Device Malfunction Issued
P0540
(Ground
Short,
+B
when
the
intake
heater
relay
is
Open)
Exhaust
Gas
Temperature detected.
Possible
causes
include
sensor
Vehicles
with
DPF
Installed
Operation Section
1 34
DTC
Detection Item
Code
DTC Description
Remarks
Exhaust
Gas
Temperature detected.
Possible
causes
include
sensor
wiring harness.
P0605
P0606
P0607
P0611
ECU
ECU
Monitor
Abnormality
Faulty Engine ECU Charge Issued when injector activation voltage is too low.
Circuit (Lo)
P0617
P0628
P0629
SCV +B Short
P0686
P0704
P0850
Vehicle-External
P1133
Accelerator Issued
when
the
vehicle-external
accelerator
(Hi)
P1211
Injector
Common
Short
P1212
P1212
and wiring.
Possible open or short circuit to +B. Check the
injector and wiring.
Possible open or short circuit to +B. Check the
injector and wiring.
Vehicles
with
DPF
Installed
Operation Section
DTC
Detection Item
Code
P1214
Injector
Common
DTC Description
1 35
Remarks
Short
and wiring.
P1215
P1215
Malfunction
Sensor Characteristics)
DPF
P1427
Possible
causes
include
sensor
Malfunction (Lo)
wiring harness.
Issued when exhaust pressure cannot be correctly
P1428
Possible
causes
include
sensor
Malfunction (Hi)
harness.
P1458
P1459
P1530
when
the
engine
stop
switch
Vehicles
with
DPF
Installed
Vehicles
with
DPF
Installed
is
Engine Stop Switch Closing malfunctioning or there is short circuit in the wiring.
Monitor switch status and check the ON/OFF
Malfunction
judgment.
P1601
P1601
P1601
QR
Code
(Unreadable)
QR
Code
the QR code.
Malfunction Issued when there is an error in the QR code. Check
(EEPROM Error)
QR Code Malfunction (Out of Issued when there is an error in the QR code. Check
Range)
Exhaust Brake Solenoid Valve
P1681
the QR code.
the QR code.
Issued when the exhaust brake solenoid valve is
malfunctioning. Possible causes include a solenoid
valve malfunction, and/or an open/short circuit to
ground in the wiring harness.
Issued when the exhaust brake solenoid valve is
P1682
P2002
Vehicles
with
DPF
Installed
Vehicles
with
DPF
Installed
DPF
Installed
Operation Section
1 36
DTC
Detection Item
Code
DTC Description
Remarks
Exhaust
Gas
Temperature detected.
Possible
causes
include
sensor
P2033
Exhaust
Gas
Temperature detected.
Possible
causes
include
sensor
Vehicles
with
DPF
Installed
Vehicles
with
DPF
Installed
P2080
Exhaust
Gas
Temperature
Sensor
Malfunction
(Abnormal
Sensor
Characteristics)
DPF
P2084
Exhaust
Gas
Temperature
Sensor
Malfunction
(Abnormal
Sensor
Characteristics)
Electronic
P2100
Ground
Control
Short
P2101
Electronic
Control
Seizure
is detected.
Possible causes include an open circuit in the wiring
P2103
Electronic
Control
Open Circuit
P2120
P2122
P2123
P2127
DPF
Operation Section
DTC
Detection Item
Code
P2128
DTC Description
Remarks
P2228
Malfunction (Lo)
Malfunction (Hi)
SCV Seizure
P2635
Pump Replacement
U0073
U0101
U0101
U0104
U0121
U0132
U0155
U1001
U1122
(ABS)
Communication
lost.
Disruption Issued when communication with the air suspension
(Air Suspension)
Communication
ECU is lost.
Disruption Issued when communication with the meter ECU is
(Meter)
lost.
ECU is lost.
