UntukDENSOResmiECDLayananDealerHanya

InjectionDieselPump

SERVICEMANUAL
RailSistemumumuntukHINOJ05D/J08E
JenisMesin
OPERASI
00400041E
-1

Oktober2003

DAFTARISI
1.ProdukAplikasi-------------------------------------------------------------------------------------1
1.1Aplikasi-------------------------------------------------------------------------------------------------------------------11.2
KomponenSistemBagianNomor---------------------------------------------------------------------------------12.Garis
------------------------------------------------------------------------------------------------------2
2.1FiturSistem-------------------------------------------------------------------------------------------------------
Karakteristik2[1]Sistem------------------------------------------------------------------------------------------------2[2]
PerbandingandenganKonvensionalsistem-------------------------------------------------------------------------32.2Garis
BesarSistem----------------------------------------------------------------------------------------------------------4[1]
Komposisi--------------------------------------------------------------------------------------------------------------4[2]
Operasi-----------------------------------------------------------------------------------------------------------------42.3Sistem
BahanBakardanSistemPengendalian--------------------------------------------------------------------------------------5
[3]SistemBahanBakar---------------------------------------------------------------------
-----------------------------------------5[4]SistemPengendalian-----------------------------------------------------
-----------------------------------------------------53.KonstruksidanOperasi-----------------------------------------
----------------------------------6
3.1DeskripsiKomponenUtama-------------------------------------------------------------------------------------6[1]
PasokanPompa(HP3,HP4)---------------------------------------------------------------------------------------------6[2]
DeskripsiPasokanpompaKomponen------------------------------------------------------------------------13[3]Rail
--------------------------------------------------------------------------------------------------------------------------16[4]
Injector(G2Type)-------------------------------------------------------------------------------------------------------17[5]
MesinECU(ElectronicControlunit)-----------------------------------------------------------------------------223.2
DeskripsiControlSystemKomponen------------------------------------------------------------------------22[1]Sistem
EngineControlDiagram------------------------------------------------------------------------------------22[2]Sensordan
Relay-----------------------------------------------------------------------------------------------------233.3BerbagaiJenis
Kontrol-----------------------------------------------------------------------------------------------29[1]FuelInjectionRate
Control-------------------------------------------------------------------------------------------30[2]FuelInjectionQuantity
Kontrol---------------------------------------------------------------------------------------31[3]FuelInjectionTiming
Kontrol-----------------------------------------------------------------------------------------353.4lainMesinrelevan
Kontrol-----------------------------------------------------------------------------------------36[1]EGRKontrol
--------------------------------------------------------------------------------------------------------------363.5MesinECU
-----------------------------------------------------------------------------------------------------------------37[1]Kode
Diagnosis--------------------------------------------------------------------------------------------------------37[2]ECU
EksternalWiringDiagram---------------------------------------------------------------------------------------44[3]ECU
ConnectorDiagram----------------------------------------------------------------------------------------------45
0

1.ProdukAplikasi1.1Aplikasi
KendaraanNamaKendaraanModelMesinModelExhaustVolumeReferensi
HINO145,MediumTruckHINO185
1,2KomponenSistemBagianNomor
HINO165,
J05D4.73L
PenjualandariHINO238,
HINO268,HINO308,HINO338
J08E7.68L
Awal'04
BagianNama
KendaraanNama
DENSOBagianNomor
MobilProdusenPartNomor
Referensi
PasokanPompa
MediumTruckHINO238,HINO268,HINO308,HINO338
294.050-0.01122730-1311A
Injector095.000-528123910-1360A
Rail095.440-0.48022760-1180A
mesinECU102758-301089560-6540A
AcceleratorPositionSensor198.800-3.16078010-1200A
PendinginTemp.Sensor071560-011083420-1250A
CrankshaftPositionSensor029.600-0.57089410-1280A
CylinderPengakuansensor949.979-1.36089410-1590A
IntakeAirPressureSensor079.800-5.89089390-1080A
EGRValve135.000-709117350-1220A
AirFlowMeter197.400-2.00022204-21010B
UntukKontrol
EGR
PasokanPompa
MediumTruckHINO145,HINO165,HINO185
294.000-0.25122730-1321A
Injector095.000-539123910-1310A
Rail095.440-0.53022760-1220A
MesinECU102.758-3.01089560-6540A
AcceleratorPositionSensor198.800-3.16078010-1200A
CoolantTemp.Sensor071560-011083420-1250A
CrankshaftPositionSensor029.600-0.57089410-1280A
CylinderPengakuansensor949.979-1.36089410-1590A
IntakeAirPressureSensor079.800-5.89089390-1080A
EGRValve135.000-707117350-1210A
AirFlowMeter197.400-2.00022204-21010B
untukKontrol
EGR
1

2.Outline2.1Fitursystem
sistemcommonraildikembangkanterutamauntukmengatasiperaturangasbuanguntukmesin
diesel,danbertujuanuntuk1.lebihditingkatkanekonomibahanbakar;Pengurangan2.
kebisingan;dan3.outputdayatinggi.[1]KarakteristikSistem
Sistemcommonrailmenggunakanjenisruangakumulasidisebutreluntukmenyimpanbahan
bakarpressur-terwujud,daninjectoryangmengandungkatupsolenoiddikontrolsecara
elektronikuntukmenyemprotbahanbakarsurizedPres-kedalamsilinder.KarenaECUmesin
mengontrolsisteminjeksi(termasuktekananinjeksi,lajuinjeksi,daninjeksitiming),sistemini
tidakterpengaruholehkecepatanmesinataubeban.Halinimemastikantekananinjeksiyang
stabilsetiapsaat,khususnyadirentangkecepatanmesinrendah,dansecaradramatismengurangi
jumlahasaphitamordi-narilydipancarkanolehmesindieselselamastart-updanpercepatan.
Akibatnya,emisigasbuanglebihbersihdanmengurangi,danoutputdayayanglebihtinggi
dicapai.(1)TekananInjeksiKontrol
a.Memungkinkaninjeksitekanantinggi,bahkandalamrentangkecepatanmesinrendah.b.
MengoptimalkankontroluntukmeminimalkanpartikulatdanNOxemisi.
(2)TimingInjectionKontrol
a.Secaraoptimalmengontrolwaktuyangsesuaidengankondisiberkendara.
(3)InjeksiRateControl
a.Kendalipilotinjectionsemprotansejumlahkecilbahanbakarsebeluminjeksiutama.

RailSistemumum
InjectionPressureControlInjectionTimingKontrolInjectionRateControl
Optimization,TinggiTekanan
Optimization
CommonRailSistemeru

(4)EGR(ExhaustGasRecirculation)Kontrol
a.Dengansirkulasigasbuangkesisiintakemesin,pembakaran
suhuberkurangdanNOxmenurun.
etaRtidakada
PercontohanInjeksi
SistemCommonRail
itcejn
InjectionUtamasse
gnim
saya
CrankshaftAnglerPada
dkk
iT

InjectionJumlahPengendalianitc
Saya
konvensionalPompa
ucitrP
xON
noitc
konvensional
InjectionCylinderEJN
saya
EJN
Pompa
VolumeKoreksi
InjectionPressureKecepatanKecepatan
mendalamS
1342
QD0734E
2

[2]PerbandingandenganSistemKonvensional
Sistem
In-line,VEPump
commonRailSistem
bertekanantinggipipa
SesaattekananTinggi
Rail
TWV
Timer
Gubernur
Nozzle
PasokanPompa
BiasanyatekananTinggi
PengirimanValve
In-linePompa
PakanPumpSCV(SuctionControlValve)
InjectorFuelTankVEPump
InjectionQuantityKontrolPompa(Gubernur)
MesinECU,Injector(TWV)*1Injection
TimingKontrolPompa(Timer)
MesinECU,Injector(TWV)*1
MeningkatnyaTekananPompa
MesinECU,PasokanPompadistributor
Pompa
MesinECU,RailInjectionPressure
ControlTergantungpadaKecepatandanInjectionQuantity
MesinECU,PasokanPompa(SCV)*2*1TWV:TwoWayValve*2SCV:SuctionControlValve
QD2341E
3

2.2GarisBesarSistem[1]Composition
Sistemcommonrailterutamaterdiridaripompapasokan,keretaapi,injector,danECUmesin.
SuhubahanbakarSensorKecepatanKendaraanAcceleratorIntakePembukaanTekananAirIntakeAirTemperatureSuhu
PendinginCrankshaftPositionCylinderPengakuanSensor

