COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation

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1 N04C-# Engine COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation Issued : March 2007 Revised : December 2009 Applicable Vehicle : Manufacturer TOYOTA HINO Vehicle Name DYNA COASTER DUTRO EB

2 Revision History Date 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 (FEBRUARY 2007, JUNE 2009) Engine ECU External Wiring Diagram and Connector Terminal Layout ENGINE ECU DIAGNOSTIC TROUBLE CODES (DTC) Basic CRS content omitted, June, 2009 model CRS content added. Items added are as per the following: APPLICABLE VEHICLES AND PRODUCT INFORMATION INJECTOR Engine ECU External Wiring Diagram and Connector Terminal Layout 2009 DENSO CORPORATION All rights reserved. This material may not be reproduced or copied, in whole or in part, without the written permission of DENSO Corporation.

3 Table of Contents Operation Section 1. APPLICABLE VEHICLE AND PRODUCT INFORMATION 1.1 Introduction Applicable Vehicles Applicable Product List SYSTEM OUTLINE 2.1 Layout of Main Components SUPPLY PUMP 3.1 Outline Suction Control Valve (SCV) Fuel Temperature Sensor RAIL 4.1 Outline INJECTOR 5.1 Outline CONTROL SYSTEM 6.1 Control System Diagram Engine ECU Electronic Drive Unit (EDU) Sensors EXHAUST GAS CONTROL SYSTEM (FEBRUARY 2007, AND JUNE 2009) 7.1 Outline E-EGR System DPF System ENGINE ECU DIAGNOSTIC TROUBLE CODES (DTC) 8.1 DTC Table CONTROL SYSTEM COMPONENTS 9.1 Engine ECU External Wiring Diagram Connector Terminal Layout

4 APPLICABLE VEHICLE AND PRODUCT INFORMATION 1.1 Introduction This manual describes the Common Rail System (CRS) equipped with the NO4C-# engines used in the HINO DUTRO, TOYOTA DYNA (both pickup trucks), as well as the TOYOTA COASTER (bus.) For information on items common to all CRSs, refer to the previously published CRS general addition manual (Doc ID: E). [Items common to all CRSs: CRS development process, system control, construction and operation of main components (supply pump, rail, injectors.)] 1.2 Applicable Vehicles November 2003 Vehicle Name Engine Model Remarks DUTRO/DYNA N04C-TF March 2007 Vehicle Name Engine Model Destination Remarks DUTRO/DYNA COASTER Vehicle power supply voltage: 24 V, Engine N04C-TP ECU 12 V spec., with Diesel Particulate Filter Europe (DPF), MT N04C-TQ Vehicle power supply voltage: 24 V, MT with DPF N04C-TR N04C-TS N04C-TT General Vehicle power supply voltage: 24 V, Engine ECU 12 V spec., MT Vehicle power supply voltage: 24 V, Engine N04C-TU ECU 12 V spec., AT Australia Vehicle power supply voltage: 24 V, Engine N04C-TV ECU 12 V spec., MT N04C-TW Europe, Hong Kong Vehicle power supply voltage: 24 V, Engine ECU 12 V spec., with DPF, MT N04C-TQ Europe, Australia Vehicle power supply voltage: 24 V, with DPF, MT N04C-TY China Vehicle power supply voltage: 24 V, MT June 2009 Vehicle Name Engine Model Remarks DUTRO/DYNA/COASTER N04C-#

5 1 2 Operation Section 1.3 Applicable Product List November 2003 Part Name DENSO Part Number Manufacturer Part Number Remarks Supply Pump # S Rail # A Injector # A Engine ECU # Electronic Drive Unit (EDU) # Accelerator Pedal Module # Crankshaft Position Sensor # A Camshaft Position Sensor # A Coolant Temperature Sensor # A Mass Air Flow (MAF) Meter # Intake Air Temperature Sensor # A Manifold Absolute Pressure (MAP) Sensor Exhaust Gas Recirculation (EGR) Valve Exhaust Gas Temperature Sensor # A # A # (IN) (IN) # (OUT) (OUT) March 2007 Part Name DENSO Part Manufacturer Number Part Number Supply Pump # E # E0080 China Only Rail # E0010 Injector # E # E0090 General Only # E0190 China Only Remarks

