MR 647470 2019-04 en

647470EN (01/04/2019)
ENGINE
V2607-CR-E4B,
V2607-CR-TE4B,
V2607-CR-TIE4B (DOC only),
V3307-CR-TE4B,
V3307-CR-TIE4B (DOC only)
Repair Manual
647470EN
2
DATE OF ISSUE OBSERVATION
11 / 06 / 2014 - 1st ISSUE
01 / 11 / 2014 - Update
20 / 07 / 2018 - Update
01 / 04 / 2019 - Update + DIAGNOSIS MANUAL
MANITOU BF S.A Limited liability company with a Board of Directors.

Head office: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other,
in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document
organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned
may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF
and may not be used without express and formal authorization. All rights are reserved.
WORKSHOP MANUAL
DIESEL ENGINE
V2607-CR-E4B,V2607-CR-TE4B,
V3307-CR-TE4B,
KiSC issued 04, 2017 A

TO THE READER
This Workshop Manual tells the servicing personnel about the mechanism, servicing and
maintenance of the V2607-CR-E4B, V2607-CR-TE4B and V3307-CR-TE4B. It contains 4 parts:
"Information", "General", "Mechanism" and "Servicing".
 Information
This section primarily contains information below.
• Safety First
• Specification
• Performance Curve
• Dimension
• Wiring Diagram
 General
• Engine Identification
• Muffler Full Assembly Identification
• General Precautions
• Maintenance Check List
• Check and Maintenance
• Special Tools
 Mechanism
This section contains information on the structure and the function of the unit. Before you continue
with the subsequent sections, make sure that you read this section.
Refer to Workshop Manual (Code No. 9Y021-01870) for the diesel engine mechanism that this
workshop manual does not include.
 Servicing
• Troubleshooting
• Servicing Specifications
• Tightening Torques
• Checking, Disassembling and Servicing
All illustrations, photographs and specifications contained in this manual are of the newest
information available at the time of publication.
KUBOTA reserves the right to change all information at any time without notice.
Since this manual includes many models, information or illustrations and photographs can show
more than one model.
December, 2012
© KUBOTA Corporation 2012

Record of Revisions
For pdf, use search function {Search word} to find the all revised locations.
Last digit
Issue Reference
of the Main Revised Point and Corrective Measures {Search word}
month Page
Code No.
1 2013.03 Numbering from (1) to (36) were added in the system wiring diagram. I-25,
Number of missing sealing parts was corrected. G-28,
Number of actual sell depth was corrected. G-29,
(a) and (b) were corrected. G-54
2 2013.06 Pressure limiter information about replacement unit was added. 1-M14,
1-S42
Applying engine oil to the injector O-ring was added. 1-S45
3 2014.06 Correction of Workshop Manual
4. MAINTENANCE CHECK LIST G-6

[9] EVERY 1500 HOURS G-21
Replacement of Oil Separator Element G-22
Check of PCV (Positive Crankcase Ventilation) Valve G-22
4 2015.01 Added the information of V2607-CR-TIE4 / V3307-CR-TIE4 (DOC only)
5 2016.08 Design change of DPF muffler full assy serial number label mounting G-4
position
Added the information of timing gear alignment marks 1-S55
6 2016.12 Added the following information
(1) Decision on Reusability According to the Pin Gauge G-29
Measurement of Actual Cell Depth
(2) Decision on Reusability According to the Differential Pressure G-30
(Differential Pressure Measuring Instrument Manufactured by FSX)
Differential Pressure Measurement
7 2017.04 Correction of Workshop Manual
The procedure of removing and installing for following parts
1. SCV 1-S52
2. Fuel Temperature Sensor 1-S54
Correction of Biodiesel fuel information

I INFORMATION

INFORMATION
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1

2. SPECIFICATIONS.......................................................................................................................... I-5
3. PERFORMANCE CURVES............................................................................................................ I-7
4. DIMENSIONS ............................................................................................................................... I-12
5. WIRING DIAGRAM....................................................................................................................... I-17
[1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS)....................................... I-17
[2] INJECTOR INTERMEDIATE HARNESS
(ENGINE SIDE HARNESS).................................................................................................... I-19
[3] ECU INTERMEDIATE HARNESS (OEM SIDE HARNESS)................................................... I-20
[4] SYSTEM WIRING DIAGRAM................................................................................................. I-25

V2607-CR-E4B, V2607-CR-TE4B, V2607-CR-TIE4B (DOC only), V3307-CR-TE4B, V3307-CR-TIE4B (DOC only), WSM INFORMATION
1. SAFETY FIRST
SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you try to repair or use this
unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
WSM000001INI0001US1
BEFORE YOU START SERVICE
• Read all instructions and safety instructions in this
manual and on your engine safety decals.
• Clean the work area and engine.
• Park the machine on a stable and level ground.
• Let the temperature of the engine decrease before
you start a job.
• Stop the engine, then remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE" tag in the operator
station.
WSM000001INI0002US0
START SAFELY
• Do not do the procedures below when you start the
engine.
– short across starter terminals
– bypass the safety start switch
• Do not make unauthorized modifications to the
engine. This can cause damage and decrease the
engine life.
WSM000001INI0003US0
I-1
OPERATE SAFELY
• Do not use the machine after you consume alcohol
or medication or when you are tired.
• Put on applicable clothing and safety equipment.
• Use applicable tools only. Do not use alternative
tools or parts.
• When 2 or more persons do servicing, make sure
that you do it safely.
• Do not touch the hot parts or parts that turn when the
engine operates.
• Do not remove the radiator cap when the engine
operates, or immediately after it stops. If not, hot
water can spout out from the radiator. Only remove
the radiator cap when it is at a sufficiently low
temperature to touch with bare hands. Slowly loosen
the cap to release the pressure before you remove it
fully.
• Released fluid (fuel or hydraulic oil) under pressure
can cause damage to the skin and cause serious
injury. Release the pressure before you disconnect
hydraulic or fuel lines. Tighten all connections before
you apply the pressure.
• Do not open a fuel system under high pressure.
The fluid under high pressure that stays in fuel lines
can cause serious injury. Do not disconnect or repair
the fuel lines, sensors, or any other components
between the fuel pump and injectors on engines with
a common rail fuel system under high pressure.
• Put on an applicable ear protective device (earmuffs
or earplugs) to prevent injury against loud noises.
• Be careful about electric shock. The engine
generates a high voltage of more than DC100 V in
the ECU and is applied to the injector.
WSM000001INI0004US0
PROTECT AGAINST HIGH PRESSURE SPRAY

• Spray from high pressure nozzles can penetrate the
skin and cause serious injury. Keep spray from
contacting hands or body.
• If an accident occurs, see a doctor immediately. Any
high pressure spray injected into the skin must be
surgically removed within a few hours or gangrene
may result.
Doctors unfamiliar with this type of injury should
reference a knowledgeable medical source.
9Y1210651INI0014US0
I-2
AVOID HOT EXHAUST
• Servicing machine or attachments with engine
operating can result in serious personal injury. Avoid
exposure and skin contact with hot exhaust gases
and components.
• Exhaust parts and streams become very hot during
operation. Exhaust gases and components reach
temperatures hot enough to burn people, ignite, or
melt common materials.
9Y1210651INI0015US0
EXHAUST FILTER CLEANING

• Servicing machine or attachments during exhaust
filter cleaning can result in serious personal injury.
Avoid exposure and skin contact with hot exhaust
gases and components.
• During auto or manual/stationary exhaust filter
cleaning operations, the engine will operate at
elevated idle and hot temperatures for an extended
period of time. Exhaust gases and exhaust filter
components reach temperatures hot enough to burn
people, or ignite, or melt common materials.
9Y1210651INI0016US0
PREVENT A FIRE
• Fuel is very flammable and explosive under some
conditions. Do not smoke or let flames or sparks in
your work area.
• To prevent sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• The battery gas can cause an explosion. Keep the
sparks and open flame away from the top of battery,
especially when you charge the battery.
• Make sure that you do not spill fuel on the engine.
WSM000001INI0005US0
KEEP A GOOD AIRFLOW IN THE WORK AREA

• If the engine is in operation, make sure that the area
has good airflow. Do not operate the engine in a
closed area. The exhaust gas contains poisonous
carbon monoxide.
WSM000001INI0006US0
I-3
DISCARD FLUIDS CORRECTLY
• Do not discard fluids on the ground, down the drain,
into a stream, pond, or lake. Obey related
environmental protection regulations when you
discard oil, fuel, coolant, electrolyte and other
dangerous waste.
WSM000001INI0007US0
PREVENT ACID BURNS

• Keep electrolyte away from your eyes, hands and
clothing. Sulfuric acid in battery electrolyte is
poisonous and it can burn your skin and clothing and
cause blindness. If you spill electrolyte on yourself,
clean yourself with water, and get medical aid
immediately.
WSM000001INI0008US0
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher ready at all
times.
• Keep the emergency contact telephone numbers
near your telephone at all times.
WSM000001INI0009US0
I-4
2. SPECIFICATIONS
Model V2607-CR-E4B V2607-CR-TE4B V3307-CR-TE4B
Number of Cylinder 4
Engine Type Vertical, water-cooled, 4-cycle DI diesel engine
87.0 × 110 mm 94.0 × 120 mm
Bore × Stroke
(3.43 × 4.33 in.) (3.70 × 4.72 in.)
Total Displacement 2615 cm3 (159.6 cu.in.) 3331 cm3 (203.3 cu.in.)
-1
34.3 kW / 2700 min (rpm) 43.5 kW / 2700 min-1 (rpm) 45.6 kW / 2600 min-1 (rpm)
SAE Net Continuous
(46.0 HP / 2700 min-1 (rpm)) (58.3 HP / 2700 min-1 (rpm)) (61.2 HP / 2600 min-1 (rpm))
42.0 kW / 2700 min-1 (rpm) 53.0 kW / 2700 min-1 (rpm) 55.4 kW / 2600 min-1 (rpm)
SAE Gross Intermittent
(56.3 HP / 2700 min-1 (rpm)) (71.1 HP / 2700 min-1 (rpm)) (74.3 HP / 2600 min-1 (rpm))
Maximum Bare Speed 2900 min-1 (rpm) 2800 min-1 (rpm)
Minimum Bare Idling Speed 800 min-1 (rpm)
Combustion Chamber Reentrant Type, Center Direct Injection Type (E-CDIS)
Fuel Injection Pump
Governor
Injector DENSO Common Rail System
Fuel Injection Timing
Fuel Injection Pressure
Direction of Rotation Counter-clockwise (Viewed from flywheel side)
Firing Order 1-3-4-2
Compression Ratio 18.0 16.8 17.5
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical Type Switch
Lubricating Filter Full Flow Paper Filter (Cartridge Type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starter Motor 12 V, 2.5 kW 12 V, 3.0 kW
Starting Support Device By Glow Plug in Combustion Chamber
EGR External EGR (EGR Cooler + Electric EGR Valve + Reed Valve)
Battery 12 V, 92 AH equivalent 12 V, 108 AH equivalent
Charging Alternator 12 V, 720 W
Fuel Diesel Fuel No. 2-D S15, see page G-8.
Class CJ-4 lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils, see page G-8.
Lubricating Oil Capacity 10.2 L (2.69 U.S.gals) 11.2 L (2.96 U.S.gals)
Weight (Dry) 267 kg (589 lbs) 272 kg (600 lbs) 305 kg (672 lbs)
• The specification described above is of the standard engine of each model.
• Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW
9Y1210674INI0001US0
I-5
Model V2607-CR-TIE4B V3307-CR-TIE4B

Number of Cylinder 4
Engine Type Vertical, water-cooled, 4-cycle DI diesel engine
87.0 × 110 mm 94.0 × 120 mm
Bore × Stroke
(3.43 × 4.33 in.) (3.70 × 4.72 in.)
Total Displacement 2615 cm3 (159.6 cu.in.) 3331 cm3 (203.3 cu.in.)
-1
44.5 kW / 2700 min (rpm) 46.7 kW / 2600 min-1 (rpm)
SAE Net Continuous
(59.7 HP / 2700 min-1 (rpm)) (62.6 HP / 2600 min-1 (rpm))
53.0 kW / 2700 min-1 (rpm) 55.4 kW / 2600 min-1 (rpm)
SAE Gross Intermittent
(71.1 HP / 2700 min-1 (rpm)) (74.3 HP / 2600 min-1 (rpm))
Maximum Bare Speed 2900 min-1 (rpm) 2800 min-1 (rpm)
Minimum Bare Idling Speed 800 min-1 (rpm)
Combustion Chamber Reentrant Type, Center Direct Injection Type (E-CDIS)
Fuel Injection Pump
Governor
Injector DENSO Common Rail System
Fuel Injection Timing
Fuel Injection Pressure
Direction of Rotation Counter-clockwise (Viewed from flywheel side)
Firing Order 1-3-4-2
Compression Ratio 16.0 15.6
Lubricating System Forced lubrication by trochoid pump
Oil Pressure Indicating Electrical Type Switch
Lubricating Filter Full Flow Paper Filter (Cartridge Type)
Cooling System Pressurized radiator, forced circulation with water pump
Starting System Electric Starting with Starter
Starter Motor 12 V, 2.5 kW 12 V, 3.0 kW
Starting Support Device By Glow Plug in Combustion Chamber
EGR External EGR (EGR Cooler + Electric EGR Valve + Reed Valve)
Battery 12 V, 92 AH equivalent 12 V, 108 AH equivalent
Charging Alternator 12 V, 720 W
Fuel Diesel Fuel No. 2-D S15, see page G-8.
Class CJ-4 lubricating oil as per API classification is recommended.
Lubricating Oil
For details on recommended lubricating oils, see page G-8.
Lubricating Oil Capacity 10.2 L (2.69 U.S.gals) 11.2 L (2.96 U.S.gals)
Weight (Dry) 259 kg (571 lbs) 295 kg (650 lbs)
• The specification described above is of the standard engine of each model.
• Conversion Formula: HP = 0.746 kW, PS = 0.7355 kW
9Y1210674INI0021US0
I-6
3. PERFORMANCE CURVES
V2607-CR-E4B
(1) Torque (2) B.S.F.C. (Brake Specific Fuel (3) Engine Speed (4) Brake Horsepower
Consumption)
9Y1210674INI0002US0
I-7
V2607-CR-TE4B
Comsumption)
9Y1210674INI0003US0
I-8
V3307-CR-TE4B
Comsumption)
9Y1210674INI0014US0
I-9
V2607-CR-TIE4B
Comsumption)
9Y1210674INI0019US0
I-10
V3307-CR-TIE4B
Comsumption)
9Y1210674INI0020US0
I-11
4. DIMENSIONS
V2607-CR-E4B
V2607-CR-E4B
A 875 mm (34.4 in.)
B 542 mm (21.3 in.)
C 723 mm (28.5 in.)
9Y1210674INI0004US0
I-12
V2607-CR-TE4B
V2607-CR-TE4B
A 875 mm (34.4 in.)
B 542 mm (21.3 in.)
C 723 mm (28.5 in.)
9Y1210674INI0015US0
I-13
V3307-CR-TE4B
V3307-CR-TE4B
A 900 mm (35.4 in.)
B 592 mm (23.3 in.)
C 753 mm (29.6 in.)
9Y1210674INI0016US0
I-14
V2607-CR-TIE4B
V2607-CR-TIE4B
A 888 mm (35.0 in.)
B 524 mm (20.6 in.)
C 723 mm (28.5 in.)
9Y1210674INI0022US0
I-15
V3307-CR-TIE4B
V3307-CR-TIE4B
A 901 mm (35.5 in.)
B 559 mm (22.0 in.)
C 739 mm (29.1 in.)
9Y1210674INI0023US0
I-16
5. WIRING DIAGRAM
[1] ENGINE INTERMEDIATE HARNESS (ENGINE SIDE HARNESS)
(1) − CAN and EGR

(2) CN202 Intake Air Temperature Sensor
(3) CN203 Coolant Temperature Sensor
(4) CN215 Engine Joint Connector 1
(5) CN204 Rail Pressure Sensor
(6) CN205 Crankshaft Position Sensor
(8) CN206 Resistance Connector (1.1 kΩ)
(9) CN207 Oil Pressure Switch
(10) CN208 Boost Pressure Sensor
(11) CN209 / 210 Supply Pump
(12) − Camshaft Position Sensor
(13) CN212 Intake Throttle Valve (V2607-CR-E4 / V2607-CR-TE4 / V3307-CR-TE4)
(14) − Shield Cable
NOTE
• The picture shows the pin arrangement of the connector housing viewed from wire side, not mating side.
9Y1210674INI0024US0
I-17
(1) − CAN and EGR

(3) CN223 EGR Valve
(4) CN226 Resistance Connector (120 Ω)
(5) CN224 / 225 Can Tool
(6) C227 Crankshaft Angle Sensor
(7) CN228 / 229 Connector
(8) CN222 Camshaft Position Sensor
NOTE
9Y1210674INI0006US0
I-18
[2] INJECTOR INTERMEDIATE HARNESS

(ENGINE SIDE HARNESS)
(1) CN306 Injector Intermediate Connector

(2) CN305 Injector Joint Connector 1
(4) CN301 Injector #1
NOTE
9Y1210674INI0007US0
I-19
[3] ECU INTERMEDIATE HARNESS (OEM SIDE HARNESS)
(1) CN501 ECU (1)

(2) CN502 ECU (2)
(3) CN503 ECU Joint Connector 1
(4) − Power Unit
(5) − Diesel Particulate Filter (hereinafter referred to as the "DPF")
(6) − Engine
(7) − Injector
NOTE
9Y1210674INI0008US0
I-20
(1) − Power Unit

(2) CN401 Accel Sensor
(3) CN402 Alternator
(4) CN403 Starter Relay
(5) CN404 Starter
(6) CN405 Connector
(7) CN406 Connector
(8) CN413 Main Relay
(9) − Glow Plug
(10) CN416 Glow Relay
(11) CN414 Connector
(13) − Fuel Feed Pump
(14) − Battery Unit
(15) − Battery
(16) − Key Switch
(17) − Speed Sensor
(18) − CAN for Vehicle
(19) CN407 / 408 CAN Tool
NOTE
9Y1210674INI0009US0
I-21
(1) − Diesel Particulate Filter (DPF)