[2]Operasi
(1)pompaSupply(HP3)
a. Pompapasokanmenarikbahanbakardaritangkibahanbakar,danpompabahanbakartekanan
tinggi untuk rel. Kuantitas bahan bakar keluar dari pompa pasokan mengontrol tekanan di rel.
The SCV (Suction Control Valve) dalamefekpompapasokankontrolinisesuaidenganperintah
yangditerimadariECU.
(2)Rail
a.Reldipasangantarapompapasokandaninjektor,dantokobakartinggi.
bahantekanan
(3)Injector(tipeG2)
a. Injector ini menggantikan nozzle injeksi konvensional, dan mencapai injeksi optimal dengan
mempengaruhi kontrol sesuai dengan sinyal dari ECU. Sinyal dari ECU menentukan lamanya
waktu dan waktu di mana saat ini diterapkan injektor. Hal ini pada gilirannya, menentukan
kuantitas,tingkatdanwaktudaribahanbakaryangdiinjeksikandariinjektor.
(4)MesinECU
a. ECU mesin menghitung data yang diterima dari sensor secara komprehensif mengendalikan
kuantitasinjeksi,waktudantekanan,sertaEGR(exhaustgasrecirculation).
MesinECU
IntakeAirflowTingkat
Rail
RailPressureSensor
PasokanPompa
TekananLimiter
FuelTank
Injector
BahanBakarSuhuSensor
SCV(SuctionControlValve)
Q000144E
4

2.3SistemBahanBakardanSistemPengendalian[1]SistemBahanBakar
Sisteminiterdiridariruteyangdilaluibahanbakardieselmengalirdaritangkibahanbakarke
pompalapisdukungan-,melaluirel,dandisuntikkanmelaluiinjektor,sertaruteyangdilalui
bahanbakarkembaliketangkimelaluipipaoverflow.[2]ControlSystem
Dalamsistemini,ECUmesinmengontrolsisteminjeksibahanbakarsesuaidengansinyal-
sinyalyangditerimadariberbagaisensor.Komponen-komponensisteminidapatdibagimenjadi
tigajenisberikut:(1)Sensor;(2)ECU;dan(3)Aktuator.(1)sensor
a.Mendeteksimesindanmengemudikondisi,danmengubahnyamenjadisinyallistrik.
(2)MesinECU
a.Melakukanperhitunganberdasarkansinyal-sinyallistrikyangditerimadarisensor,dan
mengirimkannyakeaktuatoruntukmencapaikondisiyangoptimal.
(3)aktuator
a. Beroperasi sesuai dengan sinyal-sinyal listrik yang diterima dari ECU. Kontrol sistem injeksi
dilakukan secara elektronik mengendalikan aktuator. Kuantitas injeksi dan waktu ditentukan
dengan mengontrol lamanya waktudanwaktudimanasaatiniditerapkanpadaTWV(Two-Way
Valve) di injektor. Tekanan injeksi ditentukan dengan mengontrolSCV(SuctionControlValve)
dipompapasokan.
SensorActuator
KecepatanEngineCrankshaftPositionSensorNE
InjectorCylinderPengakuan
InjectionQuantityKontrol
CyliderPengakuansensorG
InjectionTimingKontrol
AcceleratorPositionSensor
Beban
MesinECU
PasokanPump(SCV)
RailPressureSensor
InjectionPressureControl
EGR,mesinPeringatanLight
SensordanSwitchesLain
Q000282E
5

3.KonstruksidanOperasi3.1DeskripsiKomponenUtama[1]PasokanPompa(HP3,HP4)
(1)Garis
a.Pompapasokanterutamaterdiridaritubuhpompa(poroscam,camcincin,dan
plunger),SCV(SuctionControlValve),sensorsuhubahanbakar,danpompafeed.b.Duapiston
untukHP3atautigapistonuntukHP4diposisikansecaravertikalpada
camcincinluaruntukkekompakan.c.Mesinmenggerakkanpompapasokanpadarasio1:1.
Pompapasokanmemilikipompafeedbuilt-in(tipetrochoid),danmenarikbahanbakardari
tangkibahanbakar,mengirimnyakeruangplunger.d.Camshaftinternalyangmendorongdua
piston,danmerekamenekanbahanbakaryangdikirimkeruangplungerdanmengirimkannyake
rel.KuantitasbahanbakaryangdipasokkereldikendalikanolehSCV,menggunakansinyaldari
ECUmesin.TheSCVadalahjenisbiasanyadibuka(intakevalveterbukaselama
de-energization).
HP3
SCV
SuhuFuelSensor
Q000252E
HP4
SuhuFuelSensor
SCV
Q000253E
6

Injector
Rail
KembaliFuelOverflow
FuelTank
Camshaft
DischargeValve
7
IntakeValve
Plunger
KembaliMusimSemi
Saring
IntakeTekananPakanTekananTekananTinggiKembaliTekanan
SVC
RegulatingValve
UmpanPump
FuelInlet
Intake
FuelFilter(denganprimingPump)
QD0704E

HP3
SCV
Pompatubuh
plunger
plunger
feedpompa
Cincincam
FuelSensor
Suhu
RegulatingValve
driveShaft
Saring
8
Q000254E

HP4
SCV
Pompatubuh
plunger
plunger
SuhuFuelSensor
driveShaft
Saring
Cincincam
RegulatingValve
9
PakanPump
Q000255E

(2)PasokanPompainternalBBMArus
a.Bahanbakaryangdiambildaritangkibahanbakarmelewatirutedipompapasokanseperti
yangdigambarkan,dandimasukkankerel.
PasokanPompaInterior
RegulatingValve
Feedpompa
SCV(SuctionControlValve)
PumpingBagian(plunger)RailOverflow
IntakeValve
FuelTank
Q000283E

(3)PembangunanpasokanPompa(dalamkasuspompaHP3)
a.Cameksentrikmelekatpadaporoscam.Cameksentrikterhubungke
camcincin.
CamShaft
EksentrikCam
Cincincam

QD0
706Eb.Sebagaiporoscamberputar,cameksentrikberputareksentrik,dancamcincinbergerak
naikdanturunsaatberputar.
Plunger
EksentrikCam
CincinCam
CamShaft
QD0727E
10

c.Plungerdankatuphisapyangmelekatpadacamcincin.Pompapakan
terhubungkebagianbelakangporoscam.
PlungerSebuah
Cincincam
Feedpompa
plungerB
QD0728E
11

(4)OperasiSupplyPompa
a. Seperti yang ditunjukkan pada ilustrasi di bawah (dalam kasus pompa HP3), rotasi cam
eksentrik menyebabkan cam cincin untuk mendorong plunger A ke atas. Karena gaya pegas,
Plunger B ditarik dalam arah yang berlawanan untuk plunger A. Akibatnya, Plunger B menarik
dalam bahan bakar, sementara Plunger A memompanya ke rel. Dalam kasus mesin 4-silinder
digunakan dengan pompa HP3, masing-masing plunger pompa bahan bakar dalam gerakan
timbal balik selama rotasi cam 360 . Sebaliknya, dalam kasus mesin 6 silinder digunakan
dengan pompa HP4, 3 piston pompa bahan bakar dalam gerakan timbal balik untuk
masing-masingrotasicam.
SuctionValvePengirimanValvePlungerA
EksentrikCam
CincinCam
SCV
PlungerB
PlungerA:LengkapKompresiPlungerB:LengkapIntake
PlungerA:LengkapIntakePlungerB:LengkapKompresi

CATATAN:Ada3pistonuntukHP4.
PlungerA:MulailahIntake
plungerB:MulailahIntake
plungerB:MulailahKompresi
plungerA:MulailahKompresi
QD0707E
12

[2]DeskripsiPasokanPompaKomponen
(1)PakanPompa
a. Jenis trochoid pompa feed, yang terintegrasi dalampompapasokan,menarikbahanbakardari
tangki bahan bakar dan feed ke dua piston melalui filter bahan bakar danSCV(SuctionControl
Valve). Pompapakandidorongolehdriveshaft.Denganrotasirotorbatin,pompapakanmenarik
bahan bakar dari pelabuhan hisap dan pompa keluar melalui pelabuhan debit. Hal ini dilakukan
sesuaidenganruangyangmeningkatkandanmenurundengangerakanrotorluardandalam.
OuterRotor
untukPompaChamber
JumlahPenurunan
JumlahPenurunan(FuelDischarge)
batinRotor
IntakePelabuhan
dariFuelTank
DischargePelabuhan
JumlahMeningkatkan
JumlahKenaikan(BahanBakarIntake)
QD0708E