6 1 3 Part Name Engine DYNA/ ECU DUTRO DENSO Part Manufacturer Number Part Number # N04C-TQ, DPF # N04C-TP, DPF Remarks Vehicle power supply voltage: 24 V # N04C-TW, DPF # # N04C-TS # N04C-TT # N04C-TV # # N04C-TR # N04C-TS Vehicle power supply voltage: 24 V, Engine ECU 12 V specs # N04C-TU # Engine COASTER # Vehicle power supply N04C-TQ, DPF ECU # voltage: 24 V # N04C-TY Vehicle power supply voltage: 12 V # N04C-TQ, DPF Vehicle power supply voltage: 24 V EDU # N04C-TQ # Accelerator Pedal # Module # N04C-TQ EGR Valve # E0010 Without N04C-TR, TS, TT Camshaft Position Sensor # A Crankshaft Position Sensor # A MAF Meter # Exhaust Gas # DPF, Upstream of Catalyst Temperature Sensor # DPF, Downstream of Catalyst Differential Pressure # DPF Sensor

7 1 4 Operation Section June 2009 Part Name DENSO Part Manufacturer Number Part Number Remarks Supply Pump # E0060 Rail # E0010 Injector # E V use # E V use # # Engine ECU # # # # EDU # Accelerator Pedal # DUTRO right-hand driver vehicles Module # DUTRO left-hand driver vehicles Accelerator Position Sensor # DYNA, COASTER EGR Valve # E0010 Camshaft Position Sensor # A Crankshaft Position Sensor # A Intake Air Temperature # E0060 Sensor MAP Sensor # Differential Pressure Sensor #

8 SYSTEM OUTLINE 2.1 Layout of Main Components

9 1 6 Operation Section 3. SUPPLY PUMP 3.1 Outline The November 2003, and June 2009 model supply pumps are equipped with an SV1 type Suction Control Valve (SCV). The March 2007 supply pump is equipped with an SV2 type SCV. Additionally, supply pumps in the part number series # are equipped with the SV1 type SCV as of June Supply pumps in the part number series # are equipped with the SV1 type SCV as of October (1) November 2003 ( #), March 2007 ( # * ) and June 2009 ( #) * : Beginning from October 2007 (2) March 2007 ( #, -063#)

10 Suction Control Valve (SCV) (1) November 2003 ( #) The supply pumps in the part number series above are equipped with a conventional, normally open type SCV. Operation Concept Diagram Operation

11 1 8 Operation Section (2) March 2007 ( #, -063#) The supply pumps in the part number series above are equipped with a compact, normally closed SCV. Operation Concept Diagram Operation

12 1 9 (3) March 2007 ( # * ) and November 2009 ( #) The supply pumps in the part number series above are equipped with a conventional, normally closed type SCV * : Beginning from October 2007 Operation Concept Diagram Operation

13 1 10 Operation Section 3.3 Fuel Temperature Sensor A conventional sensor is used with the NO4C-# engine CRS. Sensor resistance values in relation to fuel temperature are provided below.

14 RAIL 4.1 Outline Rails in the part number series # have a flow damper to suppress fuel pulsations. Since rails in the part number series # have a built-in function to suppress fuel pulsations, there is no flow damper. (1) November 2003 (Rail: #) (2) March 2007, and June 2009 (Rail: #)

15 1 12 Operation Section 5. INJECTOR 5.1 Outline The CRS detailed herein uses solenoid injectors with QR codes. The injectors used in the June 2009 model CRS were designed to show improved responsiveness, as well as to increase resistance against foreign material adherence to the nozzle. (1) November 2003 (Injector: #)

16 1 13 (2) March 2007 (Injector: #, -652#, -655#)

17 1 14 Operation Section (3) June 2009 (Injector: #, -848#)

18 CONTROL SYSTEM 6.1 Control System Diagram

19 1 16 Operation Section 6.2 Engine ECU General export vehicles for Europe, Oceania, and Asia use 12 V specification engine ECUs in relation to the 24 V vehicle power supply (battery voltage). Accordingly, in the event that service such as repairs are necessary, always verify the engine ECU specifications. To verify the specifications, look behind the passenger seat back and check the engine ECU case, as well as whether or not there is a DC-DC converter. < ATTENTION > When performing checks, do not apply vehicle power supply voltage to the engine ECU. If the vehicle power supply voltage (24 V) is applied to a 12 V specification engine ECU, the ECU may be damaged. The figure below is an external view of the engine ECU. For the connector pin layout and external wiring diagram: Refer to [Connector Terminal Layout] on P1-57.