(2) CN101 DPF Temperature Sensor (T2) (V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B)
(5) CN104 DPF Differential Pressure Sensor (ΔP) (V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B)
(6) CN105 Air Flow Sensor
NOTE
9Y1210674INI0025US0
I-22
(1) − Engine
NOTE
9Y1210674INI0011US0
I-23
(1) − Injector
NOTE
9Y1210674INI0012US0
I-24
[4] SYSTEM WIRING DIAGRAM

V2607-CR-E4B, V2607-CR-TE4B, V3307-CR-TE4B
(1) Main Relay (10) Battery (21) Vehicle Speed Sensor (29) Stop Switch
(2) Fuel Feed Pump (11) Glow Relay (22) DPF Differential Pressure (30) Parked Regeneration Switch
(3) CAN1 Connector (12) Glow Plug Sensor (ΔP) (31) Parking Switch
(For Service) (13) Injector 1 (23) SCV (Suction Control Valve) (32) Regeneration Inhibit Switch
(4) CAN2 Connector (14) Injector 2 (24) Fuel Temperature Sensor (33) Neutral Switch
(For OEM Machine) (15) Injector 3 (25) Coolant Temperature Sensor (34) Oil Switch
(5) EGR Valve (16) Injector 4 (26) Rail Pressure Sensor (35) DPF Temperature Sensor (T0)
(6) Starter (17) Crankshaft Position Sensor (27) Boost Sensor (36) DPF Temperature Sensor (T1)
(7) Air Flow Sensor (18) Camshaft Position Sensor (28) Intake Air Temperature (37) DPF Temperature Sensor (T2)
(8) Intake Throttle Valve (19) Accel Sensor 1 Sensor
(9) Starter Relay (20) Accel Sensor 2 DPF: Diesel Particulate Filter
NOTE
• Terminal names and terminal numbers marked with * have become invalid.
9Y1210674INI0026US0
I-25
V2607-CR-TIE4B, V3307-CR-TIE4B
(1) Main Relay (8) Starter Relay (17) Camshaft Position Sensor (24) Rail Pressure Sensor
(2) Fuel Feed Pump (9) Battery (18) Accel Sensor 1 (25) Boost Sensor
(3) CAN1 Connector (10) Glow Relay (19) Accel Sensor 2 (26) Intake Air Temperature
(For Service) (11) Glow Plug (20) Vehicle Speed Sensor Sensor
(4) CAN2 Connector (12) Injector 1 (21) SCV (Suction Control Valve) (27) Stop Switch
(For OEM Machine) (13) Injector 2 (22) Fuel Temperature Sensor (28) Neutral Switch
(5) EGR Valve (14) Injector 3 (23) Coolant Temperature Sensor (29) Oil Switch
(6) Starter (15) Injector 4
(7) Air Flow Sensor (16) Crankshaft Position Sensor
NOTE
9Y1210674INI0027US0
I-26
G GENERAL

GENERAL
CONTENTS
1. ENGINE IDENTIFICATION .......................................................................................................... G-1

[1] MODEL NAME AND ENGINE SERIAL NUMBER.................................................................. G-1
[2] E4B ENGINE .......................................................................................................................... G-3
[3] CYLINDER NUMBER ............................................................................................................. G-3
2. MUFFLER FULL ASSEMBLY IDENTIFICATION ......................................................................... G-4
[1] PART NUMBER AND SERIAL NUMBER .............................................................................. G-4
3. GENERAL PRECAUTIONS.......................................................................................................... G-5
4. MAINTENANCE CHECK LIST ..................................................................................................... G-6
5. CHECK AND MAINTENANCE ................................................................................................... G-10
[1] DAILY CHECK POINTS ....................................................................................................... G-10
[2] INITIAL 50 HOURS .............................................................................................................. G-13
[3] EVERY 50 HOURS .............................................................................................................. G-14
[4] EVERY 250 HOURS ............................................................................................................ G-14
[5] EVERY 500 HOURS ............................................................................................................ G-16
[6] EVERY 1000 HOURS .......................................................................................................... G-20
[7] EVERY 1500 HOURS .......................................................................................................... G-21
[8] EVERY 3000 HOURS .......................................................................................................... G-23
[9] EVERY 1 YEAR.................................................................................................................... G-31
[10]EVERY 2 YEARS ................................................................................................................. G-33
6. SPECIAL TOOLS ....................................................................................................................... G-37

V2607-CR-E4B, V2607-CR-TE4B, V2607-CR-TIE4B (DOC only), V3307-CR-TE4B, V3307-CR-TIE4B (DOC only), WSM GENERAL
1. ENGINE IDENTIFICATION
[1] MODEL NAME AND ENGINE SERIAL NUMBER
You must identify the engine model name and serial number
before you start a job. When you get in touch with the manufacturer,
always tell your engine model name and serial number.
Engine Serial Number
The engine serial number is an identified number for the engine.
It appears after the engine model name.
It shows the month and year of manufacture as below.
Engine Series
Number or Number or
Series Series
Alphabet Alphabet
GZ, OC, AC, EA,
1 05 (include: WG) 6
E
2 V3 7 03
3 08 8 07
4 SM (include: WG) A EA, RK
Air Cooled 03 (KET
5 B
Gasoline Production)
Production Year
Alphabet or Alphabet or
Year Year
Number Number
1 2001 F 2015
2 2002 G 2016
3 2003 H 2017
4 2004 J 2018
5 2005 K 2019
6 2006 L 2020
7 2007 M 2021
8 2008 N 2022
9 2009 P 2023
A 2010 R 2024
B 2011 S 2025
C 2012 T 2026
D 2013 V 2027
E 2014
(1) Engine Model Name and Serial

Number
(To be continued)
G-1
(Continued)
Production Month and Lot Number
Month Engine Lot Number
January A0001 ~ A9999 B0001 ~
February C0001 ~ C9999 D0001 ~
March E0001 ~ E9999 F0001 ~
April G0001 ~ G9999 H0001 ~
May J0001 ~ J9999 K0001 ~
June L0001 ~ L9999 M0001 ~
July N0001 ~ N9999 P0001 ~
August Q0001 ~ Q9999 R0001 ~
September S0001 ~ S9999 T0001 ~
October U0001 ~ U9999 V0001 ~
November W0001 ~ W9999 X0001 ~
December Y0001 ~ Y9999 Z0001 ~
* Alphabetical letters "I" and "O" are not used.

(a) (b)(c)(d) (e)
e.g. V2607 - 8 C L A001
(a) V2607: Engine Model Name
(b) 8: Engine Series (07 series)
(c) C: Production Year (2012)
(d) L: Production Month (June)
(e) A001: Lot Number: (0001 ~ 9999 or A001 ~ Z999)
9Y1210674GEG0001US0
G-2
[2] E4B ENGINE

[Example: Engine Model Name V2607-CR-E4B-XXXX]
The emission controls previously implemented in various countries to prevent air pollution will be stepped up as
Nonroad Emission Standards continue to change. The timing or applicable date of the specific Nonroad Emission
regulations depends on the engine output classification.
Over the past several years, KUBOTA has been supplying diesel engines that comply with regulations in the
respective countries affected by Nonroad Emission regulations. For KUBOTA Engines, E4B will be the designation
that identifies engine models affected by the next emission phase (See the table below).
When servicing or repairing ###-E4B series engines, use only replacement parts for that specific E4B engine,
designated by the appropriate E4B KUBOTA Parts List and perform all maintenance services listed in the appropriate
KUBOTA Operator's Manual or in the appropriate E4B KUBOTA Workshop Manual. Use of incorrect replacement
parts or replacement parts from other emission level engines (for example: E3B engines), may result in emission
levels out of compliance with the original E4B design and EPA or other applicable regulations.Please refer to the
emission label located on the engine head cover to identify Output classification and Emission Control Information.
E4B engines are identified with "EF" at the end of the Model designation, on the US EPA label. Please note: E4B is
not marked on the engine.
Category (1) Engine output classification EU regulation
P From 37 to less than 56 kW STAGE IIIB
N From 56 to less than 75 kW STAGE IIIB
M From 75 to less than 130 kW STAGE IIIB
Category (2) Engine output classification EPA regulation

Less than 19 kW Tier 4
From 19 to less than 56 kW Interim Tier 4
EF
(1) EU regulation engine output classification category

(2) "E4B" engines are identified with "EF" at the end of the Model designation, on
the US EPA label.
"E4B" designates some Interim Tier 4 / Tier 4 models, depending on engine
output classification.
9Y1210674GEG0002US0
[3] CYLINDER NUMBER

You can see the cylinder numbers of KUBOTA diesel engine in
the figure.
The sequence of cylinder numbers is No.1, No.2, No.3 and No.4
and it starts from the front cover side.
9Y1210674GEG0003US0
G-3
2. MUFFLER FULL ASSEMBLY IDENTIFICATION

[1] PART NUMBER AND SERIAL NUMBER
Diesel Particulate Filter (hereinafter referred to as the "DPF")
Muffler Full Assembly Serial Number
You must keep the records of the DPF part number and serial
number (3) and catalyst (DOC) part number and serial number (4)
before you remove the DPF for cleaning.
(1) Muffler Assy Part Number and (A) V2607-CR-E4B
Serial Number (B) V2607-CR-TE4B, V3307-CR-TE4B
(2) DPF Muffler Full Assy Part Number (Engine Serial Number:
and Serial Number 8CZZ999 and below)
(3) DPF Part Number and Serial (C) V2607-CR-TE4B, V3307-CR-TE4B
Number (Engine Serial Number:
(4) Catalyst (DOC) Part Number and 8DA0001 and above)
Serial Number (D) V2607-CR-TIE4B,
(5) Catalyst Comp (DOC 1) Part V3307-CR-TIE4B
Number and Serial Number
(6) Catalyst Comp (DOC 2) Part
(7) Muffler Assy (DOC) Part Number
and Serial Number
(8) Muffler Full Assy (DOC) Part
9Y1210674GEG0005US0
G-4
3. GENERAL PRECAUTIONS
• When you disassemble, carefully put the parts in a clean area
to make it easy to find the parts.
You must install the screws, bolts and nuts in their initial position
to prevent the reassembly errors.
• When it is necessary to use special tools, use KUBOTA special
tools. Refer to the drawings when you make special tools that
you do not use frequently.
• Before you disassemble or repair machine, make sure that you
always disconnect the ground cable from the battery first.
• Remove oil and dirt from parts before you measure.
• Use only KUBOTA genuine parts for replacement to keep the
machine performance and to make sure of safety.
• You must replace the gaskets and O-rings when you assemble
again. Apply grease (1) to new O-rings or oil seals before you
assemble.
• When you assemble the external or internal snap rings, make
sure that the sharp edge (3) faces against the direction from
which force (2) is applied.
• Make sure that you try to operate the engine after you repair or
assemble it.
(1) Grease (A) External Snap Ring
(2) Force (B) Internal Snap Ring
(3) Sharp Edge
9Y1210674GEG0006US0
G-5
4. MAINTENANCE CHECK LIST

To make sure that the engine operates safely for a long time, refer to the table below to do regular inspections.
Service Interval
Inspection Item Initial Every Every Every Every Every Every Every Every
Daily
50 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 1500 hrs 3000 hrs 1 year 2 years
Check of engine oil level 
Check of fuel level 
Check of coolant level 
Check of fan belt 
Check of fuel hoses and clamp

bands
Check of draining of water

separator
Check of radiator hoses and clamp

bands
Cleaning of air cleaner element
(Replace the element after 6-times 
cleaning)
Adjustment of fan belt tension 
Check of intake air line 
Change of engine oil  
Replacement of oil filter cartridge  
Replacement of fuel filter cartridge 
Cleaning of water separator 
1 Cleaning of fuel tank interior 
Cleaning of water jacket and
1 
radiator interior
1 Replacement of fan belt  
1 Check of valve clearance 
1,2 Check of injector 
1,2 Check of EGR cooler 
Replacement of oil separator
2 
element
Check of PCV (Positive Crankcase
1,2 
Ventilation) Valve
1,2 Check of turbocharger 
1,2 Cleaning of DPF 
1,2 Check of EGR system 
1 Replacement of air cleaner element 
Check of DPF differential pressure
1 
pipes and hoses
1 Check of EGR piping 
Check of intake air line 
Check of exhaust manifold (Crack,

gas leakage and mounting screw)
Replacement of oil separator
1 
rubber hose
Replacement of rubber hose of
1 
DPF differential pressure sensor
Replacement of intake hose
1 
(After air flow sensor)
Replacement of pressure detection
1 
hose of boost sensor
1 Replacement of EGR cooler hose 
1 Replacement of water hose 
1 Replacement of lubricant hose 
Change of radiator coolant (L.L.C.) 
Replacement of radiator hoses and
1 
clamp bands
Replacement of fuel hoses and
1 
clamps
G-6
Service Interval
Inspection Item Initial Every Every Every Every Every Every Every Every
Daily
50 hrs 50 hrs 250 hrs 500 hrs 1000 hrs 1500 hrs 3000 hrs 1 year 2 years
1 Replacement of intake air line 
• When the battery is used for less than 100 hours in a year, check its electrolyte yearly. (for refillable battery's only)
• 1: Consult your local KUBOTA dealer for this service.
• The items above (2 marked) are registered as emission related critical parts by KUBOTA in the U.S. EPA
nonroad emission regulation. As the engine owner, you are responsible for the performance of the required
maintenance on the engine according to the above instruction.
Please see the warranty statement in detail.
• The items listed above other than 2 marked are not necessary to keep the emission-related warranty valid.
• Failure to perform the maintenance will cause problems that will significantly degrade the engine performance.
9Y1210674GEG0007US0
CAUTION
• When changing or inspecting, be sure to level and stop the engine.
NOTE
• Changing interval of engine oil:
Models Interval
V2607-CR-E4B
V2607-CR-TE4B
Initial 50 hrs,
V2607-CR-TIE4B
Every 500 hrs or 1 year whichever comes first
V3307-CR-TE4B
V3307-CR-TIE4B
API service classification: above CJ-4 grade
Ambient temperature: below 35 °C (95 °F)
9Y1210674GEG0008US0
G-7
NOTE
Engine Oil:
• Refer to the following table for the suitable American Petroleum Institute (API) classification of engine oil
according to the engine type and the Fuel Type.
Engine oil classification (API classification)
Fuel Type
Engines with DPF
Ultra Low Sulfur Fuel
[Sulfur Content CJ-4
< 0.0015 % (15 ppm)]
• Engine oil should be API classification CJ-4.
• Change the type of engine oil according to the ambient temperature.
• When using oil of different brands from the previous one, be sure to drain all the previous oil before adding the
new engine oil.
• On DPF-equipped engines, part of the fuel may get mixed with engine oil during the regenerating process. This
may dilute the oil and increase its quantity. If the oil rises above the oil level gauge upper limit, it means the oil
has been diluted too much, resulting in a trouble. In such case, immediately change the oil for new one.
• If the interval of DPF regeneration becomes 5 hours or less, be sure to change the oil for new one.
Fuel:
• Cetane Rating: The minimum recommended Fuel Cetane Rating is 45. A cetane rating greater than 50 is
preferred, especially for ambient temperatures below −20 °C (−4 °F) or elevations above 1500 m (4921 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission
regulations for the area in which the engine is operated.
• DO NOT USE Fuels that have sulfur content greater than 0.0015 % (15 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)
• These engines use Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory for these engines, when
operated in US EPA regulated areas. Therefore, please use No.2-D S15 diesel fuel as an alternative to No.2-D,
and use No.1-D S15 diesel fuel as an alternative to No.1-D for ambient temperature below −10 °C (14 °F).
a) SAE: Society of Automotive Engineers
b) EN: European Norm
c) ASTM: American Society of Testing and Materials
d) US EPA: United States Environmental Protection Agency
e) No.1-D or No.2-D, S15: Ultra Low Sulfur Diesel (ULSD)) 15 ppm or 0.0015 wt.%
IMPORTANT
• Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble.
• Do not operate the fuel tank level too low or completely out of fuel. You may experience improper engine
operating and/or a DTC (Diagnostic Trouble Code) error code may be recorded in the Engine Control.
Additionally, fuel system bleeding may be necessary if air enters the fuel system.
(To be continued)
G-8
(Continued)
 Biodiesel fuel
[When the B7 blended fuel is used]
When the finally blended Biodiesel fuel is B7, make sure it conforms to the updated EN590 (European) standard.
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN590 (European) standard and that
the B100 blend conforms to the updated EN14214 (European) standard.
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN5950 (European) standard or the
ASTM D975 (U.S.) standard and that the B100 blend conforms to the updated EN 14214 (European) standard or the
ASTM D6751 (U.S.) standard.
 Precautions in handling Biodiesel fuels
1. Keep the fuel tank full whenever possible to prevent water vapor from accumulating inside the fuel tank. Tighten
up the fuel tank filler cap to avoid the entry of moisture.
2. Routinely check the oil level before the operation. Also strictly follow the specified oil change intervals.
3. Biodiesel fuels (BDF) during the supply process or in the machine easily deteriorate due to oxygen, water, heat
and other foreign substances. With this in mind, take the following precautions.
• Do not leave those fuels in the fuel tank or a metallic drum longer than 3 months.
• Before storing the machine for a prolonged period, change such fuel for a conventional type of diesel fuel and
operate the machine for 30 minutes or longer to clean up the fuel system.
4. Bear it in mind that Biodiesel fuels have the characteristics below. Referring to the servicing intervals specified in
the KUBOTA products' Operator's Manuals, be sure to keep and clean up the fuel system, replace the fuel hose
with new ones and take other necessary measures. It is advisable to replace the fuel filter with a new one after
half the specified replacement intervals. (Compared with the use of mineral oil diesel fuels, the filtration
performance of fuel filters gets degraded earlier than expected.)
• Biodiesel fuels easily induce the growth of microorganisms and foul themselves. This may get the fuel system
corroded and the fuel filter clogged.
• In cold weather, some problems may occur: the clog of the fuel line or fuel system, starting failure, and other
unforeseen troubles.
• Biodiesel fuels easily soak up moisture, which means that they may contain higher moisture content than
conventional diesel fuels.
5. Palm oil-based Biodiesel fuels are inferior in low-temperature fluidity to soy-based and rapeseed-based Biodiesel
fuels. In cold season in particular, this may clog the fuel filter.
6. If Biodiesel fuels are spilt on a coated surface, the coating may get damaged. Immediately wipe the spill off the
surface.
9Y1210674GEG0009US0
G-9
5. CHECK AND MAINTENANCE

