Hino J05D & J08E Engine Common Rail System (CRS) Service Manual PDF (EN)

J05D/J08E Engine COMMON RAIL SYSTEM (CRS) SERVICE MANUAL: Operation Issued : September 2007 Revised : May 2010 00400041EB

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Revision History © 2010 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. Date Revision Contents 2007.09 ‡ 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

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Table of Contents Operation Section 1. APPLICABLE VEHICLE AND PRODUCT INFORMATION 1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Applicable Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.3 Applicable Products List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2. COMMON RAIL SYSTEM (CRS) OUTLINE 2.1 CRS Outline (Diagram) . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 3. SUPPLY PUMP 3.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 3.2 Suction Control Valve (SCV) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8 3.3 Fuel Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 4. RAIL 4.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 5. INJECTOR 5.1 Outline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 6. CONTROL SYSTEM 6.1 Engine ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18 6.2 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20 7.

EXHAUST GAS CONTROL SYSTEM 7.1 Exhaust Gas Recirculation (EGR) System (2004 Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26 7.2 Diesel Particulate Filter (DPF) System (2007, 2010 Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-27 7.3 Selective Catalytic Reduction (SCR) System (2010 Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29 8. ENGINE ECU DIAGNOSTIC TROUBLE CODES (DTC) 8.1 DTC Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30 9.

ATTACHED MATERIALS 9.1 Engine ECU External Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45 9.2 Connector Terminal Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-49

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Operation Section 1 ± 1 1. APPLICABLE VEHICLE AND PRODUCT INFORMATION 1.1 Introduction This manual describes the Common Rail System (CRS) equipped with J05D/J08E engines used in the HINO Medium Truck. For information on items common to all CRSs, refer to the previously published CRS general addition manual (Doc ID: 00400076E). [Items common to all CRSs: CRS development process, system control, construction and operation of main components (supply pump, rail, injectors), sensors and actuators] Minor changes have been made to the HINO medium truck as of June 2010.

With this minor change, the CRS equipped with the J08E engine has also changed, and now this engine uses the Selective Catalytic Reduction (SCR) system. The SCR system dramatically reduces the quantity of NOx exhaust, and achieves superior environmental protection functionality suited to the stringent emission standards stipulated in the "US10" regulations. Changes to the CRS are shown below. ‡ Maximum injection pressure increased to 200 MPa. ‡ Fuel path related with the supply pump changed. ‡ Rail is compliant with a pressure of 200 MPa. ‡ Engine ECU changed to a direct-mount type. ‡ CRS now equipped with G3 type injectors.

‡ The J08E engine now uses the Selective Catalytic Reduction (SCR) system. 1.2 Applicable Vehicles 2004 model Vehicle Type Vehicle Model Engine Model Engine Displacement Release Date Medium Truck HINO145 HINO165 HINO185 J05D 4.73 L April 2004 HINO238 HINO268 HINO308 HINO338 J08E 7.68 L

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