Technical Manual Hitachi 4HK1 Engine Interim Tier 4 Compatible | ETDCA-EN-01

Technical Manual Hitachi 4HK1 Engine Interim Tier 4 Compatible ETDCA-EN-01 (Preview)

ETDCA-EN-01
FOREWORD
0 Introduction (All)
Introduction
safety information
14A Service Information Guide (All)
Contents included in service information
Plastic gauge
Recommended liquid gasket
Thread locking adhesive agent
Term
Abbreviations
Standard bolts
15B Maintenance Information (4HK1)
Maintenance precautions
Primary specifications
Function,Structure,Operation
Introduction to the trouble diagnosis
15C Functional Inspection (4HK1)
Engine compression pressure inspection
Fuel system check
Lubrication system check
Air intake system check
Exhaust system check
DPD control system check
EGR control system check
Starting system check
Glow control system check
OBD system check
Inspection of the diagnostic light warning light illumination circuit system
Inspection of the diagnostic light warning light blinking circuit system
Inspection of the starter circuit system
15D Symptom (4HK1)
Engine start failure
Engine stalling
Engine hunching,rough idling
Excessive white smoke in the exhaust gas
Excessive black smoke in the exhaust gas
Abnormal noise
Large fuel consumption
Large oil consumption
Insufficient engine output
DPD system manual regeneration frequently
DPD system regeneration long time
15E DTC Information (4HK1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
DTC U0110 (Flash Code 87) Lost Communication with VNT System
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction
DTC mapping table
1A Engine Control (4HK1)
DTC P0016 (Flash Code 16) Crankshaft Position -Camshaft Position Correlation
DTC P0045 (Flash Code 33) Turbocharger Boost Control Solenoid Circuit
DTC P0087 (Flash Code 225) Fuel Rail/System Pressure -Too Low
DTC P0088 (Flash Code 118) Fuel Rail/System Pressure -Too High
DTC P0089 (Flash Code 151) Fuel Pressure Regulator Performance
DTC P0091 (Flash Code 247) Fuel Pressure Regulator Control Circuit Low
DTC P0092 (Flash Code 247) Fuel Pressure Regulator Control Circuit High
DTC P0093 (Flash Code 227) Fuel System Leak Detected
DTC P0102 (Flash Code 91) Mass Air Flow Circuit Low Input
DTC P0103 (Flash Code 91) Mass Air Flow Circuit High Input
DTC P0112 (Flash Code 22) Intake Air Temperature Sensor Circuit Low
DTC P0113 (Flash Code 22) Intake Air Temperature Sensor Circuit High
DTC P0117 (Flash Code 23) Engine Coolant Temperature Sensor Circuit Low
DTC P0118 (Flash Code 23) Engine Coolant Temperature Sensor Circuit High
DTC P0122 (Flash Code 43) Throttle Position Sensor Circuit Low
DTC P0123 (Flash Code 43) Throttle Position Sensor Circuit High
DTC P0182 (Flash Code 211) Fuel Temperature Sensor Circuit Low
DTC P0183 (Flash Code 211) Fuel Temperature Sensor Circuit High
DTC P0192 (Flash Code 245) Fuel Rail Pressure Sensor Circuit Low
DTC P0193 (Flash Code 245) Fuel Rail Pressure Sensor Circuit High
DTC P0201 (Flash Code 271) Injector Circuit -Cylinder 1
DTC P0202 (Flash Code 272) Injector Circuit -Cylinder 2
DTC P0203 (Flash Code 273) Injector Circuit -Cylinder 3
DTC P0204 (Flash Code 274) Injector Circuit -Cylinder 4
DTC P0217 (Flash Code 542) Engine Coolant Over Temperature Condition
DTC P0219 (Flash Code 543) Engine Overspeed Condition
DTC P0234 (Flash Code 42) Turbocharger Overboost Condition
DTC P0237 (Flash Code 32) Turbocharger Boost Sensor Circuit Low
DTC P0238 (Flash Code 32) Turbocharger Boost Sensor Circuit High
DTC P0335 (Flash Code 15) Crankshaft Position Sensor Circuit
DTC P0336 (Flash Code 15) Crankshaft Position Sensor Circuit Range/Performance
DTC P0340 (Flash Code 14) Camshaft Position Sensor Circuit
DTC P0404 (Flash Code 45) Exhaust Gas Recirculation 1 Control Circuit Range/Performance
DTC P0409 (Flash Code 44) Exhaust Gas Recirculation 1 Sensor Circuit
DTC P041C (Flash Code 27) Intake Manifold Temperature Sensor Circuit High
DTC P041D (Flash Code 27) Intake Manifold Temperature Sensor Circuit Low
DTC P0426 (Flash Code 143) Catalyst Temperature Sensor Circuit Range/Performance Sensor 1