(2)SCV:SuctionControlValve(tipeBiasanyaterbuka)
a.Jenissolenoidvalvelineartelahdiadopsi.ECUmengontrolrasiotugas(durasidimanasaatini
diterapkanpadaSCV),untukmengontroljumlahbahanbakaryangdipasokkeplungertekanan
tinggi.b.Karenahanyakuantitasbahanbakaryangdiperlukanuntukmencapaitargettekananrel
ditarikdi,bebanpenggerakpompapasokanberkurang.c.KetikaarusmengalirkeSCVitu,
gayageraklistrikvariabeldibuatsesuaidenganrasiokewajiban,bergerakangkerkesisikiri.
Angkerbergeraksilinderkesisikiri,mengubahpembukaanbagianbahanbakardandengan
demikianmengaturkuantitasbahanbakar.d.DenganSCVOFF,kontrakpegaskembali,
benar-benarmembukabagianbahanbakardan
memasokbahanbakaruntukpiston.(Asupankuantitaspenuhdankuantitasdebitpenuh)e.
KetikaSCVadalahON,kekuatanmusimsemikembalibergeraksilinderkekanan,menutup
bagianbahanbakar(biasanyadibuka).f.DenganmemutarSCVON/OFF,bahanbakar
disuplaidalamjumlahyangsesuaidenganaktuasi,
rasiotugasdanbahanbakardibuangolehpiston.
ExteriorViewdariSCVCross-bagianSCV
PompaTubuh
KembaliMusimSemi
13
SCV
Cylinder
Q000270E

[DalamhalwaktusingkatONtugas]waktupendekONtugasbukaankatupbesar
maksimumkuantitasasupan
Plunger
Q000051E
14
PakanPump
SCV
Cylinder
besarPembukaan
Cylinder

[DalamkasuslamaONtugas]lamaONtugasbukaankatupkecilminimumkuantitas
asupan
Plunger
15
PakanPump
SCV
Cylinder
kecilmembukaCylinder
Q000052E

[3]Rail
(1)Garis
a.Tokobertekananbahanbakar(0-150MPa{0-1528,5kg/cm2})yangtelahdisampaikandari
pompapasokandanmendistribusikanbahanbakaruntuksetiapinjectorsilinder.Sebuahsensor
tekananreldanlimitertekanandiadopsidirel.b.Sensortekananrel(sensorPc)mendeteksi
tekananbahanbakarpadareldanmengirimsinyalkeECUmesin,limitertekananmencegah
tekananreldariyangabnormaltinggi.Halinimemastikanpembakaranyangoptimaldan
mengurangipembakarankebisingan.
(2)Tekanan
limiter.Tekananlimiterterbukauntukmelepaskantekananjikatekananyangabnormaltinggi
dihasilkan.b.Ketikatekananrelmencapaisekitar200MPa(2038kg/cm2),ituperjalanan
limitertekanan(valveterbuka).Ketikatekananturunmenjadisekitar50MPa(509,5kg/cm2),
tekananlimiterkembalikekeadaannormal(katupmenutup)untukmempertahankantekanan
yangtepat.
TekananLimiter
tekananSensor
Q000256E
ValveTerbuka
200MPa(2038kg/cm2)
ValveTutup
50MPa(509,5kg/cm2)
Q000257EQ000271E
16

(3)tekananSensor
a.Sensortekananrel(sensorPc)melekatreluntukmendeteksibahan
tekananbakar.b.Iniadalahsensortekananjenissemikonduktoryangmemanfaatkan
karakteristiksilikon,
dimanahambatanlistrikberubahketikatekananditerapkanuntukitu.
REFERENSI:Halinidiperlukanuntukme-resetnilaiECUstandarmenggunakanalatdiagnosis
Hinopadasaatpenggantianlayananpompapasokan.Selainitu,ECUmemilikifungsi
memungkinkanuntukmempelajarikinerjapompapasokanpadasaatpenggantianlayananECU,
sehinggamemastikanwaktuyangcukup(beberapamenit)tersedia.
4.2V
V
C
V
OUT
GND
1.0V
0200MPa(2038kg/cm2)
Q000258E
Q000272E
17

[4]Injector(G2Type)
(1)Garis
a. Injector menyuntikkan bahan bakar bertekanan tinggi dari rel ke dalam ruang pembakaran di
injeksi timing yang optimal, kondisi tingkat, dan semprot, sesuai dengan perintah yangditerima
dariECU.
(2)Karakteristik
a.Sebuahkompak,solenoid-controlhematenergijenisTWV(Two-WayValve)injektortelah
diadopsi.b.KodeQRmenampilkanberbagaikarakteristikinjectordankodeIDyang
menunjukkaninidalambentuknumerik(30angkaalfanumerik)yangterukirdikepalainjector.
TheJ05/mesinJ08sistemcommonrailmengoptimalkankontrolvolumeinjeksimenggunakan
informasiini.Ketikainjectorbarusajadipasangdikendaraan,perlumemasukkanIDkodedi
ECUmesinmenggunakanalatHINODiagnostik.
(3)Konstruksi
30alfanumerikAngka
HFGE
HF
D
GE
HC
FD
GB
E
C
FA
DEB
CA
DB
CA
B
A
QRCodes
SolenoidValveKontrolChamber
bertekananBahanBakar(dariRail)
CommandPiston
Nozzlemusimsemi
TekananPin
NozzleNeedle
Q000259E
18

(4)Operasi
a.TheTWV(Two-WayValve)solenoidvalvemembukadanmenutuplubangstopkontakuntuk
mengontrol
keduatekanandidalamruangkontrol,danawaldanakhirinjeksi.[Tidakadainjeksi]
Ketikaadaarusdipasokkesolenoid,gayapegaslebihkuatdaritekananhidrolikdiruang
kontrol.Dengandemikian,katupsolenoiddidorongkebawah,secaraefektifmenutuplubang
stopkontak.Untukalasanini,tekananhidrolikyangditerapkanpadapistonperintah
menyebabkanmusimseminozzleuntukkompres.Inimenutupjarumnozzle,dansebagai
hasilnya,bahanbakartidakdisuntikkan.[Injeksi]
Ketika saat ini pada awalnya diterapkan untuk solenoid, tarik kekuatan solenoid menarik
solenoid valve up, secara efektif membuka lubang stopkontak dan memungkinkan bahan bakar
mengalir dari ruang kontrol. Setelah bahan bakar mengalir keluar, tekanan di dalam ruang
kontrol berkurang, menarik perintah piston up. Hal ini menyebabkan jarum nozzle meningkat
daninjeksiuntukmemulai.
Bahan bakar yang mengalir melewati orifice stopkontak mengalir ke pipa bocor dandibawah
piston perintah. Bahan bakar yang mengalir di bawah piston mengangkat jarum piston ke atas,
yangmembantumeningkatkanpembukaandanpenutupanresponnozzleini.
Ketika saat ini terus diterapkan solenoid, nozzle mencapai angkat maksimum, dimanatingkat
injeksi juga di tingkat maksimum. Ketika saat ini untuk solenoid dalam keadaan OFF, solenoid
valvejatuh,menyebabkanjarumnozzleuntukmenutupsegeradaninjeksiuntukberhenti.
Solenoid
TWV
Outletorifice
Inletorifice
Commandpiston
Nozzlejarum
Leakpipa
aktuasi
aktuasisaat
saatValvemusimsemi
Rail
Kontroltekananruang
tekananKontrol
ruang
tekananruangKontrol
tingkattingkattingkatInjeksiInjeksiInjeksiTidakadainjeksiInjeksiAkhirinjeksi
19
aktuasisaatini
Q000149E

(5)QRCodes
sebuah.Dalamrangkameminimalkantoleransikinerjainjektorpadamenggantinya,QR*
1(Quick
KodeResponse)telahdiadopsiuntukmeningkatkankoreksipresisi.b.KodeQR
menggunakantelahmenghasilkanpeningkatanyangsubstansialdalamjumlahinjeksibahan
bakarpoinkuantitaskoreksi,dandengandemikianinjeksikontrolkuantitaspresisitelah
membaik.Karakteristiksilindermesintelahlanjutbersatu,kontribusiuntukperbaikandalam
efisiensipembakaran,penguranganemisigasbuangdansebagainya.[QRpoinkodekoreksi]
kuantitasInjectionQ
ActuatinglebarpulsaTQ

*1:LokasikodeQR
QRcodepadakonektorinjector
CodesQR(9.9mm)
ID(30Kode
angkaalfanumerik)16bahanbakartokohinjeksikuantitasalfanumerikkoreksi
notasi
informasiuntukpenggunaanlayananpasar.
Q000261E
20
TekananParameter
Q000260E