[1] DAILY CHECK POINTS
Check of Engine Oil Level
1. Make the engine level.
2. Pull out the dipstick (1) and clean it. Put in and pull it out again.
Make sure that the oil level is between the 2 notches.
3. If the level is too low, add new oil to the specified level.
IMPORTANT
• On Diesel Particulate Filter (DPF) equipped engines, part of
the fuel may get mixed with engine oil during the
regenerating process. This may dilute the oil and increase
its quantity. If the oil rises above the dipstick upper limit, it
means the oil has been diluted too much, resulting in a
trouble. In such case, immediately change the oil for new
one.
• When you use an oil of different brand or viscosity from the
previous, drain the remaining oil. Do not mix 2 different
types of oil.
NOTE
• When you check the engine oil level, make sure that you
put it in a level position. If not, you cannot measure oil
quantity accurately.
• Make sure that you keep the oil level between the upper and
lower lines of the dipstick. Too much oil can decrease the
output or cause too much blow-by gas. On the closed
breather type engine, the port absorbs the mist and too
much oil can cause oil hammer.
But if the oil level is not sufficient, the moving parts of
engine can get a seizure.
(1) Dipstick (a) Upper Line
(b) Lower Line
9Y1210674GEG0010US0
Check of Fuel Level
1. Make the engine level.
2. Make sure that the fuel level is above the lower limit of the fuel
level gauge.
3. If the fuel level is too low, add fuel to the upper limit.
IMPORTANT
• Be sure to use a strainer when filling the fuel tank, or dirt or
sand in the fuel may cause trouble.
• Do not operate the fuel tank level too low or completely out
of fuel. You may experience improper engine operating
and/or a DTC (Diagnostic Trouble Code) error code may be
recorded in the Engine Control. Additionally, fuel system
bleeding may be necessary if air enters the fuel system.
9Y1210674GEG0081US0
G-10
Check of Coolant Level
CAUTION
• Do not remove the radiator cap when the engine is hot.
Then loosen the cap slightly to release unwanted pressure
before you remove the cap fully.
1. Without recovery tank: Remove the radiator cap (1). Make sure
that the coolant level is immediately below the port.
With recovery tank (2): Make sure that the coolant level is
between FULL A and LOW B.
2. If the coolant level is too low, find out the cause that there is less
coolant. Case 1 If the coolant decreases by evaporation, add
only clean and soft water. Case 2 If the coolant decreases by
leak, add coolant of the same manufacturer and brand in the
specified mixture ratio (clean, soft water and L.L.C.). If you
cannot identify the coolant brand, drain all the remaining coolant
and add a new brand of coolant mix.
IMPORTANT
• When you add the coolant, release the air from the engine
coolant channels. The engine releases the air when it
shakes the radiator upper and lower hoses.
• Make sure that you close the radiator cap correctly. If the
cap is loose or incorrectly closed, coolant can flow out and
the engine can overheat.
• Do not use an anti-freeze and scale inhibitor at the same
time.
• Do not mix the different type or brand of L.L.C..
(1) Radiator Cap A: FULL
(2) Recovery Tank B: LOW
9Y1210674GEG0012US0
G-11
Check of Fan Belt
1. Check if the fan belt is worn out and sunk in the pulley groove,
and if it is, replace it.
2. Push the belt halfway between the fan drive pulley and
alternator pulley at a specified force 98 N (10 kgf, 22 lbf) to
measure the deflection (3).
3. If the measurement is out of the factory specifications, loosen
the alternator mounting screws and adjust its position.
10 to 12 mm
Deflection (3) Factory specification
0.40 to 0.47 in.
(1) Fan Belt (A) OK

(2) Alternator Mounting Screw (B) Wear
(3) Deflection
9Y1210674GEG0015US0
G-12
[2] INITIAL 50 HOURS

Change of Engine Oil
CAUTION
• Make sure that you stop the engine before you change the
engine oil.
1. Start and warm-up the engine for approximately 5 minutes.
2. Put an oil pan below the engine.
3. Remove the drain plug (1) at the bottom of the engine and drain
the oil fully.
4. Tighten the drain plug (1).
5. Fill new oil until the upper line on the dipstick (2).
IMPORTANT
previous, drain the remaining oil.
• Do not mix 2 different types of oil.
• Engine oil must have the properties of API classification
CJ-4. Use the correct SAE Engine Oil by reference to the
ambient temperature.
Above 25 °C (77 °F) SAE 30 or SAE 10W-30, SAE 15W-40
0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30, SAE 15W-40
SAE 10W or SAE 10W-30,
Below 0 °C (32 °F)
SAE 15W-40
V2607-CR-E4B,
10.2 L
V2607-CR-TE4B,
2.69 U.S.gals
Engine oil capacity V2607-CR-TIE4B
V3307-CR-TE4B, 11.2 L
V3307-CR-TIE4B 2.96 U.S.gals
45 to 53 N·m
Tightening torque Drain plug 4.5 to 5.5 kgf·m
33 to 39 lbf·ft
(1) Drain Plug (a) Upper Line

(2) Dipstick (b) Lower Line
9Y1210674GEG0013US0
Replacement of Oil Filter Cartridge
CAUTION
• Make sure that you stop the engine before you replace the
oil filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a thin layer of oil on the new cartridge gasket.
3. Install the new cartridge by hand. Do not tighten too much
because it can cause deformation of the rubber gasket.
4. After you replace the cartridge, the engine oil usually decrease
by a small level. Make sure that the engine oil does not flow
through the seal and read the oil level on the dipstick. Fill the
engine oil until the specified level.
IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Oil Filter Cartridge
9Y1210674GEG0014US0
G-13
[3] EVERY 50 HOURS

Check of Fuel Hoses and Clamp Bands
1. If the clamp (2) is loose, apply oil to the threads and tighten it
again correctly.
2. Replace the fuel hose (1) together with the clamp in a 2 years
interval.
3. But if the fuel hose and clamp has damages before 2 years, then
replace them.
4. After you replace the fuel hose and the clamp, bleed the fuel
system.
(1) Fuel Hose (2) Clamp Band
9Y1210674GEG0016US0
Check and Draining of Water Separator
1. Check if water and dirt contained in fuel precipitate inside the
water separator.
2. When such foreign substances are precipitated, set the water
separator handle (1) to the "CLOSE" (A) position.
3. Loosen the top screw (4) first and then the bottom valve (3) to
let the foreign substances out of the separator.
4. Loosen and remove the cup (5) properly, and clean its inside
with diesel fuel.
5. Tighten up the cup (5) properly.
6. Finally be sure to air-bleed the fuel system.
IMPORTANT
• As water is accumulated, the red float (6) goes up. When
the float (6) has reached the specified line (2), immediately
drain the water separator.
• In reattaching the water separator, be careful to keep off
dust and dirt.
• Be sure to air-bleed the fuel system before operating
engine.
(1) Water Separator Handle (A) Close
(2) Line
(3) Valve
(4) Screw
(5) Cup
(6) Float
9Y1210674GEG0059US0
[4] EVERY 250 HOURS

Check of Radiator Hoses and Clamp Bands
1. Make sure that the radiator hoses connections (1), (2) are
correct for every 250 hours of operation.
2. If the clamp is loose, apply oil to the threads and tighten it again
correctly.
3. You must replace the radiator hose(s) every 2 years. Also
replace the clamp every 2 years and tighten it correctly.
(1) Upper Hose (2) Lower Hose
9Y1210674GEG0019US0
G-14
Cleaning of Air Cleaner Primary Element
1. Remove the primary element (2).
2. Use clean dry compressed air on the inner side of the primary
element (2). The pressure of compressed air must be less than
205 kPa (2.1 kgf/cm2, 30 psi).
NOTE
• Replace the primary element once a year or every sixth
cleaning.
• The air cleaner uses a dry element, never apply oil.
• Do not operate the engine with filter element removed.
• Do not touch the secondary element (1) except in cases
where replacing is required.
(1) Secondary Element (2) Primary Element
9Y1210674GEG0018US0
Adjustment of Fan Belt Tension
1. Check if the fan belt is worn out and sunk in the pulley groove,
and if it is, replace it.
2. Push the belt halfway between the fan drive pulley and
measure the deflection (3).
the alternator mounting screws and adjust its position.
10 to 12 mm
Deflection (3) Factory specification
0.40 to 0.47 in.
(1) Fan Belt (A) OK

(2) Alternator Mounting Screw (B) Wear
(3) Deflection
9Y1210674GEG0017US0
G-15
Check of Intake Air Line
1. Make sure that the intake air hose(s) (1) connections are correct
for every 250 hours of operation.
again correctly.
3. You must replace the intake air hose(s) every 2 years. Also
IMPORTANT
• To prevent serious damage to the engine, keep out dust in
the intake air line.
(1) Intake Air Hose (2) Clamp
9Y1210674GEG0020US0
[5] EVERY 500 HOURS

Change of Engine Oil
CAUTION
• Make sure that you stop the engine before you change the
engine oil.
1. Start and warm-up the engine for approximately 5 minutes.
3. Remove the drain plug (1) at the bottom of the engine and drain
the oil fully.
4. Tighten the drain plug (1).
5. Fill new oil until the upper line on the dipstick (2).
IMPORTANT
previous, drain the remaining oil.
• Do not mix 2 different types of oil.
• Engine oil must have the properties of API classification
CJ-4. Use the correct SAE Engine Oil by reference to the
ambient temperature.
Above 25 °C (77 °F) SAE 30 or SAE 10W-30, SAE 15W-40
0 °C to 25 °C (32 °F to 77 °F) SAE 20 or SAE 10W-30, SAE 15W-40
SAE 10W or SAE 10W-30,
Below 0 °C (32 °F)
SAE 15W-40
V2607-CR-E4B,
10.2 L
V2607-CR-TE4B,
2.69 U.S.gals
Engine oil capacity V2607-CR-TIE4B
V3307-CR-TE4B, 11.2 L
V3307-CR-TIE4B 2.96 U.S.gals
45 to 53 N·m
Tightening torque Drain plug 4.5 to 5.5 kgf·m
33 to 39 lbf·ft
(1) Drain Plug (a) Upper Line

(2) Dipstick (b) Lower Line
9Y1210674GEG0013US0
G-16
Replacement of Oil Filter Cartridge
CAUTION
• Make sure that you stop the engine before you replace the
oil filter cartridge.
1. Remove the oil filter cartridge (1) with the filter wrench.
2. Apply a thin layer of oil on the new cartridge gasket.
3. Install the new cartridge by hand. Do not tighten too much
because it can cause deformation of the rubber gasket.
4. After you replace the cartridge, the engine oil usually decrease
by a small level. Make sure that the engine oil does not flow
through the seal and read the oil level on the dipstick. Fill the
engine oil until the specified level.
IMPORTANT
• To prevent serious damage to the engine, replacement
element must be highly efficient. Use only a KUBOTA
genuine filter or its equivalent.
(1) Oil Filter Cartridge
9Y1210674GEG0014US0
Replacement of Fuel Filter Cartridge
1. Remove the fuel filter cartridge (1) with filter wrench.
2. Apply a thin layer of fuel to the surface of the new filter cartridge
gasket before you put it on.
3. Tighten the new cartridge by hand.
4. Open the fuel valve and bleed the fuel system.
5. Operate the engine for a while and check if there is not the fuel
leakage from the filter.
(1) Fuel Filter Cartridge
9Y1210674GEG0023US0
Cleaning of Water Separator
1. Remove and flush the filter cup (3) if the float (2) goes up with
water, or the filter cup (3) has the dust.
2. Flush the element (1) with kerosene to prevent dust to go into
the inner element (1).
3. After you replace, bleed the fuel system.
(1) Element (3) Filter Cup
(2) Float
9Y1210674GEG0060US0
G-17
Cleaning of Water Jacket and Radiator Interior
CAUTION
1. Stop the engine and let the coolant temperature decreases.
2. Remove the radiator cap (1) to drain the coolant fully.
3. Open the drain valve (2) and drain plug (3).
4. After you drained all coolant, close the drain valve (2) and plug
(3).
5. Fill with clean water and cooling system cleaner.
6. Obey the directions of the cleaner instruction.
7. After you flush, fill with clean water and anti-freeze until the
coolant level is immediately below the port. Install the radiator
cap (1) correctly.
8. Fill with the coolant until the "FULL" A mark on the recovery tank
(4).
9. Start and operate the engine for a few minutes.
Check the coolant level of radiator and recovery tank (4) and
add coolant if necessary.
IMPORTANT
• Do not start the engine without coolant.
• Use clean and soft water with anti-freeze to fill the radiator
and recovery tank.
• Make sure that when you mix the anti-freeze and water, the
ratio of anti-freeze is less than 50 %.
(2) Drain Valve B: LOW
(3) Drain Plug
(4) Recovery Tank
(To be continued)
G-18
(Continued)
 Anti-freeze
• There are 2 types of anti-freeze available: use the permanent
type (PT) for this engine.
• When you add anti-freeze for the first time, flush the water
jacket and radiator interior with clean, soft water several times.
• The brand of the anti-freeze and the ambient temperature have
an effect on the procedure to mix water and anti-freeze. Refer
to the SAE J1034 standard, especially to the SAE J814c.
• Mix the anti-freeze with clean, soft water, and then fill into the
radiator.
IMPORTANT
Vol % Freezing Point Boiling Point*
Anti-freeze °C °F °C °F
40 −24 −11 106 223
50 −37 −35 108 226
* At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Use a radiator pressure
cap that lets the pressure collect in the cooling system to get a higher boiling point.
NOTE
• The above data is the industrial standards that shows the
minimum glycol content necessary in the concentrated
anti-freeze.
• When the coolant level decreases because of evaporation,
add clean, soft water only to keep the anti-freeze mixing
ratio less than 50 %. If there is a leakage, add anti-freeze
and clean, soft water in the specified mixing ratio.
• The anti-freeze absorbs moisture. Keep new anti-freeze in
a tightly sealed container.
• Do not use the radiator cleaning agents after you add
anti-freeze to the coolant. Anti-freeze contains an
anti-corrosive agent, which reacts with the radiator
cleaning agent to make sludge and cause damages to the
engine parts.
9Y1210674GEG0025US0
Replacement of Fan Belt
1. Remove the alternator.
2. Remove the fan belt (1).
3. Replace the fan belt with a new one.
4. Install the alternator.
5. Check the deflection (A) of fan belt.
10 to 12 mm / 98 N
Deflection (A) Factory specification 0.40 to 0.47 in. / 98 N
(10 kgf, 22 lbf)
(1) Fan Belt (A) Deflection

9Y1210674GEG0024US0
G-19
[6] EVERY 1000 HOURS

Check of Valve Clearance
IMPORTANT
• You must check and adjust the valve clearance when the
engine is cold.
1. Remove the injection pipes, glow lead, glow plugs and cylinder
head cover.
2. Align the "1TC" mark line on the flywheel and projection on the
housing. Make sure that the No.1 piston (front cover side)
comes to the compression or overlap top dead center.
3. Check the subsequent valve clearance at the mark "1TC" with
a feeler gauge. If the clearance is out of the factory
specifications, adjust with the adjusting screw (1) and tighten
the lock nut (2) of the adjusting screw.
0.13 to 0.17 mm
Valve Clearance (A) Factory specification
0.0052 to 0.0066 in.
NOTE
• After you adjust the valve clearance, tighten the lock nut (2)
of the adjusting screw.
Adjustable Cylinder Location of Piston IN. EX.
1  
When No. 1 piston is at compression top 2 

dead center 3 
4
1
2 
When No. 1 piston is at overlap position
3 
4  
9.81 to 11.2 N·m

Cylinder head cover screw 1.00 to 1.15 kgf·m
7.24 to 8.31 lbf·ft
Tightening Torque
30 to 40 N·m
Injection pipe retaining nut 3.1 to 4.0 kgf·m
23 to 29 lbf·ft
(1) Adjusting Screw A: Valve Clearance

(2) Lock Nut
9Y1210674GEG0026US0
G-20

Check of Injector
1. Connect the diagnosis tool.
2. Stop the injector for each cylinder using active testing and make
sure that the injectors are injecting normally.
If it is injecting normally, the engine vibration and noise will
increase and engine speed will fluctuate when the injector is
stopped.
3. If it is determined that there is a failure, check for a plug in the
injection pipe.
4. If the injector pipe is normal, this may be an injector failure so
replace the injector using the procedure for replacing injectors.
(1) Interface (a) CAN1 Connector
9Y1210674GEG0028US0
Check of EGR Cooler
(Exhaust gas passage)
1. Block the EGR cooler exhaust gas outlet (2).
2. Attach an air hose to the EGR cooler exhaust gas inlet (1) and
then submerge it in a water tank.
3. Check that the coolant passage is full of water.
4. Apply the specified amount of air pressure (a) (290 kPa,
3.0 kgf/cm2, 43 psi) to the air hose side, and check that there are
no air leaks in any of the EGR cooler parts.
5. If there are air leaks, replace the EGR cooler.
(Coolant passage)
1. Block the EGR cooler exhaust gas inlet (1), EGR cooler exhaust
gas outlet (2), and the coolant outlet (3).
2. Attach an air hose to the EGR cooler coolant inlet (4), and then
submerge it in a water tank.
3. Apply the specified amount of air pressure (a) (250 kPa,
2.5 kgf/cm2, 36 psi) to the air hose side, and check that there are
no air leaks in any of the EGR cooler parts.
4. If there are air leaks, replace the EGR cooler.
290 kPa
Exhaust gas
3.0 kgf/cm2
EGR cooler Factory passage
43 psi
leakage test specifica-
pressure tion 250 kPa
Coolant
2.5 kgf/cm2
passage
36 psi
(1) Exhaust Gas Inlet (a) Air Pressure

(2) Exhaust Gas Outlet
(3) Coolant Outlet
(4) Coolant Inlet
9Y1210674GEG0029US0
G-21
Replacement of Oil Separator Element
CAUTION
• Be sure to stop the engine before replacement the oil
separator element.
1. Remove the case (5).
2. Remove the oil separator element (3) and O-ring (4).
3. Replace the oil separator element and O-ring with a new one.
9.50 to 10.5 N·m
Tightening torque Case of oil separator 0.969 to 1.07 kgf·m
7.01 to 7.74 lbf·ft
(1) Oil Separator Assembly (4) O-ring