DTC P0427 (Flash Code 48) Catalyst Temperature Sensor Circuit Low Sensor 1
DTC P0428 (Flash Code 48) Catalyst Temperature Sensor Circuit High Sensor 1
DTC P042B (Flash Code 145) Catalyst Temperature Sensor Circuit Range/Performance Sensor 2
DTC P042C (Flash Code 49) Catalyst Temperature Sensor Circuit Low Sensor 2
DTC P042D (Flash Code 49) Catalyst Temperature Sensor Circuit High Sensor 2
DTC P0522 (Flash Code 295) Oil Pressure Sensor Circuit Low
DTC P0523 (Flash Code 295) Oil Pressure Sensor Circuit High
DTC P0560 (Flash Code 155) System Voltage
DTC P0563 (Flash Code 35) System Voltage High
DTC P0601 (Flash Code 53) Internal Control Module Memory Check Sum Error
DTC P0602 (Flash Code 154) Control Module Programming Error
DTC P0604 (Flash Code 153) Internal Control Module Random Access Memory (RAM)Error
DTC P0606 (Flash Code 51) ECM/PCM Processor
DTC P060B (Flash Code 36) Internal Control Module A/D Processing Performance
DTC P0638 (Flash Code 61) Throttle Actuator Control Range/Performance
DTC P0641 (Flash Code 55) Sensor Reference Voltage 1 Circuit
DTC P0650 (Flash Code 77) Malfunction Indicator Lamp (MIL)Control Circuit
DTC P0651 (Flash Code 56) Sensor Reference Voltage 2 Circuit
DTC P0685 (Flash Code 416) ECM/PCM Power Relay Control Circuit/Open
DTC P0687 (Flash Code 416) ECM/PCM Power Relay Control Circuit High
DTC P0697 (Flash Code 57) Sensor Reference Voltage 3 Circuit
DTC P1093 (Flash Code 227) Fuel Rail Pressure (FRP)Too Low
DTC P1112 (Flash Code 295) Boost Temperature Sensor Circuit Low
DTC P1113 (Flash Code 295) Boost Temperature Sensor Circuit High
DTC P1261 (Flash Code 34) Injector Positive Voltage Control Circuit Group 1
DTC P1262 (Flash Code 34) Injector Positive Voltage Control Circuit Group 2
DTC P1293 (Flash Code 221) Fuel Filter Pressure Sensor Circuit Low
DTC P1294 (Flash Code 221) Fuel Filter Pressure Sensor Circuit High
DTC P1404 (Flash Code 45) Exhaust Gas Recirculation 1 Closed Position Performance
DTC P1455 (Flash Code 132) PM Over Accumulation
DTC P1471 (Flash Code 149) DPD Insufficient Regeneration
DTC P1621 (Flash Code 54) Control Module Long Term Memory Performance
DTC P1655 (Flash Code 59) Sensor Reference Voltage 4 Circuit
DTC P1669 (Flash Code 75) DPD Lamp Control Circuit
DTC P2122 (Flash Code 121) Pedal Position Sensor 1 Circuit Low Input
DTC P2123 (Flash Code 121) Pedal Position Sensor 1 Circuit High Input
DTC P2127 (Flash Code 122) Pedal Position Sensor 2 Circuit Low Input
DTC P2128 (Flash Code 122) Pedal Position Sensor 2 Circuit High Input
DTC P2138 (Flash Code 124) Pedal Position Sensor 1 -2 Voltage Correlation
DTC P2146 (Flash Code 158) Fuel Injector Group 1 Supply Voltage Circuit
DTC P2149 (Flash Code 159) Fuel Injector Group 2 Supply Voltage Circuit
DTC P2228 (Flash Code 71) Barometric Pressure Circuit Low
DTC P2229 (Flash Code 71) Barometric Pressure Circuit High
DTC P242F (Flash Code 131) DPD Restriction
DTC P2452 (Flash Code 142) DPD Differential Pressure Sensor Circuit
DTC P2453 (Flash Code 141) DPD Differential Pressure Sensor Circuit Range/Performance
DTC P2454 (Flash Code 47) DPD Differential Pressure Sensor Circuit Low
DTC P2455 (Flash Code 47) DPD Differential Pressure Sensor Circuit High
DTC P2456 (Flash Code 47) DPD Differential Pressure Sensor Learned Position
DTC P2458 (Flash Code 139) DPD Regeneration Duration
DTC U0001 (Flash Code 84) CAN-Bus Malfunction (ISO-CAN)
DTC U0073 (Flash Code 84) CAN-Bus Malfunction (J1939)
DTC U0101 (Flash Code 85) Lost Communication with TCM
DTC U0110 (Flash Code 87) Lost Communication with VNT System
DTC U0411 (Flash code 87) Turbo Charger Control Module Signal Malfunction
Wiring Diagram
Using the Wiring Diagram
Structure and Content of This Document
1. Wiring Diagram
2. Location Diagram
3. Connector Information
4. Terminal Name
5. Circuit Symbols
6. Abbreviations
Engine
Engine Control
Location Diagram
Connector Location Diagram
Connector List
T …（Connector List ）
H …（Connector List ）
S …（Connector List ）
Terminal Name
Terminal Name
SERVICE MANUAL REVISION REQUEST FORM