(6)ProsedurPerbaikanPerubahan
a.Perbedaandibandingkandenganmetodekonvensionalmenggantikaninjector
perakitansepertiyangditunjukkandibawahini.CATATAN:Saatmenggantiinjektordengan
kodeQR,atauECUmesin,perluuntukmerekamIDkode(kodeQR)diECU.(JikakodeIDdari
injektordipasangtidakterdaftardenganbenar,kegagalanmesinsepertiidlingkasardan
kebisinganakanmenghasilkan.)
New(InjectordenganKodeQR)
30alfanumeriktokoh-enambelasangkaalfanumeriknotasidariinjeksibahanbakarinformasijumlahkoreksidisplaeduntuk
pasarlayananpenggunaan
IDKode

Menggantiinjector
MenggantiengineECU
Q000284E
"TidakadakoreksiKendaraan-sisiinjector,
ketahanansehinggatidakada~
kemampuanpengenalanlistrik"
SparemesinECU
*DiperlukanuntukmerekamkodeinjectorIDdimesinECU
QD1537E
"Tidakadaperlawanankoreksi,sehinggatidakadakemampuanpengenalanlistrik"
injectorSpare

~
*DiperlukanuntukmerekamkodeinjectorIDdimesinECU
QD1536E
21
MesinECU

[5]MesinECU(ElectronicControlunit)
(1)Garis
a.Iniadalahpusatkomandoyangmengendalikansisteminjeksibahanbakardanoperasimesin
padaumumnya.
3.2DeskripsiControlSystemKomponen[1]SistemEngineControlDiagram
GarisDiagram
SensorMesinECUActuator
DeteksiPerhitunganaktuasi
QD2352E
IntakeAirTemperatureSensor
EGRValve
MassAirflowmeter
Inter-Cooler
SensorTekananIntakeAir
(J08E-ganda,J05D-tunggal)
InjectorG2
EGRCooler
VGTPengendali
EGRSensor
ValveLift
VGTActuator
Coolant
OksidasiCatalyst
Q000262E
22

[2]SensordanRelay
(1)NESensor(CrankshaftPositionSensor)
a.Ketikalubangsinyalpadarodagilabergerakmelewatisensor,garisgayamagnetik
yangmelewatiperubahancoil,menghasilkanteganganbolak-balik.b.Lubang-lubangsinyal
terletakdirodagilapadainterval6,5derajat.Adatotal56lubang,denganlubanghilangditiga
tempat.Olehkarenaitu,setiapduarevolusimesinoutput112pulsa.c.Sinyalinidigunakan
untukmendeteksiputaranmesindanposisicrankshaftdalam7,5
intervalderajat.
(2)TDCSensor(CylinderPengakuanSensor)
a.BerbedadengansensorNE,sensorTDCadalahsensorMRE(resistensimagnetikelemen).
Sebagaipulsardekatsensorberputar,perubahanmedanmagnet.Halinimenyebabkanvariasi
arusyangdihasilkan,yangdiperkuatdalamsirkuitinternalunitsensorsebelumsinyaladalah
outputkeECUmesin.b.Mesincamshaftgear(saturevolusiuntuksetiapduarevolusidari
mesin)digunakansebagaipulsar.TheJ05DdanJ08Emenggunakanberbagaijenisgigi,sehingga
outputsinyalberbedasebagaiberikut.UntukJ05D:Selainempatpinketukanterletakpada
interval90derajat,adalubangsinyalekstrapadagigi.Olehkarenaitusetiaprevolusidarigigi,
yaituduarevolusimesin,output4+1=5TDCsinyalpulsa.
UntukJ08E:Selainenampinketukanterletakpadainterval60derajat,adalubangsinyalekstra
padagigi.Olehkarenaitusetiaprevolusidarigigi,yaituduarevolusimesin,output6+1=7
TDCsinyalpulsa.
NE(CrankshaftPosition)Sensor
Q000263E
TDC(CylinderRecognition)Sensor
Q000264E
23

c.KombinasipulsaNEdanpulsaTDCdigunakanuntukreferensi
pulsasilinder,danpulsatidakteraturdigunakanuntukmenentukanNo1silinder.Untukmesin
J08ESilinderpadarotasi78setelahNo1sinyalreferensiTDCsetelahpulsatidakteratur
adalahnomorsatusilinderTDC(lihatgrafikdihalamanberikut).
UntukJ08E
ECUVCC
VCCTDC
sirkuitMasukan
GND
NE
sirkuitMasukan
GND
Q000273E

untukmesinJ05DSilinderpadarotasi96setelahNo1sinyalreferensiTDCsetelahpulsatidak
teraturadalahnomorsatusilinderTDC(lihatbagandihalamanberikut).
UntukJ05D
VCC
VCC
GND
Masukansirkuit
GND
ECU
TDC
sirkuitMasukan
NE
Q000274E
24

untukJ08E
0CA120CA240CA360CA480CA600CA720CA
#5TDC#3TDC#6TDC#2TDC#4TDC#1TDCNE+
11121314151617181920212223242526272829303132333435363738394041424344454647
484950515253545556123456789101112131415161718192021222324252627282930313233343536
3738394041424344454647484950515253545556123456789101112131415(NE-Standard)
G-4
HilangGigi
3CA
30CA
(G-GNDStandard)
78CA78CA78CA78CA78CA78CA
3CAEkstraGigi
UntukJ05D
0CA180CA360CA540CA0CA
#1TDC#3TDC#4TDC#2TDC#1TDCNE+
1112131415161718192021222324252627282930313233343536373839404142434445464748
495051525354555612345678910111213141516171819202122232425262728293031323334353637
38394041424344454647484950515253545556123456789101112131415(NE-Standard)
G(GStandard)
4HilangGigi
3CA96CA96CA96CA96CA
3CAekstraGigi
Q000276E
25
Q000275E

(3)SuhuPendinginsensor
a.Sensorsuhupendinginmendeteksisuhupendinginmesindan
outputkeECU.
Q000277E

b. Sensor menggunakan termistor, yang bervariasi ketahanan menurut suhu. Sebagai ECU
berlaku tegangan untuk termistor, menggunakan tegangan yang dihasilkan dari pembagian
resistansiinternalkomputerdanperlawananthermistoruntukmendeteksisuhu.
(V)
VTHW

(4)SensorSuhuFuel(THL)
a. Sensor suhu bahan bakar mendeteksi suhu bahan bakar dan output ke ECU. Sensor
menggunakan termistor, yang bervariasi ketahanan menurut suhu. Sebagai ECU berlaku
tegangan untuk termistor, menggunakan tegangan yang dihasilkan dari pembagian resistansi
internalkomputerdanperlawananthermistoruntukmendeteksisuhu.
VTHL
ECU
VTHW
5
+5V
4
3TeganganOutput
2
A-GND
1
0
THW-40-20020406080100120(C)-40-43268104140176212248(F)
SuhuPendingin
Q000105E
ECU
VTHL
(V)5
+5V
4
3Teganganoutput
2
A-GND
1
0
THL-40-20020406080100120(C)-40-43268104140176212248(F)
BahanBakarsuhu
Q000106E
26

(5)AtmosferAirPressureSensor(Built-inECU)
a.Sensorinimengubahtekananudaraatmosfermenjadisinyallistrikuntukmemperbaikipenuh.
volumeyangbebaninjeksi
VPATM
OutputTegangan(V)
3,8
107{1,09}AtmosphericAirPressure(kPa{kg/cm2})
Q000278E

(6)AcceleratorPositionSensor
a. Sensor ini mengubah sudut upaya pedal diterapkan pada pedal gas menjadi sinyal listrik dan
mengirimkannya ke ECU. Sensor accelerator menggunakan unsur-unsur hall. Sebuah magnet
dipasang pada poros yang bergerak berbarengan dengan pedal gas, dan orientasi medan magnet
berubahdenganrotasiporos.Perubahanorientasimedanmagnetmenghasilkantegangan.
V
PA
1GND1VC1V
PA
2GND2VC2
Q000266E
elemenHall(2buah)
TeganganOutput
Magnet(1pasang)
V
PA
1
V
PA
1GND1
GND1
V
PA
25VC1
VC1
4
4.0V
V
PA
3V
PA
2
V
PA
12
2
3.2V
GND2VC2
GND2
1,6V
1VC2
0,8V
05101520
AcceleratorPembukaanAngle()
Q000265E
27