(2) Body (5) Case
(3) Element
9Y1210674GEG0061US0
Check of PCV (Positive Crankcase Ventilation) Valve

1. After you remove the oil separator case (5) and element (3),
look into the hole leading to the PCV valve of the oil separator
body (2) inside, and then check if there is no crack, break or
abnormal sediment in the PCV valve.
2. Check the oil separator assembly (1) for crack, oil leakage and
loose connections.
3. If you find a crack or oil leakage, replace the oil separator
assembly (1) with a new one.
4. If you find loose connections, tighten the clamp or replace the
hoses.
(1) Oil Separator Assembly (4) O-ring
(2) Body (5) Case
(3) Element
9Y1210674GEG0078US0
G-22

Check of Turbocharger
(Turbine Side)
1. Check the exhaust port (3) and the inlet port (5) side of the
turbine housing (1) for exhaust gas leakage.
2. If you find a gas leakage, tighten the bolts and nuts again or
replace the gasket (2), (4), (6) with a new one.
(Compressor Side)
1. Check the inlet hose of the compressor cover (9) for air leakage.
2. If you find an air leakage, change the clamp (8) and / or the inlet
hoses.
3. Replace the inlet hose (7) and check the suction side of the
intake hose for loose connections or cracks.
4. If you find loose connections or cracks, tighten the clamp or
replace the hoses.
(Radial Clearance)
1. If the wheel touches the housing, replace the turbocharger
assembly with a new one.
(1) Turbine Housing (6) Gasket
(2) Gasket (7) Inlet Hose
(3) Exhaust Port (8) Clamp
(4) Gasket (9) Compressor Cover
(5) Inlet Port
9Y1210674GEG0030US0
G-23
Cleaning of DPF (V2607-CR-E4B)
IMPORTANT
• Since the DPF that was dropped or given a shock cannot be
reused even if there is no damage outwardly, replace it with
a new one.
• Be sure to loosen the temperature sensor tightening nut or
the differential pressure pipe tightening nut with crowfoot
wrench to prevent the damage of the sensor or pipe.
If it is still hard to loosen, apply the lubricant spray to
threaded portion and soak it with lubricant.
NOTE
• Always work in the workshop equipped with a electric hoist
(including mobile hoist).
• Put a product (engine) on a stable ground, and set the
parking brake.
• As the DPF muffler full assembly is hot just after the engine
shutdown, make sure to start operation after it gets cool.
• Make sure not to let any foreign substances enter the
opening section during the operation.
• Make sure not to damage the DPF muffler full assembly by
falling or impact as it contains a ceramic filter.
• Before removing the DPF muffler full assembly from a
product (engine), connect the diagnosis tool (Diagmaster),
check the failure history, and save the project.
• Before removing the DPF for cleaning, keep the records of
the engine serial number, DPF part number, DPF serial
number, catalyst (DOC) part number, catalyst (DOC) serial
number, and engine operating time, which are required in
preparing the DPF cleaning order form.
Since the engine operating time is recorded in the ECU,
check the operating time by connecting the service tool
(Diagmaster).
• When installing and removing the muffler full assembly
(DPF), make sure that the temperature sensor, differential
pressure sensor, and differential pressure pipe do not
make contact with surrounding parts.
1. Disconnect the harness from the connector (4), (5), (6) of
temperature sensor and differential pressure sensor (8).
2. Remove the connector (4), (5), (6) of temperature sensor from
the bracket.
3. Remove the 2 clamps (3).
4. Remove the differential pressure sensor bracket (7).
5. Remove the 4 screws (1) of muffler flange (2).
6. Remove the muffler full assembly (DPF) mounting screws (10).
7. Remove the DPF muffler assembly (9).
8. Remove the tube (15), (16) from the differential pressure pipe
(12), (13).
9. Remove the differential pressure sensor (8).
10. Loosen the DPF mounting bracket (11), (14) and remove the
DPF (19).
(To be continued)
G-24
(Continued)
(When reassembling)
• Replace the gaskets (18), (20) with new ones.
• If the differential pressure tube is damaged or cracked, replace
it.
• When the differential pressure pipe (12), (13) and temperature
sensor (22), (23), (24) is removed, wipe off the anti-seize &
lubricating compound, apply a anti-seize & lubricating
compound (Bostik, NEVER SEEZ, Pure Nickel Special Grade),
and then attach them to their correct position.
• When replacing the differential pressure pipe (12), (13) apply a
anti-seize & lubricating compound (Bostik, NEVER SEEZ, Pure
Nickel Special Grade), and then attach it to its correct position.
• When replacing the temperature sensor, check that it is coated
with anti-seize & lubricating compound, and then attach it to its
correct position.
• Tighten bolts and nuts to their specified torque. Also tighten the
temperature sensor tightening nut or the differential pressure
pipe tightening nut to the specified torque with crowfoot wrench.
• After attaching the assembly, start the engine and make sure
that there are no gas leaks.
• Reassemble the DPF (19) in the correct direction.
24 to 27 N·m
Screw of muffler flange 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
49 to 55 N·m
Muffler full assembly (DPF)
5.0 to 5.7 kgf·m
mounting screw
37 to 41 lbf·ft
16 to 20 N·m
Tightening torque DPF mounting bracket 1.7 to 2.0 kgf·m
12 to 14 lbf·ft
25 to 34 N·m
Temperature sensor 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
16 to 22 N·m
Differential pressure pipe 1.6 to 2.3 kgf·m
12 to 16 lbf·ft
(1) Screw of Muffler Flange (11) DPF Mounting Bracket

(2) Muffler Flange (12) Differential Pressure Pipe
(3) Clamp (13) Differential Pressure Pipe
(4) Connector of Temperature Sensor (14) DPF Mounting Bracket
(T1) (15) Tube
(5) Connector of Temperature Sensor (16) Tube
(T2) (17) Body (DPF Outlet)
(6) Connector of Temperature Sensor (18) Gasket
(T0) (19) DPF
(7) Differential Pressure Sensor (20) Gasket
Bracket (21) Catalyst (DOC)
(8) Differential Pressure Sensor (22) Temperature Sensor (T0)
(9) Muffler Full Assembly (DPF) (23) Temperature Sensor (T1)
(10) Muffler Full Assembly (DPF) (24) Temperature Sensor (T2)
Mounting Screw
9Y1210674GEG0031US0
G-25
Cleaning of DPF (V2607-CR-TE4B / V3307-CR-TE4B)
IMPORTANT
a new one.
NOTE
parking brake.
preparing the DPF cleaning order form.
(Diagmaster).
the bracket.
5. Remove the 4 nuts (1) of muffler flange (2).
7. Remove the DPF muffler assembly (9).
8. Remove the tube (13), (15) from the differential pressure pipe
(14), (16).
10. Loosen the DPF mounting screw (11), (12) and remove the DPF
(18).
(To be continued)
G-26
(Continued)
(When reassembling)
• Replace the gaskets (22), (24), (25) with new ones.
it.
correct position.
24 to 27 N·m
Nut of muffler flange 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
49 to 55 N·m
5.0 to 5.7 kgf·m
mounting screw
37 to 41 lbf·ft
49.0 to 63.7 N·m
Tightening torque DPF mounting screw 5.00 to 6.49 kgf·m
36.2 to 46.9 lbf·ft
25 to 34 N·m
Temperature sensor 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
16 to 22 N·m
12 to 16 lbf·ft
(1) Nut of Muffler Flange (12) DPF Mounting Screw

(2) Muffler Flange (13) Tube
(4) Connector of Temperature Sensor (15) Tube
(T0) (16) Differential Pressure Pipe
(5) Connector of Temperature Sensor (17) Body (DPF Outlet)
(T1) (18) DPF
(6) Connector of Temperature Sensor (19) Collar (DPF)
(T2) (20) Catalyst (DOC)
Bracket (22) Gasket
(9) Muffler Full Assembly (DPF) (24) Gasket
(10) Muffler Full Assembly (DPF) (25) Gasket
Mounting Screw (26) Temperature Sensor (T2)
(11) DPF Mounting Screw
9Y1210674GEG0077US0
G-27
Judgment of Reuse of DPF Before Cleaning [V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B]
Judgment of Reuse by Service Dealer
IMPORTANT
• Before ordering to a cleaning contractor, follow the
procedures below to make a Judgment on whether the
separated DPF is reusable.
1. Check to see that the surface of the removed DPF on the
exhaust gas outlet side is not darkened.
2. Check whether there is no crack or loss of the sealing part of the
cell holes on both ends of the filter (inlet side and outlet side).
If the number of missing sealing parts more than the allowable
limit, the filter comp cannot be reused even after cleaning.
Number for Number of missing sealing
V2607-CR-E4B
Judgment of Allowable parts: 10 or more
non-reusability limit V2607-CR-TE4B Number of missing sealing
of filter V3307-CR-TE4B parts: 15 or more
3. Check whether there is no crack and loss of the ceramics
element.
If there are any cracks or losses of the ceramics element, the
DPF cannot be reused even if it is cleaned.
4. If it is judged that the DPF is not reusable, report the result of the
evaluation to the customer that requested the filter cleaning,
and replace the DPF with a new one.
9Y1210674GEG0032US0
G-28
Judgment of Reuse of DPF After Cleaning (Cleaning Contractor) [V2607-CR-E4B / V2607-CR-TE4B /
V3307-CR-TE4B]
(1) Decision on Reusability According to the Pin Gauge
Measurement of Actual Cell Depth
IMPORTANT
• After the cleaning contractor has cleaned the DPF,
measure the quantity of remaining ash in the following
procedure, and evaluate the reusability.
1. After having cleaned the DPF, measure the actual cell depth (E)
with a pin gauge in the each block shown in the figure. One cell
(The measurement point is not specified) is measured in each
block.
Model Measurement total
V2607-CR-E4B 16 blocks
V2607-CR-TE4B 25 blocks
V3307-CR-TE4B 25 blocks
2. If the actual cell depth (E) is less than the allowable limit, the
DPF cannot be reused.
If the DPF is judged as non-reusable, report the result of the
judgment to the customer that requested the filter cleaning via
the service dealer, and replace the DPF with a new one.
(Reference)
Actual Cell Depth (E) = Cell Depth (G) − Accumulated Ash
Depth (F)
NOTE
• Select a metal pin gauge having a wire size slightly thinner
than the cell width (0.60 to 0.80 mm dia., 0.024 to
0.031 in. dia.).
• When the pin gauge is inserted into the cell hole, insert it
by lightly tapping on the gage end with a finger tip.
• If the pin gauge is forcibly pushed in, the pin pierces
through the accumulated ash and it cannot be measured
accurately. So be careful not to push the pin forcibly.
Actual Cell Depth
(Average of all Allowable limit 119 mm (4.68 in.)
measurement blocks)
(1) Pin Gauge (0.60 to 0.80 mm dia., (E) Actual Cell Depth
0.024 to 0.031 in. dia.) (F) Accumulated Ash Depth
(2) DPF (G) Cell Depth
(A) Exhaust Inlet Side (a) Serial Number

(B) Exhaust Outlet Side
(C) Accumulated Ash [A] V2607-CR-E4B
(D) 150 mm (5.91 in.) [B] V2607-CR-TE4B, V3307-CR-TE4B
9Y1210674GEG0033US0
Check of EGR System

1. Perform an EGR actuation test.
2. Based on test results, check that the EGR valve gas passage
and coolant passage are not clogged.
3. Clean any soot from the gas passage so that it does not damage
the EGR valve.
4. Clean the coolant passage by operating it with water.
9Y1210674GEG0034US0
G-29
(2) Decision on Reusability According to the Differential Pressure (Differential Pressure Measuring
Instrument Manufactured by FSX)
Differential Pressure Measurement
IMPORTANT
• After the DPF is cleaned by a cleaning contractor, use the
procedure below to measure the amount of soot remaining,
and evaluate the reusability.
• Set the DPF so that the exhaust inlet is on top.
• The decision on reusability depends on the differential
pressure of the DPF, however, this is assuming no issues
are found on inspection of the exterior.
NOTE
• There are 22 types of standard ring, ranging from 4.0 in. to
14.5 in. in diameter (0.5 in. increments).
• Use a ring that is compatible with the DPF to be measured.
• Measurement cannot be performed accurately if there is a
gap between the flow adaptor and differential pressure
measuring instrument.
1. Because the size is different for each DPF, use ring type [A] or
[B] and select a ring (2) that fits the size of the DPF (7).
2. Set the Flow Adaptor (3) on the FSX-manufactured differential
pressure measurement device (4).
3. Select orifice (5) "1" or "2" of the flow adaptor (3).
4. Set the selected ring (2) on the flow adaptor (3).
5. Set the DPF (7) to be measured on the ring, while ensuring that
the exhaust inlet is on top.
6. Measure the differential pressure of the DPF. (air flow during
measurement (6))
7. If the measured differential pressure of the DPF is within the
factory spec for determining reusability, it is deemed reusable.
8. If the measurement is outside the factory spec, the DPF cannot
be reused.
(1) Ring Size [A] V2607-CR-E4B
(2) Ring [B] V2607-CR-TE4B, V3307-CR-TE4B
(3) Flow Adaptor
(4) FSX-manufactured Differential
Pressure Measurement Device
(5) Orifice
(6) Air Flow Direction
(7) DPF
(To be continued)
G-30
(Continued)
Flow Adaptor
Engine Model Ring Type Ring Size (1)
Orifice (5)
6.5 in. dia.
V2607-CR-E4B [A] 2
(170 mm dia.)
V2607-CR-TE4B, 7.5 in. dia.
[B] 1
V3307-CR-TE4B (190 mm dia.)
0.90 to 1.2 in. Aq

V2607-CR-E4B
Reusability evaluation (23 to 30 mm Aq)
standard V2607-CR-TE4, 2.7 to 3.5 in. Aq
V3307-CR-TE4 (69 to 88 mm Aq)
(2) Ring [A] V2607-CR-E4B

(3) Flow Adaptor [B] V2607-CR-TE4B, V3307-CR-TE4B
(5) Orifice
(6) Air Flow Direction
(7) DPF
9Y1210674GEG0079US0
[9] EVERY 1 YEAR

Replacement of Air Cleaner Element
1. Remove used air cleaner primary (2) and secondary (1)
element.
2. Replace new air cleaner primary (2) and secondary (1) element.
NOTE
• The air cleaner uses a dry element. Never apply oil to it.
• Do not operate the engine with filter element removed.
(1) Secondary Element (2) Primary Element
9Y1210674GEG0035US0
G-31
Check of DPF Differential Pressure Pipes and Hoses
[V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B]
IMPORTANT
• Be sure to loosen the differential pressure pipe tightening
nut with crowfoot wrench to prevent the damage of the
sensor or pipe.
• Tighten bolts and nuts to their specified torque.
Also tighten the differential pressure pipe tightening nut to
the specified torque with crowfoot wrench.
1. Check the DPF differential pressure pipe (1), (3) for crack, gas
leakage and loose mounting nut.
2. If you find a crack, change the DPF differential pressure pipe.
3. If you find a gas leakage, remove the DPF differential pressure
pipe and wipe off the anti-seize & lubricating compound.
4. Apply the anti-seize & lubricating compound again, then tighten
the DPF differential pressure pipe to the specified torque.
5. Check the DPF differential pressure hose (2) for crack, gas
leakage.
6. If you find a crack or gas leakage, change the DPF differential
pressure hose.
NOTE
• When you change the DPF differential pressure pipe, apply
the anti-seize & lubricating compound (Bostik,
NEVER-SEEZ, Pure nickel special grade) to the DPF
differential pressure pipe.
(1) DPF Differential Pressure Pipe [A] V2607-CR-E4B
(2) DPF Differential Pressure Hose [B] V2607-CR-TE4B, V3307-CR-TE4B
(3) DPF Differential Pressure Pipe
9Y1210674GEG0036US0
Check of EGR Piping
1. Check the EGR cooler (1) and the EGR cooler base (2) for
crack, gas leakage and loose mounting screw.
2. If you find a crack, the cracked EGR cooler (1) or the cracked
EGR cooler base (2).
3. If you find a gas leakage, tighten the mounting screw again or
replace the gasket with a new one.
4. If you find a loose mounting screw, tighten the mounting screw
again.
(1) EGR Cooler (2) EGR Cooler Base
9Y1210674GEG0037US0
Check of Intake Air Line
1. Make sure that the intake air hose(s) (1) connections are correct
for every year of operation.
again correctly.
3. You must replace the intake air hose(s) every 2 years. Also
IMPORTANT
9Y1210674GEG0038US0
G-32
Check of Exhaust Manifold
1. Check the exhaust manifold for crack, exhaust gas leakage and
loose mounting screw.
2. If you find a crack, change the exhaust manifold.
3. If you find a gas leakage, tighten the mounting screw again or
replace the gasket with a new one.
4. If you find a loose mounting screw, tighten the mounting screw
again.
9Y1210674GEG0039US0
[10] EVERY 2 YEARS

Replacement of Oil Separator Rubber Hose
1. Loosen the clamp (1), (3), (5) and remove the rubber hose (2),
(4).
2. Replace the rubber hose (2), (4) and clamp (1), (3), (5) with new
ones.
3. Tighten the clamp correctly.
(1) Clamp (4) Rubber Hose
(2) Rubber Hose (5) Clamp
(3) Clamp
9Y1210674GEG0040US0
Replacement of Rubber Hose of DPF Differential Pressure

Sensor [V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B]
1. Loosen the clamp (2), (4) and remove the rubber hose (1), (3).
2. Replace the rubber hose (1), (3) and clamp (2), (4) with new
ones.
(1) Rubber Hose (3) Rubber Hose
(2) Clamp (4) Clamp
9Y1210674GEG0041US0
Replacement of Intake Hose (After Air Flow Sensor)

1. Loosen the clamp and remove the hose.
2. Replace the hose and clamp with new ones.
9Y1210674GEG0042US0
Replacement of Pressure Detection Hose of Boost Sensor
1. Loosen the clamp (1) and remove the hose (2).
2. Replace the hose (2) and clamp (1) with new ones.
(1) Clamp (2) Hose
9Y1210674GEG0043US0
Replacement of EGR Cooler Hose