20 Electronic Drive Unit (EDU) A conventional EDU is used with the NO4C-# engine CRS. (1) Operation A high-voltage generating device converts the battery voltage into high voltage. The engine ECU sends signals to terminals B through E of the EDU in accordance with the signals from each sensor. Upon receiving these signals, the EDU outputs signals to the injectors from terminals K through N. At this time, terminal F outputs the IJf injection verification signal to the ECU. External Wiring Diagram

21 1 18 Operation Section 6.4 Sensors (1) Crankshaft position sensor and camshaft position sensor Conventional sensors are used as the crankshaft position sensor and camshaft position sensor. The crankshaft position sensor is a Magnetic Pick Up (MPU) type sensor, while the camshaft position sensor is a Magnetic Resistance Element (MRE) type.

22 1 19 (2) Accelerator position sensor and accelerator pedal module A conventional hall element type sensor is used as the accelerator position sensor. Accelerator Position Sensor: DYNA, COASTER

23 1 20 Operation Section Accelerator Pedal Module: DUTRO

24 1 21 (3) Manifold Absolute Pressure (MAP) sensor The MAP sensor is used in the NO4C-TF engine. Sensor output voltage values in relation to absolute pressure are provided below. (4) Coolant temperature sensor The coolant temperature sensor is used in the NO4C-TF engine. Sensor resistance values in relation to coolant temperature are provided below.

25 1 22 Operation Section (5) Mass Air Flow (MAF) meter A conventional sensor is used with the NO4C-# engine CRS. Operation When a heating element (heating coil) is placed in the air passage, the air absorbs heat and cools the heating element. For this reason, the resistance value of the heating element decreases, and the current increases. As the intake air volume increases, the cooling temperature of the heating element also increases. The hot-wire type airflow meter utilizes the changes in the heating element. One portion of the intake air passes by the heating element, and the temperature of the heating element resistor changes in accordance with the intake air volume. The control circuit is used to ensure the temperature of the heating element resistor is always constant. In other words, since the heating element becomes cooler as the airflow volume increases, it is necessary to heat the element by increasing current flow through the resistor. This change in current is converted into voltage by the control circuit IC. However, even if the intake air volume is constant, the temperature of the heating element resistor changes according to the intake air temperature. These changes result in errors when detecting the intake air volume. To correct these errors, an additional intake air temperature compensator resistor (air thermometer) is used.

26 EXHAUST GAS CONTROL SYSTEM (FEBRUARY 2007, AND JUNE 2009) 7.1 Outline Both an Electric-Exhaust Gas Recirculation (E-EGR) and a Diesel Particulate Filter (DPF) system are used to comply with Euro 4 emission regulations. The EGR valve, exhaust gas temperature sensor, and differential pressure sensor are made by DENSO. 7.2 E-EGR System The E-EGR system is an electronically controlled EGR system. The EGR system reduces NOx by lowering the combustion temperature through re-circulating a portion of the exhaust gas to the intake manifold. Since this system may also reduce engine output and decrease drivability, the EGR volume is controlled electronically to an optimum level in accordance with driving conditions. Both the electronically controlled EGR system and a high-capacity multipass system EGR cooler are used. Engine performance has been increased through enabling high-volume exhaust gas recirculation. A linear solenoid type valve is used as the actuator in the EGR valve. Simultaneous PM and NOx reduction have been achieved by increasing EGR quantity adjustment precision. An EGR valve lift sensor is also used. The EGR valve opening is fed back to the engine control computer to enable optimal EGR control. (1) Construction and operation To improve EGR exhaust gas purification performance, feedback control is performed using the EGR valve position. Oxygen concentration in the intake air (which changes according to EGR) is controlled to a target value in accordance with the engine state (engine speed, rising pressure, part temperatures, load and intake air volume.) To expand the EGR range, the lift sensor installed on the EGR valve performs feedback control of the actual EGR quantity in relation to the pre-set target EGR quantity. Feedback control is based on the intake restriction position and the variable nozzle turbo position.

27 1 24 Operation Section 7.3 DPF System A conventional DPF system is used with the NO4C-# engine CRS.

28 1 25 (1) Exhaust gas temperature sensor A conventional sensor is used as the exhaust gas temperature sensor. Sensor resistance values in relation to exhaust gas temperature are provided below. (2) Differential pressure sensor A conventional sensor is used as the differential pressure sensor. Sensor output voltage values in relation to exhaust gas differential pressure are provided below.