(7)MeningkatkanTekananSensor
a. Dalam rangka untuk memperbaiki volume injeksi beban penuh, sensor ini mengubahtekanan
udara intake (tekanan absolut) menjadi sinyal listrik, kemudian menguatkan menjadi sinyal
tegangankekomputer.
(8)AirFlowSensor
a.Mendeteksiasupanaliranudara(lajualiranmassa)dihot-wirejenisairflowmeter.b.Asupan
aliranudaradikonversikenilaitegangandansinyaliniditransmisikankeECU.
c. Sensor aliran udara dipasang ke bagian belakang udara bersih, dan terdiri dari pemanas,
termometer, sensor suhu udara intake, dan kontrol sirkuit (base). Ini mengalihkan sebagian dari
udaramasukdariudarabersihdanmengukuraliranudaraintakedibagianpengukuranhot-wire.
ECU
+5V
VPIMA-VCC
VPIM
KeluaranValtage(V)
A-GND
4.0
3.45
2.0
0.50
100200300{1,019}{2,038}{3,057}IntakeAirPressurePIM(kPa{kg/cm2})Q000279E
E
2
THAV
G
E
2G
+B
AirflowSensor
IntakeSensor
AirTemperature
Q000280E
GarisDiagramHot-WireJenisAirflowmeter
Throttletubuh
Suhu(Hot-Wire)
KompensasiResistor
IntakeAirTemperatureSensor
BypassAliranPemanasan(Hot-Wire)
Resistor
IntakeAirdariAirCleaner
Q000285E
28

3.3BerbagaiJenisPengendalian
sisteminimengontroljumlahinjeksibahanbakardantiminginjeksilebihoptimaldaripada
gubernurmekanikatauwaktuyangdigunakandalampompainjeksikonvensional.Forsystem
control,theECUmakesthenecessarycalculationsbasedonsignalsreceivedfromsensors
locatedintheengineandonthevehicleinordertocontrolthetiminganddura-tioninwhich
currentisappliedtotheinjectors,thusrealizingoptimalinjectiontiming.(1)FuelInjectionRate
ControlFunction
a.Thefuelinjectionratecontrolfunctioncontrolstheratioofthequantityoffuelthatis
injectedthroughthenozzleholeduringaspecifiedperiod.
(2)FuelInjectionQuantityControlFunction
a. The fuel injection quantity control function, replaces the conventional governor function,and
controls fuel injection to achieveanoptimalinjectionquantitybasedontheenginespeedandthe
acceleratoropening.
(3)FuelInjectionTimingControlFunction
a. The fuel injection timing control function, replaces the conventional timer function, and
controls the fuel injection to achieve an optimal injection timing according to the engine speed
andtheinjectionquantity.
(4)FuelInjectionPressureControlFunction(RailPressureControlFunction)
a.Thefuelinjectionpressurecontrolfunction(railpressurecontrolfunction)usesarailpressure
sensortomeasurefuelpressure,andfeedsthisdatatotheECUtocontrolthepumpdischarge
quantity.b.Pressurefeedbackcontrolisimplementedtomatchtheoptimalquantity(command
quantity)setaccordingtotheenginespeedandthefuelinjectionquantity.
InputSignalControlOutput
Acceleratorsensor
NESensor
FuelInjectionRateControl
(CrankshaftPositionSensor)
FuelInjectionQuantityControlTDC
Sensor(CylinderRecognitionSensor)
FuelControlComputer(ECU)
FuelInjectionTimingControl
RailPressureSensor
FuelInjectionPressureControl
VariousSensors
WaterTemperatureSensor
FuelTemperatureSensor
AtmosphericAir
AtmosphericAirTemperature
PressureSensorSensoretc.
Diagnosis
Q000109E
29

[1]FuelInjectionRateControl
(1)MainInjection
a.Sameasconventionalfuelinjection.
(2)PilotInjection
a.Pilotinjectionistheinjectionofasmallamountoffuelpriortothemaininjection.
MainInjection
PilotInjection
Q000110E

b. While the adoption of higher pressure fuel injection is associated with an increase in the
injection rate, the lag (injection lag) that occurs from the time fuel is injected until combustion
starts cannot be reduced below a certain value. As a result, the quantity of fuel injected before
ignition increases, resulting in explosive combustion together with ignition, and an increase in
the amount of NOx and noise. Therefore, by providing a pilot injection, theinitialinjectionrate
is kept to the minimum required level dampening, the explosive first-period combustion and
reducingNOxemissions.
TDC
CombustionProcess
SmallPriortoInjectionIgnition
Amount
HighInjectionRate
PilotInjection
InjectionRate
Improvement
LargeCombustion
Pre-mixture
(NOx,Noise)
SmallPre-mixtureCombustion
HeatRate
Generation
IgnitionDelay
Q000111E
30

(3)SplitInjection
a.Whentherotationislowatstartingtime,asmallamountoffuelisinjectedseveraltimes
priortomaininjection.
SplitInjection
Q000112E

[2]FuelInjectionQuantityControl
(1)StartingInjectionQuantity
a.Theinjectionquantityisdeterminedbasedontheenginespeed(NE)andwater
temperaturewhilestarting.
StartingInjectionQuantity
WaterTemperature
EngineSpeed
Q000127E

(2)TransientInjectionQuantityCorrection
a.Whenthechangesintheacceleratoropeningaregreatduringacceleration,theincrease
infuelvolumeisdelayedtoinhibitthedischargeofblacksmoke.
InjectionQuantity
ChangeinAcceleratorOpening
InjectionQuantityafterCorrection
DelayTime
Time
Q000128E
31

(3)BasicInjectionQuantity
a.Thisquantityisdeterminedinaccordancewiththeenginespeed(NE)andtheaccelerator
opening.b.Increasingtheacceleratoropeningwhiletheenginespeedremainsconstant
causesthe
injectionquantitytoincrease.
BasicInjectionQuantity
AcceleratorOpening
EngineSpeed
Q000129E

(4)InjectionQuantityforMaximumSpeedSetting
a.Theinjectionquantityisregulatedbyavaluethatisdeterminedinaccordancewiththe
enginespeed.
InjectionQuantityforMaximumSpeedSetting
EngineSpeed
Q000130E

(5)MaximumInjectionQuantity
a.Isdeterminedinaccordancewiththeenginespeedandcorrectedbythecoolant
temperaturesignal.
BasicMaximumInjectionQuantity
EngineSpeed
Q000131E
32

(6)AmountofInjectionQuantityIntakePressureCorrection
a.Limitsthemaximuminjectionquantityinaccordancewiththeintakepressure,inorderto
minimizethedischargeofsmokewhentheintakeairpressureislow.
AmountofIntakeAirPressureCorrection
EngineSpeed
Q000133E

(7)AmountofInjectionQuantitybyAtmosphericAirPressureCorrection
a.Withusingatmosphericairpressuresensorsignal,themaximuminjectionquantitycurve
iscorrectedasshownintherightfigure.
AmountofAtmosphericAirPressureCorrection
EngineSpeed
Q000134E

(8)IdleSpeedControlSystem(ISC)
a. Controls the idle speed by regulating the injection quantity inordertomatchthetargetspeed,
which has been calculated by the computer, with the actual speed. The functions oftheISCcan
bebroadlydividedintothefollowingtwoitems:
AutoISCControlstheidlespeedinaccordancewiththewatertemperature.
TargetSpeed
WaterTemperature
Q000135E

ManualISCControlstheidlespeedinaccordancewiththeidlespeedindicatedonthemanual
idlesetting
33

knobprovidedatthedriver'sseat.
TargetSpeed
ISCKnobTerminalVoltage
Q000136E

AirConditionerIdle-upControlWhentheconditionsshowninthechartontherightare
realized,bringtheidle-upspeedtoconstantrpm.
Conditions
AirConditioningSW="ON"
ClutchSW="ON"(ClutchConnection)
NeutralSW="ON"(Neutral)
Q000137E

(9)AutoCruiseControl
a.Controlstheactualvehiclespeedbyregulatingtheinjectionquantityinordertomatch
thetargetspeedthathasbeencalculatedbythecomputerwiththeactualspeed.b.TheCRSECU
controlstheinjectionquantityinaccordancewithsignalsfromthecruise
controlcomputer.
34

[3]FuelInjectionTimingControl
Thecharacteristicsofthefuelinjectiontimingvarydependingonwhetheritisthemaininjec-
tionorthepilotinjection.AlthougheithertheNEsensorortheauxiliaryNEsensoristheref-
erenceforcontrollingtheinjectiontiming,theNEsensorisordinarilyusedforthispurpose.(1)
MainInjectionTiming
a.Thebasicinjectiontimingiscalculatedinaccordancewiththefinalinjectionquantity,the
enginespeed,andthewatertemperature(withmapcorrection).b.Whilestarting,itis
calculatedinaccordancewiththewatertemperatureandtheenginespeed.
BasicInjectionTiming
FinalInjectionQuantity
EngineSpeed
Q000138E