1. Loosen the clamp (2), (3), (5) and remove the hose (1), (4).
2. Replace the hose (1), (4) with new ones.
(1) Hose (4) Hose
(2) Clamp (5) Clamp
(3) Clamp
9Y1210674GEG0044US0
G-33
Replacement of Water Hose
2. Replace the hose with new ones.
9Y1210674GEG0045US0
Replacement of Lubricant Hose
2. Replace the hose with new ones.
9Y1210674GEG0046US0
Change of Radiator Coolant (L.L.C.)
CAUTION
2. Remove the radiator cap (1) to drain the coolant fully. Open the
drain valve (2) and drain plug (3).
3. After you drained all coolant, close the drain valve (2) and drain
plug (3).
4. Fill with the coolant until the "FULL" A mark on the recovery tank
(4).
5. Start and operate the engine for a few minutes.
Check the coolant level of radiator and recovery tank (4) and
add coolant if necessary.
IMPORTANT
• Do not start the engine without coolant.
• Use clean and soft water with anti-freeze to fill the radiator
and recovery tank.
(2) Drain Valve B: LOW
(3) Drain Plug
(4) Recovery Tank
(To be continued)
G-34
(Continued)
 Anti-freeze
• There are 2 types of anti-freeze available: use the permanent
type (PT) for this engine.
• When you add anti-freeze for the first time, flush the water
jacket and radiator interior with clean, soft water several times.
• The brand of the anti-freeze and the ambient temperature have
an effect on the procedure to mix water and anti-freeze. Refer
to the SAE J1034 standard, especially to the SAE J814c.
• Mix the anti-freeze with clean, soft water, and then fill into the
radiator.
IMPORTANT
Vol % Freezing Point Boiling Point*
Anti-freeze °C °F °C °F
40 −24 −11 106 223
50 −37 −35 108 226
* At 1.01 × 100000 Pa (760 mmHg) pressure (atmospheric). Use a radiator pressure
cap that lets the pressure collect in the cooling system to get a higher boiling point.
NOTE
• The above data is the industrial standards that shows the
minimum glycol content necessary in the concentrated
anti-freeze.
• When the coolant level decreases because of evaporation,
add clean, soft water only to keep the anti-freeze mixing
ratio less than 50 %. If there is a leakage, add anti-freeze
and clean, soft water in the specified mixing ratio.
• The anti-freeze absorbs moisture. Keep new anti-freeze in
a tightly sealed container.
• Do not use the radiator cleaning agents after you add
anti-freeze to the coolant. Anti-freeze contains an
anti-corrosive agent, which reacts with the radiator
cleaning agent to make sludge and cause damages to the
engine parts.
9Y1210674GEG0047US0
Replacement of Radiator Hoses and Clamp Bands
CAUTION
1. Drain the coolant.
2. Loosen the clamp bands.
3. Remove the upper hose (1) and lower hose (2).
4. Replace the upper / lower hose (1), (2) and clamp bands with
new ones.
5. Tighten the clamp bands correctly.
(1) Upper Hose (2) Lower Hose
9Y1210674GEG0048US0
G-35
Replacement of Fuel Hoses and Clamps
1. Loosen the clamp (2) and remove the fuel hose (1).
2. Replace the fuel hose (1) and clamp (2) with new ones.
4. After you replace the fuel hose and the clamp, bleed the fuel
system.
(1) Fuel Hose (2) Clamp
9Y1210674GEG0049US0
Replacement of Intake Air Line

1. Loosen the clamp (2).
2. Remove the intake air hose (1) and clamp (2).
3. Replace the intake air hose (1) and clamp (2) with new ones.
4. Tighten the clamp (2) correctly.
IMPORTANT
9Y1210674GEG0050US0
G-36
6. SPECIAL TOOLS
Diesel Engine Compression Tester
Code No.
• 07909-30208 (Assembly)
Application
• To measure the diesel engine compression and to make a
decision for a large overhaul if necessary.
(1) Gauge
WSM000001GEG0113US0
Oil Pressure Tester

Code No.
• 07916-32032
Application
• To measure the engine oil pressure.
(1) Gauge (5) Adaptor 2
(2) Cable (6) Adaptor 3
(3) Threaded Joint (7) Adaptor 4
(4) Adaptor 1 (8) Adaptor 5
WSM000001GEG0114US0
Glow Plug Adapter (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)

Application
• Use to check compression pressure through glow plug hole.
NOTE
• This special tool is not provided, so make it referring to the figure.
A 3.0 mm dia. (0.12 in. dia.) through hole L 1.0 rad (60 °)
B 17.0 mm (0.669 in.) M 1.0 mm (0.039 in.)
C 16.0 mm dia. (0.630 in. dia.) P0.5 N 17.0 mm (0.669 in.)
D 13.0 mm dia. (0.512 in. dia.) O 47.0 mm (1.85 in.)
E 9.5 mm dia. (0.37 in. dia.) P 15.0 mm (0.591 in.)
F M8 x 1.0 Q 10.0 mm (0.394 in.)
G 6.50 to 6.70 mm dia. (0.256 to 0.263 in. dia.) R 100 mm (3.94 in.)
H 2.12 to 2.18 rad (121 to 125 °) S 65.0 mm (2.56 in.)
I 4.90 to 5.50 mm dia. (0.193 to 0.216 in. dia.) T 190 mm (7.48 in.)
J 0.52 rad (30 °) C1.5 Chamfer 1.5 mm (0.059 in.)
K 5.0 mm (0.20 in.)
(1) Material: SS400

9Y1210674GEG0053US0
G-37
Glow Plug Adapter (for V3307-CR-TE4B / V3307-CR-TIE4B)
Application
• Use to check compression pressure through glow plug hole.
NOTE
A 3.0 mm dia. (0.12 in. dia.) through hole L 1.0 rad (60 °)
B 17.0 mm (0.669 in.) M 1.0 mm (0.039 in.)
C 16.0 mm dia. (0.630 in. dia.) P0.5 N 17.0 mm (0.669 in.)
D 13.0 mm dia. (0.512 in. dia.) O 61.5 mm (2.42 in.)
E 9.5 mm dia. (0.37 in. dia.) P 15.0 mm (0.591 in.)
F M8 x 1.0 Q 10.0 mm (0.394 in.)
G 6.50 to 6.70 mm dia. (0.256 to 0.263 in. dia.) R 100 mm (3.94 in.)
H 2.145 to 2.148 rad (122.9 to 123.1 °) S 79.5 mm (3.13 in.)
I 4.90 to 5.50 mm dia. (0.193 to 0.216 in. dia.) T 204.5 mm (8.051 in.)
J 0.52 rad (30 °) C1.5 Chamfer 1.5 mm (0.059 in.)
K 5.0 mm (0.20 in.)
(1) Material: SS400

9Y1210674GEG0054US0
G-38
Small End Bushing Replacing Tool (for V2607-CR-E4B /
V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to press fit the small end bushing.
NOTE
• These special tools are not provided, so make it referring to
the figure.
A 140 mm (5.51 in.)
B 27.2 to 27.5 mm (1.07 to 1.08 in.)
C 75.0 mm (2.95 in.): Roulette
D 20.0 mm (0.787 in.)
E 0.52 rad (30 °)
F 25.967 to 25.980 mm dia. (1.0224 to 1.0228 in. dia.)
G 34.0 mm dia. (1.34 in. dia.)
H 2.0 mm (0.079 in.)
I 0.35 rad (20 °)
J 2.5 mm (0.098 in.)
K 0.15 to 0.25 mm (0.0059 to 0.0098 in.)
L 0.35 rad (20 °)
M 1.0 mm (0.039 in.)
N 14.5 mm (0.571 in.)
O 1.0 mm (0.039 in.)
P 0.35 rad (20 °)
Q 26.000 to 26.021 mm (1.0237 to 1.0244 in.)
R 28.900 to 28.950 mm (1.1378 to 1.1397 in.)
a Ra = 3.2a
b Ra = 1.6a
c 1.0 mm radius (0.039 in radius)
d 0.40 mm radius (0.016 in. radius)
C0.3 Chamfer 0.30 mm (0.012 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
C1 Chamfer 1.0 mm (0.039 in.)
(1) Shaft Material: SS400 (2) Guide Material: STKM12A

9Y1210674GEG0055US0
G-39
Small End Bushing Replacing Tool (for V3307-CR-TE4B /
V3307-CR-TIE4B)
Application
• Use to press out and to press fit the small end bushing.
NOTE
the figure.
[Press out]
A 157 mm (6.181 in.)
B 14.0 mm (0.5512 in.)
C 120 mm (4.7244 in.)
D 27.4 mm dia. (1.0787 in. dia.)
E 30.95 mm dia. (1.2185 in. dia.)
F 20 mm dia. (0.7874 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
[Press fit]
A 157 mm (6.181 in.)
B 14.0 mm (0.5512 in.)
C 120 mm (4.7244 in.)
D 27.4 mm dia. (1.0787 in. dia.)
E 42.000 mm dia. (1.6535 in. dia.)
F 20 mm dia. (0.7874 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
9Y1210674GEG0056US0
Idle Gear Bushing Replacing Tool
Application
• Use to press out and to press fit the bushing.
NOTE
• This special tool is not provided, so make it referring to the
figure.
A 196 mm (7.72 in.)
B 25.0 mm (0.984 in.)
C 150 mm (5.91 in.)
D 34.5 mm dia. (1.36 in. dia.)
E 38.075 to 38.100 mm dia. (1.4991 to 1.5000 in. dia.)
F 20 mm dia. (0.79 in. dia.)
a 6.3 μm (250 μin.)
b 6.3 μm (250 μin.)
(1) Material: SS400

9Y1210674GEG0057US0
G-40
Valve Guide Replacing Tool
Application
• Use to press out and press fit the valve guide.
NOTE
the figure.
[for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B]
A 220 mm (8.66 in.)
B 80 mm (3.1 in.)
C 40 mm (1.6 in.)
D 20 mm dia. (0.79 in dia.)
G 25 mm dia. (0.98 in. dia.)
H 6.00 to 6.10 mm dia. (0.237 to 0.240 in. dia.)
I 5.0 mm (0.20 in.)
J 18 mm dia. (0.71 in. dia.)
K 10.6 to 10.7 mm dia. (0.418 to 0.421 in. dia.)
L 6.90 to 7.10 mm (0.272 to 0.279 in.)
C0.3 Chamfer 0.30 mm (0.012 in.)
[for V3307-CR-TE4B / V3307-CR-TIE4B]

A 225 mm (8.86 in.)
B 70 mm (2.8 in.)
C 45 mm (1.8 in.)
D 20 mm dia. (0.79 in dia.)
G 25 mm dia. (0.98 in. dia.)
H 6.70 to 7.00 mm dia. (0.264 to 0.275 in. dia.)
I 5.0 mm (0.20 in.)
J 20 mm dia. (0.79 in. dia.)
K 12.5 to 12.8 mm dia. (0.493 to 0.503 in. dia.)
L 8.50 to 8.90 mm (0.335 to 0.350 in.)
C0.3 Chamfer 0.30 mm (0.012 in.)
(1) Material: SS400

9Y1210674GEG0058US0
G-41
Front Cover Oil Seal Replacing Tool
Application
• Use to press fit the front cover oil seal.
NOTE
A 120 mm (4.72 in.)
B 12.0 mm (0.472 in.)
C 2.90 to 3.00 mm (0.115 to 0.118 in.)
D 10.0 mm (0.394 in.)
E 80.0 mm (3.15 in.)
F 10.0 mm (0.394 in.)
G 95.0 mm dia. (3.74 in. dia.)
78.900 to 79.100 mm dia.
H
(3.1063 to 3.1141 in. dia.)
57.971 to 57.990 mm dia.
I
(2.2824 to 2.2830 in. dia.)
J 50.0 mm dia. (1.97 in. dia.)
K 15.0 mm dia. (0.591 in. dia.)
L 30.0 mm dia. (1.18 in. dia.)
M 15.0 mm (0.591 in.)
N 90.0 mm (3.54 in.)
O 2.50 mm (0.0984 in.)
P 0.35 rad (20 °)
0.15 to 0.25 mm
Q
(0.0059 to 0.0098 in.)
a Ra = 3.2 a
b Ra = 1.6 a
c 0.80 mm radius (0.031 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) Material: S43C-D

9Y1210674GEG0062US0
G-42
Flywheel Housing Oil Seal Replacing Tool (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to press fit the flywheel housing oil seal.
NOTE
A 117 mm (4.61 in.)
B 12.0 mm (0.472 in.)
C 10.0 mm (0.394 in.)
D 75.0 mm (2.95 in.): Roulette
E 10.0 mm (0.394 in.)
F 105 mm dia. (4.13 in. dia.)
78.9971 to 78.9990 mm dia.
G
(3.11013 to 3.11019 in. dia.)
H 68.0 mm dia. (2.68 in. dia.)
I 15.0 mm dia. (0.591 in. dia.)
J 30.0 mm dia. (1.18 in. dia.)
K 90.0 mm (3.54 in.)
L 2.5 mm (0.098 in.)
M 0.35 rad (20 °)
0.15 to 0.25 mm
N
(0.0059 to 0.0098 in.)
a Ra = 3.2 a
b Ra = 1.6 a
(1) Material: SS400

9Y1210674GEG0063US0
G-43
Flywheel Housing Oil Seal Replacing Tool (for V3307-CR-TE4B / V3307-CR-TIE4B)
Application
• Use to press fit the flywheel housing oil seal.
NOTE
A 118 mm (4.65 in.)
B 12.0 mm (0.472 in.)
C 0.90 to 1.0 mm (0.036 to 0.039 in.)
D 10.0 mm (0.394 in.)
E 80.0 mm (3.15 in.)
F 10.0 mm (0.394 in.)
G 120 mm dia. (4.72 in. dia.)
100.90 to 101.10 mm dia.
H
(3.9725 to 3.9803 in. dia.)
86.966 to 86.988 mm dia.
I
(3.4239 to 3.4247 in. dia.)
J 79.0 mm dia. (3.11 in. dia.)
K 15.0 mm dia. (0.591 in. dia.)
L 30.0 mm dia. (1.18 in. dia.)
M 13.0 mm (0.512 in.)
N 90.0 mm (3.54 in.)
O 2.50 mm (0.0984 in.)
P 0.35 rad (20 °)
0.15 to 0.25 mm
Q
(0.0059 to 0.0098 in.)
a Ra = 3.2 a
b Ra = 1.6 a
e 0.20 mm radius (0.0079 in. radius)
C0.3 Chamfer 0.30 mm (0.012 in.)

9Y1210674GEG0064US0
G-44
Valve Bridge Shaft Replacing Tool (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to press fit the valve bridge shaft.
NOTE
A 170 mm (6.69 in.)
B 40.0 mm (1.57 in.)
C 25.0 mm (0.984 in.)
D 105 mm (4.13 in.)
E 25.0 mm (0.984 in.)
F 10.0 mm (0.394 in.)
G 3.0 mm (0.12 in.)
H 0.35 rad (20 °)
18.45 to 18.55 mm
I
(0.7264 to 0.7303 in.)
20.95 to 21.05 mm
J
(0.8248 to 0.8287 in.)
17.057 to 17.084 mm dia.
K
(0.67154 to 0.67259 in. dia.)
L 16.0 mm dia. (0.630 in. dia.)
M 35.0 mm dia. (1.38 in. dia.)
N 60.0 mm dia. (2.36 in. dia.)
O SR 50.0 mm (1.97 in.)
8.10 to 8.15 mm dia.
P
(0.319 to 0.320 in. dia.)
Q 16.4 to 16.6 mm (0.646 to 0.653 in.)
R 25.0 mm (0.984 in.)
S 70.0 mm (2.76 in.): Roulette
T 10.0 mm (0.394 in.)
a Ra = 6.3 a
b Ra = 1.6 a
c Ra = 3.2 a
under 0.30 mm radius
f
(0.012 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) "IN" side

(2) "EX" side
(4) Bottom flat
9Y1210674GEG0065US0
G-45
Valve Bridge Shaft Replacing Tool (for V3307-CR-TE4B /
V3307-CR-TIE4B)
Application
• Use to press fit the valve bridge shaft.
NOTE
figure.
A 9.50 mm dia. (0.374 in. dia.) through hole
B 19.0 mm (0.748 in.)
C 23.2 mm (0.913 in.)
D 42.00 to 42.40 mm (1.654 to 1.669 in.)
E 12.5 mm dia. (0.492 in. dia.) through hole
F 61.0 mm (2.40 in.)
G 18.7 mm (0.736 in.)
H 30.90 to 31.70 mm (1.217 to 1.248 in.)
a 0.30 mm radius (0.012 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) Material: SS400

9Y1210674GEG0066US0
Camshaft Cover Replacing Tool (for V3307-CR-TE4B /
V3307-CR-TIE4B)
Application
• Use to press fit the camshaft cover.
NOTE
figure.
A 30.0 mm (1.18 in.)
B 30.0 mm dia., 20.0 mm depth (1.18 in. dia., 0.79 in. depth)
C 47.975 to 48.000 mm (1.8888 to 1.8897 in.)
D 52.0 mm (2.05 in.)
E 80.0 mm (3.15 in.)
F 16.5 to 16.6 mm (0.650 to 0.653 in.)
G 80.0 mm (3.15 in.)
H 10.0 mm (0.394 in.)
I 26.0 mm (1.02 in.)
J 100 mm (3.94 in.)
K 6.0 mm (0.24 in.)
L 132 mm (5.20 in.)
M 1.0 mm (0.039 in.)
b 2.0 mm radius (0.079 in. radius)
c Ra = 3.2a
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) Material: S43C

9Y1210674GEG0067US0
G-46
Crankshaft Sleeve Replacing Tool (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to fix the crankshaft sleeve of the diesel engine.
NOTE
• These special tools are not provided, so make it referring to the figure.
A 0.035 rad (2.0 °) Q 15.0 mm dia. (0.591 in. dia.)