29 1 26 Operation Section 8. ENGINE ECU DIAGNOSTIC TROUBLE CODES (DTC) 8.1 DTC Table The following are Diagnostic Trouble Code (DTC) tables for November 2003, and March 2007 vehicles. The "November 2003" DTC table is for conventional N04C-TF engines. The "March 2007" DTC table is for the N04C-TP, Q, R, S, T, U, V, and W engines. (1) November 2003 *1 : TCCS is the name designated by TOYOTA for DTCs resulting from the Malfunction Indicator Light (MIL). For details, refer to the CRS General Edition Manual ( E.) *2 : The "A" in "A#" for TCCS represents a "10". Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item P0030, P0031, P0130, 21 1 A/F sensor (B1S1) P0131, P0132 P0036, P0037, P0136, 27 1 A/F sensor (B1S2) P0137, P0138 P Rail pressure abnormality (fixed output) P Suction Control Valve (SCV) abnormality (high-pressure in rail) P Fuel leak abnormality P0095, Intake air temperature sensor No. 2 (post-turbo intake air P0097, 23 1 temperature sensor) P0098 P0100, P0102, 31 1 Mass Air Flow (MAF) meter P0103 P0105, P0107, 35 1 Manifold Absolute Pressure (MAP) sensor P0108 P0110, P0112, P Intake air temperature sensor

30 1 27 Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item P0115, P0117, 22 1 Coolant temperature sensor P0118 P0120, P0122, 41 1 Accelerator position sensor P0123 P Abnormally high fuel temperature P0180, P0182, 39 1 Fuel temperature sensor P0183 P0190, P0192, 49 1 Rail pressure sensor with back-up sensor P0193 P Rail pressure sensor with back-up sensor (out- of-range) P EDU abnormality (engine diagnostic) P VN turbo abnormality (closed-side abnormality) P Injector abnormality (FCCB abnormality) (No. 1 cylinder) P Injector abnormality (FCCB abnormality) (No. 2 cylinder) P Injector abnormality (FCCB abnormality) (No. 3 cylinder) P Injector abnormality (FCCB abnormality) (No. 4 cylinder) P VN turbo abnormality (open-side abnormality) P0335 Crankshaft position sensor (open circuit/phase difference/power 13 1 flicker) P Crankshaft position sensor (open circuit) P Crankshaft position sensor (NE power flicker) P Crankshaft position sensor (open circuit/power flicker) P Camshaft position sensor (during start-up) P Exhaust Gas Recirculation (EGR) flow malfunction P EGR valve P0405, P EGR lift sensor P Intake restriction motor control system P Vehicle speed sensor (MT) P Stop light switch P CPU abnormality P Pump abnormality (open/short circuit) P Exterior accelerator position No. 1 sensor high P Throttle knob high

31 1 28 Operation Section Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item P Pump valve abnormality P Injector injection abnormality P VN turbo (power flicker) P Emergency stop switch system P Multiple-point injector correction (EEPROM abnormality) P Internal IC abnormality P RUN pulse abnormality P Exhaust brake VSV system P2120, P2122, P2123, P2125, 19 1 Accelerator position sensor P2127, P2128, P2138 P Accelerator position sensor (out-of-range) P2226, P2228, P2229 A5 *2 1 Accelerator position sensor (open circuit)

32 1 29 (2) March 2007, and June 2009 *1 : TCCS is the name designated by TOYOTA for DTCs resulting from the Malfunction Indicator Light (MIL). For details, refer to the CRS General Edition Manual ( E.) *2 : The "A" in "A#" for TCCS represents a "10". Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item Remarks P VN turbo (open) P Rail pressure abnormality (fixed output) P Suction Control Valve (SCV) abnormality (high-pressure in rail) P Fuel leak abnormality P0095, P0097, P Intake air temperature sensor No. 2 (post-turbo intake air temperature sensor) P0100, P0102, 31 1 Mass Air Flow (MAF) meter P0103 P MAF meter (out-of-range) P0105, P0107, 35 1 MAP Sensor P0108 P MAP Sensor (out-of-range) #, -863#, 864# only P0110, P0112, 24 1 Intake air temperature sensor P0113 P0115, P0117, 22 1 Coolant temperature sensor P0118 P Coolant temperature sensor (high temperature out-of-range) P #, -899#, -900#, - Coolant temperature sensor (high 902#, -904#, -906#, -907#, - temperature stuck) 909#, -910#, -912# only P0120, P0122, 41 1 Accelerator position sensor P0123 P Abnormally high fuel temperature P0180, P0182, P Fuel temperature sensor