(2)PilotInjectiontiming(PilotInterval)
a.Thepilotinjectiontimingiscontrolledbyaddingthepilotintervaltothemaininjection
timing.b.Thepilotintervaliscalculatedinaccordancewiththefinalinjectionquantity,the
engine
speed,andthewatertemperature(withmapcorrection).c.Whilestarting,itiscalculatedin
accordancewiththewatertemperatureandtheenginespeed.
PilotInterval
FinalInjectionQuantity
EngineSpeed
Q000139E

(3)FuelInjectionPressure
a.Avalueiscalculatedasdeterminedinaccordancewiththefinalinjectionquantityandthe
enginespeed.b.Whilestarting,itiscalculatedinaccordancewiththewatertemperatureand
theenginespeed.
RailPressure
FinalInjectionQuantity
EngineSpeed
Q000140E
35

3.4OtherRelevantEngineControl[1]EGRControl
(1)ControlSystem
ECU
EGRTargetOpening
EGRDeviationCompensationControl
EGRValveAssy

(2)RelatedSensors
Therelatedsensorsareasfollows:
Airvolumesensor:Detectsthevolumeofairflowingintotheengine.
Coolanttemperaturesensor:Detectstheenginecoolanttemperature.
Atmosphericpressuresensor:Detectstheatmosphericpressurearoundtheengine(builtinto
theECU).
(3)EGRValve
a. An EGR valve is utilized as the system actuator for the electric exhaust gas recirculation
(E-EGR) system. It is constructed of an upper section and a lower section. The upper section
receives output signals from the engine ECU, and contains a solenoid that generates
electromagnetic force. The lower section is constructed of a nozzle that moves up and down in
response to the electromagnetic force, and a valve with an opening that alters inresponsetothe
nozzleposition.
FinalEGRTargetOpeningCalculation
Processing/DutyCalculation
Ratio
FeedBack
EGRValveLiftSensor(DetectsActualOpening)EGRValveActuationQ000268EQ000267E
ForJ05D
ForJ08E
Q000281E
36

(4)ControlOperation
OperationStartConditions:Duringenginewarm-up,otherthanstart-up,whennotoverheating(etc.).EGR
OperatingRange:Duringmediumengineload.
Q
NE

3.5EngineECU[1]DiagnosisCodes
P-CodeDST-1DisplayRemarksDescription
P0045VNTMalfunctionFortheVNT.TheVNTactuatorhasamalfunction.
P0049
Q000269E
TurboOverspeed
ChargerTurbine
Thesensordetected.
turbinehasbeen
rotation
Overspeedoftheturbohasbeendetected.
P0088
CommonPressure-TooRail
high
Highfuelpressurehasbeendetected.
P0093
FuelDetected
SystemLeak
Thepumpdoesnotworkproperly.(Fuelleak)
Thereisapossibilityofthefuelleakage.Performthefuelleakagecheck.
P0102
"Themassairflowsensorhasamalfunction.Therearepossibilitiesofthesensormalfunction,openandshortcircuit
togroundintheharness."
P0103
MassAirFlowSensorMalfunction(LO)
Themassairflowsensorhasamalfunction.Therearepossibilitiesofthesensormalfunctionandshortcircuitto+B
intheharness.
P0108
MassAirFlowSensorMalfunction(HI)
Theboostpressurecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuitin
theharness.
P0112
BoostPressureSensorMalfunction(HI)
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,shortcircuitto
groundintheharness."
P0113
IntakeAirTemperatureSensorMalfunction(LO)
Integratedinthemassairflowsensor.
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
P0117
IntakeAirTemperatureSensorMalfunction(HI)
Integratedinthemassairflowsensor.
EngineCoolantTemperatureSensorMalfunction(LO)
Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuitto
groundintheharness.
P0118
EngineCoolantTemperatureSensorMalfunction(HI)
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
37

P-CodeDST-1DisplayRemarksDescription
P0182
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,shortcircuitto
groundintheharness."
P0183
FuelTemperatureSensorMalfunction(LO)
Integratedinthesupplypump.
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
P0191
FuelTemperatureSensorMalfunction(HI)
Integratedinthesupplypump.
RailPressureSensorMalfunction
Characteristicmalfunc-tion
Therailpressurecannotbedetectedproperly.Thereisapossibilityofthesensormalfunction.
P0192
Therailpressurecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuitto
groundintheharness.
P0193
RailPressureSensorMalfunction(LO)
"Therailpressurecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
P0200
RailPressureSensorMalfunction(HI)
ECUChargeCircuitMalfunction(HI)
Thevoltagefortheinjectoractivationistoohigh.ReplacetheECU.
P0201Injector1OpenCircuit
ThereisapossibilityoftheInjector1malfunctionoropencircuitintheharness.
P0202Injector2OpenCircuit
ThereisapossibilityoftheInjector2malfunctionoropencircuitintheharness.
P0203Injector3OpenCircuit
ThereisapossibilityoftheInjector3malfunctionoropencircuitintheharness.
P0204Injector4OpenCircuit
ThereisapossibilityoftheInjector4malfunctionoropencircuitintheharness.
P0205Injector5OpenCircuit
ThereisapossibilityoftheInjector5malfunctionoropencircuitintheharness.
P0206Injector6OpenCircuit
ThereisapossibilityoftheInjector6malfunctionoropencircuitintheharness.
P0217
OverCondition
Temperature
Theovertemperatureconditionhasbeendetected.Checkthecoolingsystem.
P0219
EngineCondition
Overspeed
Theenginespeedexceededtheratedvalue.
P0234
TurboOverboostCharger
Condition
Theboostpressureistoohigherthanthespecifiedvalue.
P0237
"Theintakeairpressurecannotbedetectedprop-erly.Therearepossibilitiesofthesensormalfunction,openand
shortcircuitintheharness."
P0263
BoostPressureSensorMalfunction(LO)
Therotationfluctuationinthecylinder1becamebig-gerthanothercylinders.Thereisapossibilitythattheflow
damperisoperat-ing.
P0266
CorrectionErrorBetweenCylinders#1
Therotationfluctuationinthecylinder2becamebig-
CorrectionError
gerthanothercylinders.BetweenCylinders#2
Thereisapossibilitythattheflowdamperisoperat-ing.
38

P-CodeDST-1DisplayRemarksDescription
P0269
Therotationfluctuationinthecylinder3becamebig-gerthanothercylinders.Thereisapossibilitythattheflow
damperisoperat-ing.
P0272
CorrectionErrorBetweenCylinders#3
Therotationfluctuationinthecylinder4becamebig-gerthanothercylinders.Thereisapossibilitythattheflow
damperisoperat-ing.
P0275
CorrectionErrorBetweenCylinders#4
Therotationfluctuationinthecylinder5becamebig-gerthanothercylinders.Thereisapossibilitythattheflow
damperisoperat-ing.
P0278
CorrectionErrorBetweenCylinders#5
Therotationfluctuationinthecylinder6becamebig-gerthanothercylinders.Thereisapossibilitythattheflow
damperisoperat-ing.
P0335
CorrectionErrorBetweenCylinders#6
"IncasethattheNEandGsensorhavemalfunctions,thisPcodewillbeoutput."
Thepulsefromthecrankshaftpositionsensorcan-notbedetected.Therearepossibilitiesofthesensorandharness
malfunctions.
P0340
CrankshaftPositionSensorMalfunction
ThepulsefromtheenginespeedsensorcannotbeEngine
SpeedSensor
detected.Malfunction
Therearepossibilitiesofthesensorandharnessmalfunctions.
P0404EGRValve1Clogged
Clogginghasbeendetectedbytheliftsen-sor.
TheEGRvalve1iscloggedintheopenstate.
P0405
"TheEGRliftsensor1hasamalfunction.Therearepossibilitiesofthesensormalfunction,openandshortcircuitto
groundintheharness."
P0406
EGRLiftSensor1Malfunction(LO)
TheEGRliftsensor1hasamalfunction.Therearepossibilitiesofthesensormalfunctionandshortcircuitto+Bin
theharness.
P0407
EGRLiftSensor1Malfunction(HI)
"TheEGRliftsensor2hasamalfunction.Therearepossibilitiesofthesensormalfunction,openandshortcircuitto
groundintheharness."
P0408
EGRLiftSensor2Malfunction(LO)
TheEGRliftsensor2hasamalfunction.Therearepossibilitiesofthesensormalfunctionandshortcircuitto+Bin
theharness.
P0489
EGRLiftSensor2Malfunction(HI)
"TheEGRsolenoidvalve1hasamalfunction.Therearepossibilitiesofthesolenoidvalvemalfunc-tion,openand
shortcircuittogroundinthehar-ness."
P0490
EGRSolenoidValve1Malfunction
TheEGRsolenoidvalve1hasamalfunction.Therearepossibilitiesofthesolenoidvalvemalfunc-tionandshort
circuitto+Bintheharness.
P0500
EGRSolenoidValve1Malfunction
ThepulsefromthevehiclespeedsensorcannotbeVehicle
MalfunctionSpeed(LO)
Sensor
Opencircuit
detected.Therearepossibilitiesofthesensorandharnessmalfunctions.
39