B 30.0 mm (1.18 in.) R 30.0 mm dia. (1.18 in. dia.)
C 31.925 to 31.950 mm dia. (1.2569 to 1.2578 in. dia.) S 24.45 to 24.55 mm (0.9626 to 0.9665 in.)
D 22.0 mm dia. (0.866 in. dia.) T 115 mm depth (4.53 in. depth)
E 73.60 to 73.70 mm dia. (2.898 to 2.901 in. dia.) U 34.5 mm (1.36 in.)
F 10.0 mm (0.394 in.) V 120 mm (4.72 in.)
G 6.0 mm (0.24 in.) W 154.5 mm (6.083 in.)
7.0 mm dia. (0.28 in. dia.),
H 23.45 to 23.55 mm (0.9233 to 0.9272 in.) AA
Chamfer 0.50 mm (0.020 in.) both side
I 29.5 mm (1.16 in.) a Ra = 1.6 a
J 95.0 mm (3.74 in.): Roulette b Ra = 3.2 a
K 10.0 mm (0.394 in.) c 1.0 mm radius (0.039 in. radius)
L 0.52 rad (30 °) d 10.0 mm radius (0.394 in. radius)
M 0.70 to 1.0 mm dia. (0.028 to 0.039 in. dia.) C1 Chamfer 1.0 mm (0.039 in.)
N 1.0 mm (0.039 in.) C3 Chamfer 3.0 mm (0.12 in.)
O 90.0 mm dia. (3.54 in. dia.) C5 Chamfer 5.0 mm (0.20 in.)
P 74.10 to 74.20 mm dia. (2.918 to 2.921 in. dia.)
(1) Sleeve Guide Material: (2) Shaft Material: SGD400-D

SGD400-D
9Y1210674GEG0068US0
G-47
Crankshaft Sleeve Replacing Tool (for V3307-CR-TE4B / V3307-CR-TIE4B)
Application
• Use to fix the crankshaft sleeve of the diesel engine.
NOTE
• These special tools are not provided, so make it referring to the figure.
A 1.50 mm (0.0591 in.) Q 33.0 mm (1.30 in.)

B 0.52 rad (30 °) R 115 mm depth (4.53 in. depth)
C 34.925 to 34.950 mm dia. (1.3750 to 1.3759 in. dia.) S 43.0 mm (1.69 in.)
D 22 mm dia. (0.8661 in. dia.) T 120 mm (4.72 in.)
E 81.980 to 81.985 mm dia. (3.2276 to 3.2277 in. dia.) U 163 mm (6.42 in.)
F 6.0 mm (0.24 in.) V 8.0 mm dia. (0.31 in. dia.)
G 23.5 mm (0.925 in.) W 33.475 to 33.525 mm (1.3180 to 1.3198 in.)
H 29.5 mm (1.16 in.) a Ra = 1.6 a
I 58.0 mm (2.28 in.) b 0.50 mm radius (0.020 in. radius)
J 95.0 mm (3.74 in.) c Ra = 3.2 a
K 98.0 mm dia. (3.86 in. dia.) d 1.50 mm radius (0.0591 in. radius)
L 0.52 rad (30 °) e 10.0 mm radius (0.394 in. radius)
M 82.100 to 82.200 mm dia. (3.2323 to 3.2362 in. dia.) C1 Chamfer 1.0 mm (0.039 in.)
N 1.50 mm (0.0591 in.) C3 Chamfer 3.0 mm (0.12 in.)
O 15.0 mm dia. (0.591 in. dia.) C5 Chamfer 5.0 mm (0.20 in.)
P 30.0 mm dia. (1.18 in. dia.)
(1) Sleeve Guide Material: S43C (2) Shaft Material: S43C

9Y1210674GEG0069US0
G-48
Crankcase Aligning Plate (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use for aligning the crankcase 1 and 2.
NOTE
A 115 mm (4.53 in.) R 25.0 mm (0.984 in.)

B 106.5 mm (4.193 in.) S 15.0 mm (0.591 in.)
C 108 mm (4.25 in.) T 70.0 mm (2.76 in.)
D 78.0 mm (3.07 in.) U 48.0 mm (1.89 in.)
E 115 mm (4.53 in.) V 83.0 mm (3.27 in.)
F 91.0 mm (3.58 in.) W 11.0 mm (0.433 in.)
G 24.0 mm (0.945 in.) X 32.0 mm (1.26 in.)
H 26.0 mm (1.02 in.) Y 6.0 mm (0.24 in.)
I 53.0 mm (2.09 in.) Z 2.0 mm (0.079 in.)
5 X 13.0 mm dia. (0.512 in. dia.),
J 140 mm dia. (5.51 in. dia.) AA
Chamfer 0.50 mm (0.020 in.)
4 X 40.0 mm dia. (1.57 in. dia.),
K 20.0 mm (0.787 in.) AB
16.0 mm dia. (0.630 in. dia.),
L 260 mm dia. (10.2 in. dia.) AC
M 14.5 mm (0.571 in.) a 15.0 mm radius (0.591 in. radius)
N 53.0 mm (2.09 in.) b Ra = 3.2 a
O 75.0 mm (2.95 in.) c Ra = 6.3 a
P 108 mm (4.25 in.) d 0.05 mm (0.002 in.)
Q 117 mm (4.61 in.)
(1) Material: SS400

9Y1210674GEG0070US0
G-49
Crankcase Aligning Plate (for V3307-CR-TE4B /
V3307-CR-TIE4B)
Application
• Use for aligning the crankcase 1 and 2.
NOTE
figure.
A 126.6 mm (4.984 in.)
B 49.1 mm (1.93 in.)
C 37.5 mm (1.48 in.)
D 20 mm (0.79 in.)
E 14 mm dia. (0.55 in. dia.)
F 14 mm dia. (0.55 in. dia.)
G 14 mm dia. (0.55 in. dia.)
H 17.5 mm (0.689 in.)
I 17.5 mm (0.689 in.)
J 35 mm (1.4 in.)
K 19 mm (0.75 in.)
(1) Material: S43C

9Y1210674GEG0071US0
Guide Pin
Application
• To remove and install the suction control valve (SCV).
NOTE
figure.
A 30 mm (1.2 in.)
B 6.0 mm dia. (0.24 in. dia.)
C 45 mm (1.8 in.)
D M6 × Pitch 1.0
9Y1210674GEG0082US0
G-50
Flywheel Housing Guide (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to install the flywheel housing to the crankcase.
NOTE
A 70.0 mm (2.76 in.)
B 30.0 mm (1.18 in.)
C 30.0 mm (1.18 in.): Roulette
D 8.0 mm (0.31 in.)
78.60 to 78.70 mm dia.
E
(3.095 to 3.098 in. dia.)
73.8 to 74.2 mm dia.
F
(2.91 to 2.92 in. dia.)
32.009 to 32.034 mm dia.
G
(1.2602 to 1.2611 in. dia.)
H 20.0 mm dia. (0.787 in. dia.)
I 30.0 mm dia. (1.18 in. dia.)
J 75.5 mm dia. (2.97 in. dia.)
K 30.0 mm (1.18 in.)
7.0 mm dia., 8.0 mm depth
L
(0.28 in. dia., 0.31 in. depth)
M 1.1 to 1.3 mm (0.044 to 0.051 in.)
N 20.0 mm (0.787 in.)
a Ra = 3.2 a
b Ra = 1.6 a
f 1.5 mm radius (0.059 in. radius)
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) Material: SS400

9Y1210674GEG0072US0
G-51
Flywheel Housing Guide (for V3307-CR-TE4B / V3307-CR-TIE4B)
Application
• Use to install the flywheel housing to the crankcase.
NOTE
A 70.0 mm (2.76 in.)
B 8.0 mm (0.31 in.)
C 22.0 mm (0.866 in.)
D 30.0 mm (1.18 in.)
E 87.0 mm dia. (3.43 in. dia.)
82.036 to 82.071 mm dia.
F
(3.2298 to 3.2311 in. dia.)
G 77.0 mm dia. (3.03 in. dia.)
H 57.0 mm dia. (2.24 in. dia.)
I 35.0 mm dia. (1.38 in. dia.)
J 30.0 mm dia. (1.18 in. dia.)
K 84.0 mm dia. (3.31 in. dia.)
L 3.5 mm (0.14 in.)
M 3.0 mm (0.12 in.)
N 6.60 to 6.80 mm (0.260 to 0.267 in.)
O 8.0 mm (0.31 in.)
P 67.0 mm dia. (2.64 in. dia.)
4.0 mm dia. (0.16 in. dia.)
Q
through hole
a Ra = 1.6 a
c Ra = 3.2 a
C0.5 Chamfer 0.50 mm (0.020 in.)
(1) Material: SS400

9Y1210674GEG0073US0
G-52
Camshaft Position Sensor Bushing Replacing Tool (for V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B)
Application
• Use to press fit the camshaft position sensor bushing.
NOTE
A 30.0 mm dia. (1.18 in. dia.)
24.8 to 25.2 mm dia.
B
(0.977 to 0.992 in. dia.)
18.4 to 18.5 mm dia.
C
(0.725 to 0.728 in. dia.)
D 6.80 to 6.90 mm (0.268 to 0.271 in.)
E 5.0 mm (0.20 in.)
F 26.0 mm (1.02 in.)
G 105.0 mm (4.134 in.)
H 20.0 mm (0.787 in.)
I 26.0 mm (1.02 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
9Y1210674GEG0074US0
Camshaft Position Sensor Bushing Replacing Tool (for V3307-CR-TE4B / V3307-CR-TIE4B)
Application
• Use to press fit the camshaft position sensor bushing.
NOTE
A 30.0 mm dia. (1.18 in. dia.)
B 40.0 mm dia. (1.57 in. dia.)
24.8 to 25.2 mm dia.
C
(0.977 to 0.992 in. dia.)
18.4 to 18.5 mm dia.
D
(0.725 to 0.728 in. dia.)
E 8.80 to 8.90 mm (0.347 to 0.350 in.)
F 5.0 mm (0.20 in.)
G 28.0 mm (1.10 in.)
H 105.0 mm (4.134 in.)
C0.5 Chamfer 0.50 mm (0.020 in.)
9Y1210674GEG0075US0
G-53
Rotation Sensor Signal Interface Unit
Application
• Use for reading rotation sensor signal.
NOTE
(1) 9V Battery (4) LED A: for Panasonic (a) +9 V

(2) Switch (5) Clip (Red) B: for DENSO (b) Signal
(3) 3-Terminal Regulator (6) Clip (Black) C: for BOSCH cam angle (c) GND
D: for BOSCH crank angle (d) +5 V
(E) Connector Side (e) Signal
(f) GND
9Y1210674GEG0076US0
G-54
1 ENGINE

MECHANISM
CONTENTS
1. ENGINE BODY........................................................................................................................... 1-M1

[1] CYLINDER BLOCK .............................................................................................................. 1-M1
[2] COOLING JACKET .............................................................................................................. 1-M1
[3] HALF-FLOATING HEAD COVER ........................................................................................ 1-M2
[4] CYLINDER HEAD ................................................................................................................ 1-M3
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE..................................... 1-M4
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS) ............................................................. 1-M5
[7] GEAR TRAIN CONFIGURATION ........................................................................................ 1-M5
[8] PISTON ................................................................................................................................ 1-M6
2. LUBRICATING SYSTEM............................................................................................................ 1-M7
[1] OIL COOLER........................................................................................................................ 1-M7
3. COOLING SYSTEM ................................................................................................................... 1-M8
[1] THERMOSTAT ..................................................................................................................... 1-M8
[2] BOTTOM BYPASS SYSTEM ............................................................................................... 1-M9
4. FUEL SYSTEM......................................................................................................................... 1-M10
[1] OVERVIEW ........................................................................................................................ 1-M10
[2] SUPPLY PUMP .................................................................................................................. 1-M11
[3] RAIL.................................................................................................................................... 1-M14
[4] INJECTOR.......................................................................................................................... 1-M15
[5] ENGINE CONTROL SYSTEM ........................................................................................... 1-M18
(1) Engine ECU.................................................................................................................. 1-M19
(2) Sensor .......................................................................................................................... 1-M19
5. EGR SYSTEM .......................................................................................................................... 1-M21
[1] EGR VALVE ....................................................................................................................... 1-M21
[2] REED VALVE ..................................................................................................................... 1-M21
[3] EGR COOLER.................................................................................................................... 1-M22
6. AFTER TREATMENT SYSTEM ............................................................................................... 1-M23
[1] AFTER TREATMENT DEVICES [V2607-CR-E4B / V2607-CR-TE4B /
V3307-CR-TE4B]................................................................................................................ 1-M23
[2] AFTER TREATMENT DEVICES [V2607-CR-TIE4B / V3307-CR-TIE4B] .......................... 1-M29

V2607-CR-E4B, V2607-CR-TE4B, V2607-CR-TIE4B (DOC only), V3307-CR-TE4B, V3307-CR-TIE4B (DOC only), WSM ENGINE
1. ENGINE BODY
[1] CYLINDER BLOCK
The 07 series DI engine employs ladder frame
structure type crankcases - the crankcase 1 (1) with
combustion part and the crankcase 2 (2) which supports
the crankcase 1 (1).
The following benefits are in the ladder frame
structure.
1. Minimizing parts.
2. Noise reduction.
3. Reduction of loss and dispersion on friction thanks to
accuracy of axial concentricity.
The cylinder is a linerless type which enables good
cooling operation, less strain and good abrasion
resistance.
(1) Crankcase 1 (2) Crankcase 2
9Y1210674ENM0033US0
[2] COOLING JACKET

The 07 series DI engine employs coolant evenness
distribution type cooling jacket inside crankcase 1. The
coolant is evenly supplied to each cylinder through the
main gallery (3) in the jacket mold core (2).
(1) Coolant Passage between (2) Jacket Mold Core
Cylinder (3) Main Gallery
9Y1210674ENM0034US0
1-M1
[3] HALF-FLOATING HEAD COVER

The rubber packing is fitted in to keep the head cover
0.5 mm (0.02 in.) or so off the cylinder head. This
arrangement helps reduce noise coming from the
cylinder head.
(1) Cylinder Head Cover
9Y1210674ENM0035US0
1-M2
[4] CYLINDER HEAD

This engine employs four valve system, the cylinder
head is provided with double intake passage in order to
ensure appropriate air suction and give an optimum
swirl.
(1) Intake Port (Helical) A: V2607-CR-E4B /
(2) Intake Port (Direct) V2607-CR-TE4B
(3) Exhaust Port B: V3307-CR-TE4B
9Y1210674ENM0036US0
1-M3
[5] 4 SCREWS PER EACH CYLINDER ASSEMBLING STRUCTURE

The 07 series DI engine employs 4 screws per each
cylinder assembling structure.
The cylinder head (2) and the crankcase 2 (4) are
assembled from the top and bottom to the crankcase 1
(3) with each of 10 screws.
The following objectives are in the 4 screws per each
cylinder assembling structure.
1. Reduce the load share rate of combustion pressure
on outer block surface wall.
2. Flexibility of cylinder head design.
(1) Cylinder Head Mounting (3) Crankcase 1
Screw (4) Crankcase 2
(2) Cylinder Head (5) Crankcase 2 Mounting
Screw
9Y1210674ENM0037US0
1-M4
[6] CENTER DIRECT INJECTION SYSTEM (E-CDIS)

The 07 series DI engine adopts the Center Direct
Injection System (E-CDIS), in which the injector (3) is set
upright at the center of the cylinder.
This system serves to inject fuel directly at the center
of the cylinder. By so doing, injected fuel and suction air
can be mixed more uniformly, leading to more stable,
higher combustion performance. In other words, cleaner
emission, higher power output, lower fuel consumption,
lower operating noise and higher start-up performance
have been achieved.
(1) Exhaust Valves (3) Injector
(2) Piston (4) Intake Valves
9Y1210674ENM0038US0
The 07 series DI engine has two intake valves and

two exhaust valves per each cylinder.
The rocker arm (1) contacts a valve bridge arm (2)
instead of the valves stem tip.
The valve bridge arm (2) then contacts both intake
valves or both exhaust valves and causes two valves to
open simultaneously.
(1) Rocker Arm (2) Valve Bridge Arm
9Y1210674ENM0039US0
[7] GEAR TRAIN CONFIGURATION

The 07 series DI engine employs gear train located
at flywheel side. The following benefits are in the rear
gear train configuration.
1. Flexibility of auxiliary parts arrangement.
2. Reduction of gear chattering noise from crankshaft
of torsional and bending vibration.
(1) Cam Gear (3) Supply Pump Gear
(2) Idle Gear (4) Crank Gear
9Y1210674ENM0040US0
1-M5
[8] PISTON
Piston's skirt is coated with molybdenum
disulfide, which reduces the piston slap noise and
thus the entire operating noise.
Molybdenum disulfide (MoS2)

The molybdenum disulfide (1) serves as a solid
lubricant, like a Graphite or Teflon. This material helps
resist metal wears even with little lube oil.
(1) Molybdenum Disulfide
9Y1210674ENM0041US0
1-M6
2. LUBRICATING SYSTEM
[1] OIL COOLER
The 07 series engine has a coolant-cooled oil cooler
that not only cools hot oil, but also warms the cool engine
oil shortly after start up.
As shown in the figure, the oil flows inside the
connected cooler plate, whereas coolant is kept
circulating outside the cooler plate, thereby cooling down
or warming the oil.
(A) Oil Inlet Port (a) Coolant Inlet Port
(B) Oil Outlet Port (b) Coolant Outlet Port
9Y1210674ENM0042US0
1-M7
3. COOLING SYSTEM
[1] THERMOSTAT
Conventional thermostatically-controlled valves
(outlet water temperature control type) open against the
flow of coolant. In this design, the pressure (steam
pressure + water pump's discharge pressure) affects the
open/close performance of such valve. In other words,
the valve may be delayed in opening at a preset opening
temperature opening suddenly, above the preset
temperature. This is called the overshoot phenomenon.
The overshoot problem invites the undershoot
phenomenon too. Too much water cooled by the radiator
flows through the water passage, which suddenly closes
the valve below the thermostat's preset valve closing
temperature.
A repeated cycle of such overshoot (3) and
undershoot phenomena is called the water temperature
hunting. This hunting problem may adversely affect the
cooling system parts, and also the engine and its related
components.
To cope with this trouble, the 07 series engine is
equipped with the flow control thermostat. The valve has
a notch (4) to control the coolant flow-rate smoothly in
small steps.
(1) Coolant Temperature (A) Valve Lift Versus Flow-rate
(2) Time (B) Flow-rate
(3) Overshoot (C) At Short Valve Lift
(4) Notch (D) At Medium Valve Lift
(E) At High Valve Lift
(F) Valve Lift
9Y1210674ENM0043US0
1-M8
[2] BOTTOM BYPASS SYSTEM