ECU is lost
(Cruise)
Communication
(Transmission)
Communication
(Automatic Transmission)
Disruption Detected
when
there
is
communication
U1123
Communication
(VNT)
Disruption control
unit,
or
short/open
circuit
in
the
1 37
1 38
Operation Section
Detection Item
Crank/Cam Signal Synchronization Error
DIAG Information 1 from Variable Nozzle Turbo (VNT)
P0045
Controller
DIAG Information 2 from VNT Controller
Intercooler Temperature Sensor Performance Invalid
(Cranking)
P007B
P007C
P007D
P0087
P0088
P0096
P0097
P0098
P00AF
P0101
P0104
P0106
P0108
P0112
P0113
Remarks
Operation Section
DTC Code
P0116
Detection Item
Coolant Temperature Sensor Performance Invalid 1
Coolant Temperature Sensor Performance Invalid 2
P0117
P0118
P011C
P0122
P0123
P0128
Thermostat Failure
P0182
P0183
P0192
P0193
P0200
P0201
P0202
P0203
P0204
P0205
P0206
P0217
P0219
Engine Overrun
P0222
P0223
P0234
P0237
P0263
P0266
P0269
P0272
Remarks
1 39
1 40
Operation Section
DTC Code
P0275
P0278
Detection Item
Flow Damper #6 Activated
Cylinder 6 Fuel System Failure
Flow Damper #4 Activated
Cylinder 4 Fuel System Failure
P0299
P0300
P0301
#1 Misfire
P0302
#3 Misfire
P0303
#5 Misfire
P0304
#2 Misfire
P0305
#6 Misfire
P0306
#4 Misfire
P0335
P0336
P0340
P0341
P0381
P0401
P0402
P041B
P041C
P041D
P0420
P0500
P0501
P0504
P0519
P0524
P0562
P0563
P05F1
Remarks
Operation Section
DTC Code
Detection Item
P0605
P0606
P0607
P0610
P0611
P0617
P0628
P0629
P0642
P0643
P064C
P0652
P0653
P0671
P0672
P0675
P0676
P0683
P0686
P06D3
P06D4
P0704
P073D
P081A
P081B
P0850
P1133
P1197
P1198
Remarks
1 41
1 42
Operation Section
DTC Code
P119F
P1211
Detection Item
Rail Pressure Sensor Signal Rationality Check
COM1 Output Short to GND; TWV1, 3, or 5 Output Short to
GND
COM1 Output Short to Battery; TWV1, 3, or 5 Output Short to
P1212
Battery
COM1 Output Open Load; TWV1, 3 and 5 Open Load
P1214
P1215
Battery
COM1 Output Open Load; TWV2, 4 and 6 Open Load
Thermal Regenerator (BCU) Failure 1
P141F
P1426
P1427
P1428
P1458
P1459
P1515
P1530
P1601
QR Data Error
QR Definition Error (Definition Concerning QR Correction is
Incorrect)
P1676
P1681
P1682
P200C
P203F
Remarks
Operation Section
DTC Code
Detection Item
Dosing System Failure 1
Dosing System Failure 2
Dosing System Failure 3
Dosing System Failure 4
Dosing System Failure 5
Dosing System Failure 6
P204F
P207F
P20EE
P2100
P2101
P2103
P2120
P2122
P2123
P2127
P2128
P2135
P2138
P2214
P2227
P2228
P2229
P2269
Water in Fuel
P226C
P240F
Remarks
1 43
1 44
Operation Section
DTC Code
Detection Item
Exhaust Gas Catalyst Temperature 0 Sensor Performance
P242B
Malfunction (Cranking)
Exhaust Gas Catalyst Temperature 0 Sensor Performance
Malfunction (Driving)
P242C
P242D
P244A
P244B
DPF Choked 2
DPF Regeneration Incomplete
P2457
P2459
P2463
DPF Choked 1
Exhaust Gas Catalyst Temperature 2 Sensor: Performance
P246F
Malfunction (Cranking)
Exhaust Gas Catalyst Temperature 2 Sensor: Performance
Malfunction (Driving)
P2470
P2471
P2635
U0073
U010E
U029D
U029E
U1001
U110A
U111E
U1122
U1123
Remarks
Operation Section
9. ATTACHED MATERIALS
9.1 Engine ECU External Wiring Diagrams
2004 Model
1 45
1 46
Operation Section
2007 Model
Operation Section
1 47
1 48
Operation Section
Operation Section
1 49
Code
Terminal Description
Remarks
(GND)
(GND)
IN3
IN3-
+B
Power
+B
Power
+B
Power
TAC1
TAC2
10
POUT1
11
POUT2
12
POUT3
13
POUT4
14
PIN1
15
PIN2
16
17
(BATT)
18
(CASE GND)
19
KWP2000
ISO9141-K
20
IN1
21
AD1
22
AD2
23
AD10
24
AD12
25
AD19
26
AD20
Operation Section
1 50
No.