P-CodeDST-1DisplayRemarksDescription
P0501
ThepulsefromthevehiclespeedsensorhasanVehicle
SpeedSensor
error.Malfunction(HI)
Therearepossibilitiesofthesensorandharnessmalfunctions.
P0510IdleSwitchMalfunction
Noise
Theidleswitchdoesnotfunctionproperly.MonitorthestateandchecktheON/OFFjudgment.
P0524
EngineLow
OilPressureToo
Theengineoilpressurebecametoolow.
P1401EGRValveClogged
Clogginghasbeendetectedbytheliftsensor.
TheEGRvalve2systemiscloggedintheopenstate.
P0540
Theintakeheaterrelayhasamalfunction.Therearepossibilitiesoftherelayandharnessmal-functions.
P0545
PreheatingSystemMalfunction
ExhaustGasTempera-tureSensor1Malfunction(LO)
Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuitto
groundintheharness.
P0546
ExhaustGasTempera-tureSensor1Malfunction(HI)
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
P0605FlashROMMalfunction
ThereisaninternalmalfunctionintheECU.ReplacetheECU.
P0606
CPUwareMalfunctionDetected)
(Hard-
ThereisaninternalmalfunctionintheECU.ReplacetheECU.
P0607
CPUMonitoringIDMalfunction
ThereisaninternalmalfunctionintheECU.ReplacetheECU.
P0611
ECUMalfunction
ChargeCircuit
Thevoltagefortheinjectoractivationistoolow.ReplacetheECU.
P0617
StarterMalfunction
Switch
Thereisashortinthestarterswitchcircuit.MonitorthestateandchecktheON/OFFjudgment.
P0686MainRelayMalfunction
ThemainrelaycannotbeturnedOFF.Checktherelay.
P0704
ClutchMalfunction
Switch
Theclutchswitchcannotbedetectedproperly.MonitorthestateandchecktheON/OFFjudgment.
P0850
NeutralMalfunction
Switch
Theneutralswitchcannotbedetectedproperly.MonitorthestateandchecktheON/OFFjudgment.
P1132
Theacceleratorpositionsensorforoperationcannotbedetectedproperly.Checkthesensorvoltage.Thereare
possibilitiesofopenandshortcircuittoground.
P1133
AcceleratorPositionSensorforOperation(LO)
AcceleratorPositionSensorforOperation(HI)
Theacceleratorpositionsensorforoperationcannotbedetectedproperly.Checkthesensorvoltage.Thereisa
possibilityofshortcircuitto+B.
40

P-CodeDST-1DisplayRemarksDescription
P1142IdleVolume(LO)
Theidlevolumecannotbedetectedproperly.Checkthesensorvoltage.Therearepossibilitiesofopenandshort
circuittoground.
P1143IdleVolume(HI)
Theidlevolumecannotbedetectedproperly.Checkthesensorvoltage.Thereisapossibilityofshortcircuitto+B.
P1211
InjectorCommon1Malfunction
Thereisapossibilityofshortcircuittoground.Checktheinjectorandwiring.
P1212
InjectorCommon1Malfunction
Thereisapossibilityofopenorshortcircuitto+B.Checktheinjectorandwiring.
P1214
InjectorCommon2Malfunction
Thereisapossibilityofshortcircuittoground.Checktheinjectorandwiring.
P1215
InjectorCommon2Malfunction
Thereisapossibilityofopenorshortcircuitto+B.Checktheinjectorandwiring.
P1427
"Theexhaustpressurecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuittogroundintheharness."
P1428
ExhaustPressureSensorMalfunction(LO)
Theexhaustpressurecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuit
to+Bintheharness.
P1472
ExhaustPressureSensorMalfunction(HI)
Transmissionretarderrelaylinkedwiththecruisecontrolsystemforthelarge-andmedium-sizevehicles
"Thetransmissionretarderrelayhasamalfunction.Therearepossibilitiesoftherelaymalfunction,openandshort
circuittogroundintheharness."
P1473
TransmissionRetarderRelayMalfunction
Transmissionretarderrelaylinkedwiththecruisecontrolsystemforthelarge-andmedium-sizevehicles
The transmission retarder relay has a malfunction. There are possibilities of the relay malfunctionandshortcircuit
to+Bintheharness.
P1477
TransmissionRetarderRelayMalfunction
Transmissionretarderrelaylinkedwiththecruisecontrolsystemforthemedium-sizevehicle
"The cruise control retarder relay has a malfunction.Therearepossibilitiesoftherelaymalfunction,openandshort
circuittogroundintheharness."
P1478
CruiseControlRetarderRelayMalfunction
Transmissionretarderrelaylinkedwiththecruisecontrolsystemforthemedium-sizevehicle
Thecruisecontrolretarderrelayhasamalfunction.Therearepossibilitiesoftherelaymalfunctionandshortcircuit
to+Bintheharness.
P1530
CruiseControlRetarderRelayMalfunction
Theenginestopswitchhasamalfunctionorthereisshortcircuitinthewiring.Monitorthestateandcheckthe
ON/OFFjudgment.
P1565
EngineStopSwitchCloseMalfunction
CruiseControlSwitchTheMalfunction
cruisecontrolswitchhasamalfunctionandremainsON.MonitorthestateandchecktheON/OFFjudgment.
P1601QRCodeErrorTheQRcodehasanerror.ChecktheQRcode.
41

P-CodeDST-1DisplayRemarksDescription
P1681
"Theexhaustbrakesolenoidvalvehasamalfunc-tion.Therearepossibilitiesofthesolenoidvalvemalfunction,
openandshortcircuittogroundintheharness."
P1682
ExhaustBrakeSolenoidValveMalfunction
The exhaust brake solenoid valve has a malfunction. There are possibilitiesofthesolenoidvalvemalfunc-tionand
shortcircuitto+Bintheharness.
P2002
ExhaustBrakeSolenoidValveMalfunction
TheDPRsystemhasamalfunction.Therearepossibilitiesofthemeltdownandclog-ging.PerformtheDPR
systemcheck.
P2032
DPRSystemMalfunction
ExhaustGasTempera-tureSensor2Malfunction(LO)
Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunctionandshortcircuitto
groundintheharness.
P2033
ExhaustGasTempera-tureSensor2Malfunction(HI)
"Thetemperaturecannotbedetectedproperly.Therearepossibilitiesofthesensormalfunction,openandshort
circuitto+Bintheharness."
P2120
Both the accelerator sensor 1 and 2 have malfunc- tions. There are possibilities of the sensor and har- ness
malfunctions.
P2121
AcceleratorPositionSensor1&2Malfunction
AcceleratorPositionSensor1Malfunction
Theacceleratorpositionsensor1cannotbedetectedproperly.Checkthesensorvoltage.
P2122
AcceleratorPositionSensor1Malfunction(LO)
Theacceleratorpositionsensor1cannotbedetectedproperly.Checkthesensorvoltage.
P2123
AcceleratorPositionSensor1Malfunction(HI)
Theacceleratorpositionsensor1cannotbedetectedproperly.Checkthesensorvoltage.Thereisapossibilityof
shortcircuitto+B.
P2126
AcceleratorPositionSensor2Malfunction
Theacceleratorpositionsensor2cannotbedetectedproperly.Checkthesensorvoltage.
P2127
AcceleratorPositionSensor2Malfunction(LO)
Theacceleratorpositionsensor2cannotbedetectedproperly.Checkthesensorvoltage.Therearepossibilitiesof
openandshortcircuittoground.
P2128
AcceleratorPositionSensor2Malfunction(HI)
Theacceleratorpositionsensor2cannotbedetectedproperly.Checkthesensorvoltage.Thereispossibilityofshort
circuitto+B.
P2228
AtmosphericAirPres-sureSensorMalfunction(LO)
"Theatmospherepressuresensor(inECU)hasamalfunction.Ifthemalfunctionoccursfrequently,itisnecessaryto
repairorreplacetheECU."
P2229
AtmosphericAirPres-sureSensorMalfunction(HI)
"Theatmospherepressuresensor(inECU)hasamalfunction.Ifthemalfunctionoccursfrequently,itisnecessaryto
repairorreplacetheECU."
U0073
CANMalfunctionCommunication(Engine)
ThereisamalfunctionofcommunicationwiththeVNT.
U0101
Formiddle-sizedVNT
LostCommunicationCommunication(Transmission)
errorbetweenpro-shiftand
CommunicationwiththetransmissionECUislost.AT-ECU
U0104
Lost(CruiseCommunication
control)
CommunicationwiththeautocruiseECUislost.
42