Bottom bypass system is introduced in the 07 series
for improving the cooling performance of the radiator.
While the temperature of coolant in the engine is low,
the thermostat (1) is held closed and the coolant is
allowed to flow through the bypass pipe and to circulate
in the engine.
When the temperature exceeds the thermostat (1)
valve opening level, the thermostat (1) fully opens itself
to prevent the hot coolant from flowing through the
bypass into the engine.
In this way, the radiator can increase its cooling
performance.
(1) Thermostat (A) Bypass Opened
(2) Radiator (B) Bypass Closed
(3) Engine
9Y1210674ENM0044US0
1-M9
4. FUEL SYSTEM
[1] OVERVIEW
(1) Injector
(2) Rail
(3) Supply Pump
(4) Different Sensors
(5) Engine ECU
The fuel system of this engine is completely different from previous jerk fuel injection pumps. Our common rail
system not only complies with strict emission regulations, it enables multiple, precise high-pressure injections that do
not vary with engine RPM.
The system is an electronically controlled fuel injection device, with a supply pump (3) that pressurizes the fuel,
a rail (2) that stores the high-pressure fuel, injectors (1) that inject the fuel under high-pressure via solenoids into each
cylinder and an engine ECU that controls them all.
Various parameters are controlled by the engine ECU, such as the amount of fuel from the injectors and their
timing, the pressure of fuel in the rail, etc., as sensed via signals from each sensor and CAN communications from
the engine's ECU.
This results in fuel always being injected under ideal conditions, which suppresses the hallmark of a diesel engine,
the black smoke during takeoff and acceleration, so there is less smoke, it is cleaner and with a higher output of
power.
9Y1210674ENM0001US0
1-M10
[2] SUPPLY PUMP

The supply pump is equivalent to previously used
injection pumps and it delivers fuel to the rail at a
pressure more than double that of previous pumps.
It consists of a feed pump (10), regulating valve (6),
SCV (suction control valve) (2), pump unit, delivery valve
(3) and a fuel temperature sensor (1).
(1) Fuel Temperature Sensor (6) Regulating Valve
(2) SCV (Suction Control Valve) (7) Drive Shaft
(3) Delivery Valve (8) Eccentric Cam
(4) Plunger (9) Ring Cam
(5) Suction Valve (10) Feed Pump
9Y1210674ENM0002US0
Feed Pump
The feed pump sucks up fuel filtered by the fuel filter
and supplies it to the pump unit.
The feed pump is a trochoid pump with an inner rotor
and outer rotor (1) geared elliptically; the inner rotor (3)
is driven by the drive shaft (2) and drives the outer rotor
in turn in the same direction. In the process, the volume
of the part enclosed by the teeth of the rotor changes and
thus pumps the fuel.
(1) Outer Rotor A: Suction Port
(2) Drive Shaft B: From The Fuel Tank
(3) Inner Rotor C: Discharge Port
D: To Pump Chamber
9Y1210674ENM0003US0
Regulating Valve
The regulating valve controls the fuel feed pressure
(feed pump discharge pressure) so it always stays at the
set pressure.
When the feed pressure exceeds the set pressure
due to changes in the pump's RPM, the piston (4)
overcomes the pressure of the spring, opening the valve
and returning fuel to the suction side of the feed pump
(2).
(1) Pump Housing (4) Piston
(2) Feed Pump (5) Spring
(3) Bushing (6) Plug
9Y1210674ENM0004US0
1-M11
SCV (suction control valve)
(1) Drive Voltage

(2) Amperage
(3) Average Current Differential
(4) Plunger
(5) Feed Pump
(6) Regulating Valve
(7) Cylinder
(8) SCV (Suction Control Valve)
A: Low Suction Volume

B: High Suction Volume
C: ON
D: OFF
By regulating the amount of fuel supplied to the plunger (4), the SCV (8) controls the pressure of fuel in the rail.
The SCV uses a linear solenoid valve and the fuel flow is controlled by controlling how long the SCV is energized by
the ECU.
There are two types of SCV valve, the fail-open type (max flow with no power) and the fail-closed type (min flow
with no power) and the engine uses a fail-open SCV.
When power flows to the SCV (8), the actuator inside moves according to the duty ratio, pressing on the cylinder
(7) and altering the flow of fuel corresponding to the size of the cylinder opening and establishing the appropriate
amount.
1) Fail-open type
With no power to the solenoid, the cylinder is returned via spring force and the valve opens wide, supplying a large
quantity of fuel to the plunger.
When the solenoid is energized, the armature presses on the cylinder, compressing the spring and reducing the
quantity of fuel supplied. The solenoid turns ON & OFF according to the duty ratio. The quantity of fuel supplied to
the plunger is in proportion to the size of the cylinder opening.
2) Duty ratio control
The engine's ECU outputs a waveform signal for a set interval. The current amperage is the average amperage
of the average current differential. When this average value rises, the size of the valve opening is reduced, and
conversely, when it drops, the valve opens wider.
3) When the SCV operates for a short time
The average current to the solenoid is low, so the cylinder is returned via spring force and the valve opens wide,
supplying a large quantity of fuel to the plunger.
4) When the SCV operates for a long time
The average current to the solenoid is high, so the armature presses on the cylinder, compressing the spring,
closing the valve opening and supplying a smaller quantity of fuel to the plunger.
9Y1210674ENM0005US0
1-M12
Pump Unit
The pump unit works to increase the pressure of fuel
received from the SCV and consists of a drive shaft (1),
ring cam (3) and two plungers (5). A ring cam (3) is
mounted on the outside of the eccentric cam (2), which
is on the same axle as the drive shaft; the plungers are
arranged symmetrically vertically on the ring cam.
When the drive shaft rotates, the eccentric cam
rotates eccentrically and the ring cam (3) is driven up
and down by it, which operates the two plungers (5)
through their cycles.
(1) Drive Shaft (4) Feed Pump
(2) Eccentric Cam (5) Plunger
(3) Ring Cam
9Y1210674ENM0006US0
Delivery Valve
The delivery valve is integrated with the element (1)
and consists of a check ball (2), spring (3) and holder (4).
When the pressure on the plunger side (5)
equals/exceeds the pressure on the rail side, the check
ball opens and discharges fuel. As soon as the fuel
pressure feed is complete, the check ball is pressed
back by the spring and when it touches the seat of the
element, it cuts off the rail side from the plunger side,
thus preventing any backflow of fuel.
(1) Element (4) Holder
(2) Check Ball (5) Plunger
(3) Spring
9Y1210674ENM0007US0
Fuel Temperature Sensor
The fuel temperature sensor is mounted on the fuel
intake side and detects the temperature of the fuel using
the characteristic of the thermistor (1), whose electrical
conductivity varies with temperature.
(1) Thermistor A: Thermistor Temperature
(2) Resistance Change Curve
(3) Temperature
9Y1210674ENM0052US0
1-M13
[3] RAIL
The rail (2) stores fuel at the high pressure applied
by the supply pump and supplies the shared pressure to
the injectors of each cylinder. The rail incorporates
control parts-a rail pressure sensor (3) and a pressure
limiter (1).
The pressure of the fuel in the rail is detected by the
rail pressure sensor, and optimal feedback control is
provided for the engine RPM and load. This greatly
improves the ability to raise the pressure at low RPMs
and enables high-pressure injection from low speed
ranges.
Pressure Limiter
The pressure limiter operates when the pressure
inside the rail becomes excessively high (valve opens),
and then once the pressure drops to a certain pressure,
it acts to keep the pressure (valve closes).
Fuel discharged by the pressure limiter returns to the
fuel tank.
Please note that the pressure limiter is not treated as
a part, so replacement requires replacing the rail
assembly.
Approx.
Valve opening pressure 220 MPa
Reference (2240 kgf/cm2, 31900 psi)
value Approx.
Valve closing pressure 50 MPa
(510 kgf/cm2, 7300 psi)
Rail Pressure Sensor

The rail pressure sensor is mounted on the rail,
detects the pressure inside the rail and sends a signal to
the engine ECU.
This sensor is a semiconductor type of pressure
sensor, which uses the piezo resistance effect, in which
increasing the pressure on its silicon element changes
its electrical resistance. Please note that the rail
pressure sensor is not treated as a part, so replacement
requires replacing the rail assembly.
(1) Pressure Limiter A: Return
(2) Rail B: Abnormally High Pressure
(3) Rail Pressure Sensor C: Rail Pressure
(4) Valve (Open) Characteristics
(5) Valve (Close)
(6) Rail Pressure
(7) Output Voltage
(8) Rail Pressure
9Y1210674ENM0009US0
1-M14
[4] INJECTOR
The injectors inject high-pressure fuel from the rail
into the combustion chamber of the engine, using
signals from the engine's ECU to produce the ideal
timing, amount of fuel, mixture and spray.
The injector injects a finely tuned spray in three
pulses during the combustion stage. First a small
amount is injected, mitigating the effect of the initial burn
and reducing NOx (oxides of nitrogen) and noise. The
main injection follows with the real burn, and in the last
stage, a diffuse combustion is induced, thus reducing
particulate matter (PM) generated by the main injection.
Injector Architecture
Injectors consist of nozzle components (nozzle (10)
and needle valve (9)), a TWV (two-way valve) (5), which
controls the volume and mixture of fuel, a control
chamber (7) with an intake orifice and discharge orifice
(6), a command piston (8) and a nozzle spring.
(1) Engine ECU A: Pre-injection
(2) Rail Pressure Sensor B: Main Injection
(3) Rail C: After Injection
(4) Supply Pump D: Post Injection
(5) TWV (Two-way Valve)
(6) Discharge Orifice
(7) Control Chamber
(8) Command Piston
(9) Needle Valve
(10) Nozzle
(11) Injection Amount
(12) T.D.C (Top Dead Center)
(13) B.D.C (Bottom Dead Center)
(14) Crank Angle
9Y1210674ENM0010US0
1-M15
Injector Operation
(1) Solenoid
(2) TWV (Two-way Valve)
(3) Discharge Orifice
(4) Command Piston
(5) Needle Valve
(6) Leak Passage
(7) Intake Orifice
(8) Control Chamber
A: Injection Stop
B: Injection Start
C: Injection Finish
D: From Rail
E: To Fuel Tank
The injector uses the signal output from the engine ECU to control the injection with the fuel pressure in the control
chamber.
The system for controlling the pressure of the control chamber works by energizing the solenoid, which opens the
passage of the chamber's discharge orifice and the fuel is injected due to the drop in pressure. When the current
stops, the pressure in the control chamber returns to what it was and injection ceases.
1) Injection Stop
With no current to the solenoid (1), the TWV (2) cuts off the discharge orifice (3) passage, so rail pressure is
applied to the control chamber (8) and the bottom of the needle valve (5). As the diameter of the command piston (4)
on the control chamber side is larger than the diameter of the bottom of the needle valve, it works to push the needle
valve down, which is compounded by the nozzle spring pushing it down, and the needle valve is closed.
2) Injection Start
When the solenoid (1) is energized, it draws the TWV (2) up, opening the passage of the discharge orifice (3),
returning fuel in the control chamber (8) to the fuel tank via the leak passage (6) and dropping the pressure.
The drop in the pressure of the control chamber causes the pressure applied to the bottom of the needle valve
(5) to become greater than the pressure on the control chamber side, and the needle valve compresses the nozzle
spring and starts injecting fuel.
3) Injection Finish
When current to the solenoid (1) stops, the TWV (2) lowers and the discharge orifice (3) passage is closed.
When the passage of the discharge orifice closes, the fuel pressure in the control chamber (8) recovers to the rail
pressure, so the needle valve (5) is pressed back via the command piston (4), stopping the injection.
9Y1210674ENM0011US0
Injector Drive Circuit
To increase the responsiveness of the injector, the
voltage that drives the injector is raised to a high voltage,
accelerating the magnetization of the solenoid and
increasing the responsiveness of the TWV.
The battery voltage is raised to about 110 V by a
high-voltage generating circuit inside the ECU and that
voltage is supplied to the injector to actuate it.
(1) Injector (4) Control Circuit
(2) Rated Amperage Circuit (5) Engine ECU
(3) High-voltage Generating
Circuit
9Y1210674ENM0012US0
1-M16
Injector QR/ID Codes
Injectors are processed to exacting tolerances, but
there are minute variations in the amount they inject, so
to correct for these variations, a correction volume is
recorded on the QR/ID codes of the injectors.
During manufacture, the QR code is read by a
scanner and the correction value is registered in the
ECU.
(1) ID Code (2) QR Code
9Y1210674ENM0013US0
When Replacing an Injector

Register the ID code of the replacement injector into
the ECU.
(1) Engine ECU (2) Replacement Injector
9Y1210674ENM0014US0
When Replacing the Engine ECU

Register the ID codes of all of the injectors into the
replacement engine ECU.
When replacing an ECU, as it is necessary to write
all of the data, including the injector corrections, only
KUBOTA can write the data to the ECU.
(1) Replacement ECU (2) Injector
9Y1210674ENM0015US0
1-M17
[5] ENGINE CONTROL SYSTEM
(1) Key Switch ON Signal (10) Overheat Lamp Signal (25) Intake Air Temperature (33) **Temperature Sensor
(2) Starter Switch Signal (11) Glow (Air Heater) Lamp Signal Sensor (DPF Inlet Exhaust
(3) Emergency Stop Switch (12) Starter Relay (26) Glow Plug Temperature) (T1)
(4) Oil Pressure Switch (13) Glow Relay (27) Coolant Temperature Sensor (34) **Temperature Sensor (DOC
(5) CAN Communication for (14) Supply Pump (28) Crankshaft Position Sensor Inlet Exhaust Temperature)
OEM Machine (15) Fuel Temperature Sensor (29) Diesel Particulate Filter (T0)
(*Accelerator Position Signal, (16) SCV (Suction Control Valve) (Hereinafter Referred To As (35) Air Flow Sensor
*Neutral Switch, *Machine (17) Rail Pressure Sensor The "DPF") Muffler
Travel Speed Signal) (18) Rail (30) Camshaft Position Sensor (A) CAN2 Connector
(6) CAN Communication for (19) Pressure Limiter (31) **Temperature Sensor (DPF (For OEM Machine)
Service (20) Injector Outlet Exhaust Temperature) (B) CAN1 Connector
(7) Engine Warning Light Signal (21) EGR DC Motor (T2) (For Service)
(8) Stop Lamp Signal (22) EGR Lift Sensor (32) **Differential Pressure Sensor (C) Engine ECU
(9) Oil Pressure Warning Lamp (23) **Intake Throttle Valve (DPF Differential Pressure) (a) To Fuel Tank
Signal (24) Intake Air Pressure Sensor (ΔP)
NOTE
• The signals marked with * are CAN communication.
• The parts marked with ** are only for -E4B, -TE4B. (TIE4B do not equip the parts).
9Y1210674ENM0049US0
1-M18
(1) Engine ECU

The engine ECU (1) controls the amount, timing,
mixture and pressure of fuel that is injected. The engine
ECU (1) operates each kind of control based on the
signals from each type of sensor.
The actuator for controlling the amount, timing and
mixture of fuel injection is the injector, while the actuator
for controlling fuel pressure is the supply pump.
 Fuel Quantity Control
The amount of fuel to be injected is determined using
a basic injection amount, which is calculated based on
the state of the engine and driving conditions, with
corrections added for parameters such as water
temperature, fuel temperature, intake air temperature,
intake pressure, etc.
 Injection Timing Control
The ECU controls the timing for starting to energize
the injectors, first determining the timing for the main
injection and then setting the timing of other injections,
such as pilot injections.
 Fuel Mixture Control
By conducting a pilot injection, the initial fuel mixture
is kept to a minimum, mitigating the explosive initial
combustion and reducing NOx and noise.
 Fuel Pressure Control
The ECU calculates the set fuel injection pressure
based on the engine load (last injection amount and
engine RPM) and controls the amount the supply pump
supplies and the fuel pressure inside the rail.
(1) Engine ECU (2) ECU Connector
9Y1210674ENM0029US0
(2) Sensor
Crankshaft Position Sensor
The crankshaft position sensor (2) is mounted near
the supply pump gear of the flyweel housing (1) and the
sensor uses an MRE (magnetic resistance element) type
of sensor.
When the pulsar gear passes by the sensor, it alters
the magnetic field inside the sensor, generating an AC
voltage, which is output to the engine ECU.
Further, the gear has a wide part between teeth,
which alters the waveform of the AC voltage and the
sensor detects the crankshaft position with every
revolution; this change in the voltage is amplified by the
IC circuit inside the sensor and outputs it to the engine
ECU.
The engine ECU uses the signals to calculate the
piston position and engine RPM.
(1) Flyweel Housing (2) Crankshaft Position Sensor
9Y1210674ENM0030US0
1-M19
Camshaft Position Sensor
The camshaft position sensor (1) is mounted near
the camshaft gear and the sensor functions in the same
way as the crankshaft position sensor.
This sensor detects the extra teeth (two teeth) of the
camshaft pulsar gear (2) and the engine ECU uses the
signal to calculate the piston position.
(1) Camshaft Position Sensor (2) Camshaft Pulsar Gear
9Y1210674ENM0031US0
This figure shows the pulse chart of the crankshaft

position sensor output signal and camshaft position
sensor output signal.
The camshaft pulsar gear rotates once when the
crankshaft pulsar gear rotates twice (12.6 rad (720 °)
crank angle).
there is a gearless section in the crankshaft pulsar
gear. The ECU determines whether it is TDC if the
camshaft position sensor signal is detected while the
crankshaft position sensor is passing this gearless
section.
(1) 56 pulses (6.28 rad (360 °) A: Crankshaft Position
crank angle) Sensor Output Voltage
(2) 5 pulses (12.6 rad (720 °) B: Camshaft Position Sensor
crank angle) Output Voltage
(3) 5 V
(4) 0 V
9Y1210674ENM0032US0
1-M20
5. EGR SYSTEM
[1] EGR VALVE
Water Cooled EGR Valve
This is a device that regulates EGR gas flow. The
degree the valve is open is detected using a lift sensor
and a motor is used to set this to the degree of open
calculated using signals including the engine speed.
Also, passing engine coolant through the housing
enables controlling temperature rise of the EGR valve.
9Y1210674ENM0016US0
EGR Valve Lift Sensor

How far the EGR valve is open is detected by a
contact type of position sensor that detects the
movement of the motor's shaft. The motor's shaft opens
and closes the valve by changing the rotation of the
motor into linear motion via a screw deceleration
mechanism.
(1) CAN H (4) Power (+)
(2) CAN L (5) Exhaust Gas Flow
(3) GND (−) (6) CAN Communication Data
9Y1210674ENM0046US0
[2] REED VALVE