Code
Terminal Description
27
VS1
28
CASE GND
Case ground
29
IN2
30
AD14
IMC volume
31
AD15
32
AD16
33
AD17
34
AD18
35
+BF
+BF
36
OUT5
37
OUT6
38
OUT7
39
NE-SLD
40
NE+
41
NE-
42
OUT1
43
OUT2
44
OUT3
45
OUT4
46
SW1
Key switch
47
OUT8
48
SW2
Starter switch
49
SW3
50
SW4
51
SW5
52
SW6
53
SW7
Brake switch
54
A-GND4
Sensor ground 4
55
A-GND5
Sensor ground 5
56
SW1
Key switch
57
A-VCC4
58
SW8
59
SW10
60
SW12
61
SW17
62
AD21
63
AD22
64
65
A-VCC5
Remarks
Operation Section
No.
Code
Terminal Description
1 51
Remarks
66
SW9
Neutral switch
67
SW11
68
SW16
Diagnosis switch
69
SW18
70
OUT19
Glow relay
71
OUT20
Glow relay
72
GND
73
GND
74
OUT17
75
OUT18
76
+BF
+BF
77
SW27
Clutch switch
78
SW19
79
SW14
Cruise switch 2
80
SW15
81
SW24
Idle-up switch
82
S-OUT1
83
S-OUT2
84
S-OUT3
85
S-OUT4
86
87
SW31
AT identification signal
88
SW20
PTO 2 switch
89
SW21
PTO switch
90
SW25
91
SW26
92
SW13
Cruise switch 1
93
SW28
94
SW29
95
CANH
CAN 2 high
96
CANL
CAN 2 low
97
SW32
98
SW22
Warm-up switch
99
SW23
100
SW30
101
CAN-SLD
102
P-GND
Power ground
103
TWV1
104
TWV3
Operation Section
1 52
No.
Code
Terminal Description
105
TWV5
106
COMMON1
107
COMMON1
108
OUT9
109
OUT10
110
OUT11
111
OUT12
112
OUT13
Cruise light
113
OUT14
114
OUT15
115
OUT16
116
117
118
A-GND6
119
NE (MRE)
120
121
AD4
122
AD11
MAF meter
123
A-VCC3
124
NE-VCC
125
A-VCC2
126
A-VCC1
127
AD13
128
AD3
129
(GND)
130
(GND)
131
G-GND
132
AD5
133
G-VCC
134
A-GND1
Sensor ground 1
135
A-GND2
Sensor ground 2
136
A-GND3
Sensor ground 3
137
TWV2
138
TWV4
139
TWV6
140
P-GND
Power ground
141
P-GND
Power ground
142
COMMON2
143
COMMON2
Remarks
J08E engine only
Operation Section
No.
Code
Terminal Description
144
SCVLO
145
SCVLO
146
SCVHI
SCV power
147
SCVHI
SCV power
148
149
150
PCV2
151
PCV2
152
PCV1
153
PCV1
154
AD6
155
AD7
156
157
CAN1H
CAN 1 high
158
CAN1L
CAN 1 low
159
160
161
(CASE GND)
162
AD8
163
AD9
164
165
CAN1-SLD
166
167
(CASE GND)
PATM
Remarks
1 53
1 54
Operation Section