P-CodeDST-1DisplayRemarksDescription
U0121
Lost(ABS)
Communication
CommunicationwiththeABSECUislost.
U0132
Lost(Airsuspension)
Communication
CommunicationwiththeairsuspensionECUislost.
U0155
Lost(Meter)
Communication
CommunicationwiththemeterECUislost.
U1001
CANerrorCommunication(Vehicle)
CANcommunicationbusOFFjudgment
Thereisamalfunctionofcommunicationwithothercomputersequippedinvehicle.
TBD
WhenlinearsolenoidspecificPcodeisobtained
"TheEGRsolenoid1hasamalfunction.Therearepossibilitiesofsolenoidvalvemalfunction,openandshortcircuit
togroundintheharness."
TBD
EGRSolenoid1Malfunction
WhenlinearsolenoidspecificPcodeisobtained
TheEGRsolenoid1hasamalfunction.Therearepossibilitiesofsolenoidvalvemalfunctionandshortcircuitto+B
intheharness.
TBD
EGRSolenoid1Malfunction
WhenlinearsolenoidspecificPcodeisobtained
"TheEGRsolenoid2hasamalfunction.Therearepossibilitiesofsolenoidvalvemalfunction,openandshortcircuit
togroundintheharness."
TBD
EGRSolenoid2Malfunction
WhenlinearsolenoidspecificPcodeisobtainedEGRSolenoid2Malfunction
TheEGRsolenoid2hasamalfunction.Therearepossibilitiesofsolenoidvalvemalfunctionandshortcircuitto+B
intheharness.
43

[2]ECUExternalWiringDiagram
50A
Power4relay
30A
5A
ACTpowerrelay15A
KEY/SWKEY/SW
SCVHI+BF+BF
SCVLOSCVHI
SCVSCVLO
Mainrelay
+BP+BP
CANH
ForCANwire
15A
M-REL
CANL
(Twistpairwireetc.)
M-REL
Starterrelay
ST/SW
Battery12V
GND
LightsGNDP-GNDP-GNDP-GND
Enginespeedsensor
NE[+]NE[-]NE-SLD
COMMON1
InjectorL6(x6)
COMMON1
TDCsensor
G-VCCG
TWV1
G-GNDA-VCC
TWV3
Acceleratorpositionsensor
ACCP1A-GND
TWV5
THWACCP2A-GND
COMMON2SCASC
COMMON2TWV2Acceleratorpositionsensor
A-VCC
TWV4VPCRailpressuresensor
VPC
TWV6A-GND
Idlecontroller
Watertemp.sensor
Fueltemp.sensor
THLA-VCCVIMC
SwitchesA-GNDA-VCCPIM1Boostpressuresensor
A-GND
ActuatorsCaseGND
NOTE:Dashedlinesintheillustrationshowshieldline.
Q000441E
44

[3]ECUConnectorDiagram
(1)ECUConnectorTerminalLayout
34P35P32P35P31P
123456735363738394041707172737475761021031041051061071371381391401411421438910111213
1415161742434445464748495051525377787980818283848586108109110111112113114115116117144
14514614714814915015115215318192021222324252627545556575859606187888990919293949596
118119120121122123124125126127128154155156157158159160161282930313233346263646566676869
979899100101129130131132133134135136162163164165166167

(2)TerminalConnections
No.PinSymbolConnectionsNo.PinSymbolConnections
1(GND)ECUground(spare)18(CASEGND)Caseground(spare)2(GND)ECUground(spare)19KWP2000
ISO9141-K3IN3spare20IN14IN3-spare21AD1Acceleratorpositionsensor15+BPower22AD2
Acceleratorpositionsensor26+BPower23AD10Acceleratorpositionsensorforoperation7+BPower24AD12
spare8TAC1spare25AD19spare9TAC2Tachometersignal(SINK)26AD20spare10POUT1spare27VS1
Vehiclespeedsensor11POUT2spare28CASEGNDCaseground12POUT3spare29IN213POUT4spare30
AD14IMCvolume14PIN1spare31AD15spare15PIN2spare32AD16Intakeairtemp.sensor(Build-inAirflow
meter)1633AD17spare17(BATT)34AD18spare35+BF+BF53SW7Brakeswitch36OUT5
Exhaustbrakesolenoidvalve54A-GND4Sensorground437OUT6spare55A-GND5Sensorground538OUT7
spare56SW1Keyswitch39NE-SLDEngineRPMshieldground57A-VCC4Sensor(Powersupply)440NE+
EngineRPM+58SW8Acceleratorpedalswitch41NE-EngineRPM-59SW10spare42OUT1spare60SW12
Constant-speedswitch43OUT2spare61SW17Stoplampswitch44OUT3Exhaustbrakelight62AD21spare45
OUT4Glowindicatorlight63AD22EGRvalveliftsensor246SW1Keyswitch6447OUT8spare65
A-VCC5Sensor(Powersupply)548SW2Starterswitch66SW9Neutralswitch49SW3Exhaustbrakeswitch67
SW11spare50SW4spare68SW16Diag.switch51SW5spare69SW18spare52SW6spare
Q000442E
45

No.PinSymbolConnectionsNo.PinSymbolConnections
70OUT19Glowrelay8671OUT20Glowrelay87SW31ATidentificationsignal72GNDECUground88
SW20PTO2switch73GNDECUground89SW21PTOswitch74OUT17ECUmainrelay90SW25spare75
OUT18ECUmainrelay91SW26spare76+BF+BF92SW13Cruiseswitch177SW27Clutchswitch93SW28
Clutchstrokeswitch78SWspare94SW29spare79SWCruiseswitch295CANHCAN2HI80SWStoplamp
switch296CANLCAN2LOW81SWspare97SW32Hydraulicpressureswitch82S-OUT1Checkenginelight1
98SW22Warm-upswitch83S-OUT2spare99SW23spare84S-OUT3spare100SW30spare85S-OUT4spare
101CAN-SLDCAN2Shieldground102P-GNDPowerground120GCamangle103TWV1Injectordrivesignal
1121AD4Railpressuresensor1104TWV3Injectordrivesignal3122AD11Airflowmeter105TWV5Injector
drivesignal5123A-VCC3Sensor(Powersupply)3106COMMON1Injectordrivepower1124NE-VCCspare
107COMMON1Injectordrivepower1125A-VCC2Sensor(Powersupply)2108OUT9EGRlinearsolenoid
drive1126A-VCC1Sensor(Powersupply)1109OUT10EGRlinearsolenoiddrive2127AD13EGRvalvelift
sensor1110OUT11spare128AD3Boostpressuresensor111OUT12spare129(GND)ECUground(spare)112
OUT13Cruiselamp130(GND)ECUground(spare)113OUT14Constant-speedlamp131G-GNDCAMangle
ground114OUT15spare132AD5Railpressuresensor2115OUT16spare133G-VCCCamangleVCC(5V)116
134A-GND1Sensorground1117135A-GND2Sensorground2118A-GND6Airflowground136
A-GND3Sensorground3119NE(MRE)
46

No.PinSymbolConnectionsNo.PinSymbolConnections137TWV2Injectordrivesignal2153PCV1spare138
TWV4Injectordrivesignal4154AD6spare139TWV6Injectordrivesignal6155AD7Watertemp.sensor140
P-GNDPowerground156141P-GNDPowerground157CAN1HCAN1HI142COMMON2Injectordrive
power2158CAN1LCAN1LOW143COMMON2Injectordrivepower2159144SCVLOHP3or4pump
controlvalvedrivesignal160145SCVLOHP3or4pumpcontrolvalvedrivesignal161(CASEGND)Case
ground(spare)146SCVHIHP3or4pumpcontrolvalvepower162AD8spare147SCVHIHP3or4pumpcontrol
valvepower163AD9Fueltemp.sensor2148164149165CAN1-SLDspare150PCV2spare
166151PCV2spare167(CASEGND)Caseground(spare)152PCV1spareBuilt-inPATMAtmosphericair
pressuresensor
47

48