33 1 30 Operation Section Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item Remarks P0190, Rail pressure sensor with back-up P0192, 49 1 sensor P0193 P Rail pressure sensor with back-up #, -863#, 864# sensor (out- of-range) only P EDU abnormality (engine diagnostic) P VN turbo abnormality (closed-side abnormality) P Injector abnormality (FCCB abnormality) (No. 1 cylinder) P Injector abnormality (FCCB abnormality) (No. 2 cylinder) P Injector abnormality (FCCB abnormality) (No. 3 cylinder) P Injector abnormality (FCCB abnormality) (No. 4 cylinder) P VN turbo abnormality (open-side abnormality) Crankshaft position sensor (open P circuit/phase difference/power flicker) P Crankshaft position sensor (open circuit) P Crankshaft position sensor (NE power flicker) P Crankshaft position sensor (open circuit/power flicker) P Camshaft position sensor (during start-up) P EGR flow malfunction P EGR system malfunction P0405, P EGR lift sensor P0405, P EGR lift sensor P Intake restriction motor control system P Vehicle speed sensor (MT) P Stop light switch

34 1 31 Lamp DTC Detection Output Trip SAE TCCS *1 (CE) Detection Item Remarks P0544, Exhaust temperature sensor P0545, A3 *2 1 circuit malfunction (in) P0546 P CPU abnormality P Starter abnormally high P Fuel pump abnormality (Open/ short circuit) P Vehicle Identification Number (VIN) not read P EFI ECT communication fault P #, -899#, -900#, - Exterior accelerator position 902#, -904#, -906#, -907#, - sensor high 909#, -910#, -912# only P Throttle knob high P Fuel pump abnormality (open/ short circuit) P Injector injection abnormality P VN turbo (power flicker) P1425, Differential pressure sensor (open P1427, A4 *2 1 circuit) P1428 P1426 A4 *2 1 Differential pressure sensor (incorrect piping) P Emergency stop switch system P Multiple-point injector correction (EEPROM abnormality) P Internal IC abnormality P RUN pulse abnormality P Exhaust brake VSV system P DPF system abnormality P2031, P2032, A3 *2 1 Exhaust temperature sensor (out) P2033 P2120, P2122, P2123, P2125, P2127, P2128, P Accelerator position sensor

35 1 32 Operation Section Lamp DTC Detection Output Detection Item Remarks Trip SAE TCCS *1 (CE) Accelerator position sensor (outof-range) P P2226, Atmospheric pressure sensor P2228, A5 *2 1 (open circuit) P2229 Atmospheric pressure sensor P2227 A5 *2 2 (out-of-range) CAN communication (HV ECU: U0293 A2 * #, -899#, -900#, - communication disruption) 902#, -904#, -906#, -907#, - VNT ECU CAN communication U1123 A2 * #, -910#, -912# only (reception abnormality)

36 CONTROL SYSTEM COMPONENTS 9.1 Engine ECU External Wiring Diagram (1) November # (1)

37 # (2)

38 1 35 (2) March # (1)

39 1 36 Operation Section # (2)

40 #, -864# (1)

41 1 38 Operation Section #, -864# (2)

42 # (1)

43 1 40 Operation Section # (2)

44 # (1)

45 # (2)

46 #, -902#, -907#, -909# (1)

47 1 44 Operation Section #, -902#, -907#, -909# (2)

48 #, -910# (1)

49 1 46 Operation Section #, -910# (2)

50 #, -912# (1)

51 1 48 Operation Section #, -912# (2)

52 1 49 (3) June # (1)

53 # (2)

54 # (1)

55 # (2)

56 # (1)

57 # (2)

58 # (1)

59 # (2)

60 Connector Terminal Layout (1) November 2003 (2) March # # #, -864#

61 1 58 Operation Section # # #, -902#, -907#, -909# #, -910#

62 #, -912# (3) June # # #

63 1 60 Operation Section #

64 Service Department DENSO CORPORATION 1-1, Showa-cho, Kariya-shi, Aichi-ken, , Japan