The reed valves are set at the point where exhaust
gases that have passed through the EGR valve mix with
intake air and they prevent air on the air cleaner side
from flowing to the EGR cooler side.
These thin plate springs (reed valves) mounted at
the bottom of the EGR valve motor open and close the
EGR gas passage (during intake: reed valve is closed;
during exhaust: open) and prevent the intake air from
backflowing to the exhaust side.
(1) Valve (3) Stopper
(2) Case
9Y1210674ENM0018US0
1-M21
[3] EGR COOLER

The EGR (Exhaust Gas Recirculation) cooler (1) is
used to lower combustion temperature and efficiently
cool EGR gas, with the aim of reducing the NOx that is
in the exhaust gas of diesel engine.
The EGR cooler (1) is set between the cylinder head
and the EGR valve and returns the cooled exhaust
gases to the engine suction side.
The EGR cooler (1) has resistant to clogging up,
compact and efficient tubes (2) internally.
(1) EGR Cooler A: Coolant Inlet Port
(2) Tube B: Coolant Outlet Port
9Y1210674ENM0047US0
1-M22
6. AFTER TREATMENT SYSTEM

[1] AFTER TREATMENT DEVICES [V2607-CR-E4B /
V2607-CR-TE4B / V3307-CR-TE4B]
(1) Common Rail System (9) Temperature Sensor (12) Temperature Sensor (a) EGR Valve Opening
(2) ECU (DOC Inlet Exhaust (DPF Outlet Exhaust (b) Injection Pattern
(3) After Treatment Devices Temperature) (T0) Temperature) (T2) (c) Inlet Throttle Valve Angle
(4) EGR Cooler (10) Temperature Sensor (13) Diesel Oxidation Catalyst (d) Air Flow Sensor
(5) EGR Valve (DPF Inlet Exhaust (DOC) (e) T0 (DOC Inlet Exhaust
(6) Intake Throttle Valve Temperature) (T1) (14) Diesel Particulate Filter Temperature)
(7) Air Flow Sensor (11) Differential Pressure Sensor (DPF) (f) T1 (DPF Inlet Exhaust
(8) Turbo Charger (DPF Differential Pressure) Temperature)
(ΔP) (g) ΔP (DPF Differential
Pressure)
(h) T2 (DPF Outlet Exhaust
Temperature)
9Y1210674ENM0019US0
1-M23
NOTE
• Lighting patterns when the lamp is lighted by ECU directly.
9Y1210674ENM0048US0
Permit
Manual
RGN and
RGN Warning
Inhibit
Demand Lamp
Lamp
Auto Regeneration Lamp
State of Regeneration
Permit
Level 0
Regeneration is not required
(No need Regeneration)
Regeneration starts automatically when the PM level reachs to
Level 1
 this level.
(Auto Regeneration)
Parked regeneration is impossible in this level.
ECU requests parked regeneration if the PM level does not
Level 2
decrease to automatic regeneration level in 1800 seconds after
(Request parked  
automatic regeneration starts.
Regeneration)
(Automatic regeneration does not stop in this level.)
Automatic regeneration stops.
Level 3 Operator had better park the machine and start manual
  
(Parked Regeneration) regeneration as soon as possible.
During parked regeneration, machine operation is restricted.
Level 4 Parked regeneration is impossible.
(Regeneration with  Regeneration is possible with service tools only.
service tools) (Service tools are available among all levels without level 5)
Level 5 Regeneration is impossible even with service tools.

(DPF Cleaning) DPF cleaning is necessary.
: Lighting, : Blinking
9Y1210674ENM0020US0
Inhibit
Manual
RGN and
RGN Warning
Inhibit
Demand Lamp
Lamp
Auto Regeneration Lamp
State of Regeneration
Inhibit
Level 0
 Regeneration is not required
(No need Regeneration)
Level 1
 Automatic regeneration inhibit
(Auto Regeneration)
ECU requests parked regeneration if the PM level does not
Level 2
decrease to automatic regeneration level in 1800 seconds after
(Request parked  
automatic regeneration starts.
Regeneration)
(Automatic regeneration does not stop in this level.)
Automatic regeneration stops.
Level 3 Operator had better park the machine and start manual
  
(Parked Regeneration) regeneration as soon as possible.
During parked regeneration, machine operation is restricted.
Level 4 Parked regeneration is impossible.
(Regeneration with   Regeneration is possible with service tools only.
service tools) (Service tools are available among all levels without level 5)
Level 5 Regeneration is impossible even with service tools.
 
(DPF Cleaning) DPF cleaning is necessary.
: Lighting, : Blinking
9Y1210674ENM0021US0
1-M24
Diesel Oxidation Catalyst (DOC)
An oxidizing catalyst set in front of the Diesel
Particulate Filter (DPF) step that uses post injection
unburned fuel to actively regenerate the DPF.
(1) Diesel Oxidation Catalyst [A] V2607-CR-E4B
(DOC) [B] V2607-CR-TE4B,
V3307-CR-TE4B
9Y1210674ENM0022US0
1-M25
Diesel Particulate Filter (DPF)
The Diesel Particulate Filter (DPF) is a device that
captures and combusts PM in the exhaust gas.
Physically captures the PM using a filter which
spontaneously combusts when exhaust gas temperature
is high.
However, while exhaust gas temperature is low PM
does not spontaneously combust the pressure
differential between the inlet and outlet of the DPF is
detected and the PM is combusted using a heat source
generated using DOC to regenerate the filter.
(1) Diesel Particulate Filter [A] V2607-CR-E4B
(DPF) [B] V2607-CR-TE4B,
V3307-CR-TE4B
9Y1210674ENM0023US0
Intake Throttle Valve

The amount of air intake is regulated by the angle of
the throttle valve and the exhaust temperature is
controlled when regenerating the DPF muffler.
9Y1210674ENM0024US0
1-M26
Air Flow Sensor
The amount of air intake required for control of the
EGR valve used to reduce NOx is measured.
9Y1210674ENM0025US0
Temperature Sensor
This is mounted on the DPF muffler and the DPF
muffler DOC intake, DPF intake, and DPF discharge
exhaust temperature, needed for the post processing
system, are measured.
(1) Temperature Sensor [A] V2607-CR-E4B
[B] V2607-CR-TE4B,
V3307-CR-TE4B
9Y1210674ENM0026US0
1-M27
Differential Pressure Sensor
The differential pressure sensor is a sensor that
detects the pressure differential between the inlet and
the outlet of the DPF.
The engine ECU calculates the amount of
accumulated PM in the DPF using this signal.
(1) Differential Pressure Sensor
9Y1210674ENM0027US0
Oil Separator
Removes oil in the blowby gases that pass through
the element (1) and the oil is returned to the oil pan.
Blowby gases that pass through the element (1) are
mixed into the intake upstream from the turbo charger.
(1) Element
9Y1210674ENM0028US0
1-M28
[2] AFTER TREATMENT DEVICES [V2607-CR-TIE4B /

V3307-CR-TIE4B]
(1) Common Rail System (5) EGR Valve (8) Diesel Oxidation Catalyst 1 (a) EGR Valve Opening
(2) ECU (6) Air Flow Sensor (DOC 1) (b) Injection Pattern
(3) After Treatment Devices (7) Turbo Charger (9) Diesel Oxidation Catalyst 2 (c) Air Flow Sensor
(4) EGR Cooler (DOC 2)
9Y1210674ENM0050US0
Diesel Oxidation Catalyst (DOC) [V2607-CR-TIE4B /
V3307-CR-TIE4B]
Output of "DOC only" with intercooler is equivalent
with one of "DOC + DPF". "DOC only" does not require
manual regeneration and ash cleaning.
(1) Diesel Oxidation Catalyst
(DOC)
9Y1210674ENM0051US0
1-M29
SERVICING
CONTENTS
1. TROUBLESHOOTING.................................................................................................................1-S1
2. SERVICING SPECIFICATIONS ..................................................................................................1-S5
3. TIGHTENING TORQUES..........................................................................................................1-S14
[1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR GENERAL USE.........1-S14
[2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR SPECIAL USE...........1-S15
4. CHECKING, DISASSEMBLING AND SERVICING ...................................................................1-S18
[1] CHECKING AND ADJUSTING............................................................................................1-S18
(1) Engine Body ..................................................................................................................1-S18
(2) Lubricating System ........................................................................................................1-S20
(3) Cooling System .............................................................................................................1-S20
(4) Electrical System ...........................................................................................................1-S22
(5) Turbocharger .................................................................................................................1-S26
[2] DISASSEMBLING AND ASSEMBLING ..............................................................................1-S27
(1) Draining Engine Oil and Coolant ...................................................................................1-S27
(2) External Components ....................................................................................................1-S28
(3) Turbocharger and EGR .................................................................................................1-S41
(4) Common Rail.................................................................................................................1-S42
(5) Cylinder Head and Valves .............................................................................................1-S44
(6) Thermostat ....................................................................................................................1-S51
(7) SCV ...............................................................................................................................1-S52
(8) Fuel Temperature Sensor..............................................................................................1-S54
(9) Supply Pump .................................................................................................................1-S55
(10)Water Pump and Oil Cooler ..........................................................................................1-S58
(11)Front Cover ...................................................................................................................1-S59
(12)Flywheel and Timing Gears ..........................................................................................1-S60
(13)Piston and Connecting Rod ..........................................................................................1-S67
(14)Crankshaft and Crankcase............................................................................................1-S71
(15)Starter ...........................................................................................................................1-S73
(16)Alternator.......................................................................................................................1-S74
[3] SERVICING .........................................................................................................................1-S76
(1) Cylinder Head and Valves .............................................................................................1-S76
(2) Timing Gears .................................................................................................................1-S85
(3) Piston and Connecting Rod...........................................................................................1-S90
(4) Crankshaft .....................................................................................................................1-S94
(5) Cylinder .......................................................................................................................1-S100
(6) Oil Pump......................................................................................................................1-S101
(7) Relief Valve .................................................................................................................1-S102
(8) Starter..........................................................................................................................1-S102
(9) Alternator .....................................................................................................................1-S104

1. TROUBLESHOOTING
This "TROUBLESHOOTING" shows only mechanical failures. The failures related to the common rail system
(CRS), refer to the diagnosis manual (DM) for common rail system engine (9Y120-01990).
Reference
Symptom Probable Cause Solution
Page
The engine does not No fuel Fill up the fuel –
start Air in the fuel system Bleed the air –
Water in the fuel system Change the fuel and G-14
repair or replace the
fuel system
The fuel pump is damaged Replace –
The fuel hose is clogged Clean or replace G-14
The fuel filter is clogged Replace G-17
The viscosity of fuel at low temperature is too Replace the specified I-5,
high fuel G-8
The cetane number of fuel is low Replace the specified I-5,
fuel G-8
Fuel leakage because of loose injection pipe Tighten the retaining 1-S42
retaining nut nut
The injector is clogged Replace G-21,
1-S45
The supply pump is damaged Replace 1-S55
Seizure of the crankshaft, camshaft, piston or Repair or replace
–
bearing
Compression leakage from the cylinder Replace the head 1-S48,
gasket 1-S49,
Tighten the cylinder 1-S50
head screw
Incorrect valve timing Check the timing gear 1-S65,
1-S66
Piston ring and cylinder are worn out Replace 1-S92,
1-S93,
1-S100
Incorrect valve clearance Adjust valve 1-S19
clearance
The starter does not Discharged battery Charge or replace –
operate Starter is damaged Repair or replace 1-S24
The key switch is damaged Replace –
The connection of the wires is incorrect Check or correct –
1-S1
Reference
Page
The engine revolution The fuel filter is clogged Replace G-17
is not smooth The air cleaner is clogged Clean or replace the G-15
air cleaner element
Fuel leakage because of loose injection pipe Tighten the retaining 1-S42
retaining nut nut
The supply pump is damaged Replace 1-S55
The injector is damaged Replace G-21,
1-S45
The turbocharger bearing is worn out Replace the 1-S41
turbocharger
assembly
The turbocharger shaft is bent Replace the 1-S41
turbocharger
assembly
The turbocharger fin or other part has a damage Replace the 1-S41
because of unwanted materials turbocharger
assembly
The exhaust gas is Too much engine oil Reduce it to the G-10
white or blue specified level
The piston ring, piston and cylinder is worn out Replace the piston 1-S92,
ring or piston, or 1-S93,
repair the cylinder 1-S100
There is oil leakage The oil pipe is clogged or has a damage Check, replace or
–
into the exhaust pipe clean the oil pipe
or suction pipe The piston ring seal of the turbocharger is Replace the 1-S41
damaged turbocharger
assembly
The exhaust gas is DPF is damaged Replace 1-S34,
black or dark gray 1-S36
Overload Decrease the load –
The grade of the fuel is low Replace the specified I-5
fuel G-8
The fuel filter is clogged Replace G-17
The air cleaner is clogged Clean or replace the G-15
element
1-S45
1-S2
Reference
Page
The output is The moving parts of engine have a seizure Repair or replace –
deficient The supply pump is damaged Replace 1-S55
1-S45
There is compression leakage Check the 1-S18
compression
pressure and repair
There is a gas leakage from the exhaust system Repair or replace 1-S26,
1-S41
The air cleaner is clogged Clean or replace the G-15
element
There is an air leakage from the compressor Replace the 1-S41
discharge side turbocharger
assembly
The lubricant oil The gap of the piston ring points to the same Move the ring gap 1-S69
consumption is too direction direction
much The oil ring is worn out or cannot move Replace 1-S70,
1-S92,
1-S93
The piston ring groove is worn out Replace the piston 1-S92,
and piston ring 1-S93
The valve stem and valve guide are worn out Replace 1-S51
The crankshaft bearing and the crank pin bearing Replace 1-S95,
is worn out 1-S96
The fuel is mixed into The injector is damaged Replace G-21,
the lubricant oil 1-S45
Fuel leak from the overflow pipe of the inner Replace the gasket
–
cylinder head cover
Oil dilution due to regeneration Change the engine oil G-10
Water is mixed into The head gasket is damaged Replace 1-S48,
the lubricant oil 1-S49,
1-S50
The cylinder block or cylinder head is damaged Replace 1-S48
The oil pressure is The engine oil is not sufficient Fill oil to the specified G-10
low amount
The oil strainer is clogged Clean 1-S67
The relief valve does not operate with dirt Repair or replace 1-S59
The oil clearance of the bearings are too much Replace the metal, 1-S68,
bushing or shaft 1-S71,
1-S95,
1-S96
The oil passage is clogged Clean –
The type of oil used is incorrect Use the specified type I-5,
of oil G-8
The oil pump is damaged Replace 1-S101
The oil pressure is The type of oil used is incorrect Use the specified type I-5,
high of oil G-8
The relief valve is damaged Repair or replace 1-S59
1-S3
Reference
Page
The engine is The engine oil is not sufficient Fill oil to the specified I-5,
overheated amount G-8
The fan belt is broken or the fan belt tension is Replace or adjust 1-S20,
too loose 1-S21
The coolant is not sufficient Fill to the specified G-11
amount
The radiator net and the radiator fin are clogged Clean
–
with dust
There is corrosion in the inner side of the radiator Clean or replace G-34,
G-35
There is clogged in the coolant flow route Clean or replace G-34,
G-35
The radiator or radiator cap is damaged Replace 1-S21
The load is too much Reduce the load –
The head gasket is damaged Replace 1-S48,
1-S49,
1-S50
The fuel used is incorrect Replace the specified I-5,
fuel G-8
9Y1210674ENS0001US0
1-S4
2. SERVICING SPECIFICATIONS
ENGINE BODY
Item Factory Specification Allowable Limit
Cylinder Head Surface Flatness – 0.05 mm
0.002 in.
Top Clearance 0.60 to 0.80 mm –
0.024 to 0.031 in.
Compression Pressure
[V2607-CR-TE4B] 3.20 MPa / 2.20 MPa /
250 min-1 (rpm) 250 min-1 (rpm)
32.6 kgf/cm2 / 22.4 kgf/cm2 /
250 min-1 (rpm) 250 min-1 (rpm)
464 psi / 319 psi /
250 min-1 (rpm) 250 min-1 (rpm)
[V2607-CR-E4B / V3307-CR-TE4B] 3.92 MPa / 2.90 MPa /

250 min-1 (rpm) 250 min-1 (rpm)
40.0 kgf/cm2 / 29.6 kgf/cm2 /
250 min-1 (rpm) 250 min-1 (rpm)
569 psi / 421 psi /
250 min-1 (rpm) 250 min-1 (rpm)
[V2607-CR-TIE4 / V3307-CR-TIE4] 2.6 MPa / 1.6 MPa /

250 min-1 (rpm) 250 min-1 (rpm)
27 kgf/cm2 / 16 kgf/cm2 /
250 min-1 (rpm) 250 min-1 (rpm)
380 psi / 230 psi /
250 min-1 (rpm) 250 min-1 (rpm)
Variance Among Cylinders – 10 % or less

Valve Seat Angle 0.79 rad –
45 °
Width 3.3 to 3.6 mm –

0.13 to 0.14 in.
Valve Face Angle 0.79 rad –
45 °
Valve Recessing 0.65 to 0.85 mm 1.20 mm
0.026 to 0.033 in. 0.0472 in.
Valve Stem to Valve Guide Clearance (Intake) 0.030 to 0.057 mm 0.10 mm
[V2607-CR-E4B / V2607-CR-TE4B / 0.0012 to 0.0022 in. 0.0039 in.
V2607-CR-TIE4B]
• Valve Stem O.D. (Intake) 5.968 to 5.980 mm –

0.2350 to 0.2354 in.
• Valve Guide I.D. (Intake) 6.010 to 6.025 mm –

0.2367 to 0.2372 in.
1-S5

Valve Stem to Valve Guide Clearance 0.045 to 0.072 mm 0.10 mm
[V2607-CR-E4B / V2607-CR-TE4B / (Exhaust) 0.0018 to 0.0028 in. 0.0039 in.
V2607-CR-TIE4B]
• Valve Stem O.D. (Exhaust) 5.953 to 5.965 mm –

0.2344 to 0.2348 in.
• Valve Guide I.D. (Exhaust) 6.010 to 6.025 mm –

0.2367 to 0.2372 in.
Valve Stem to Valve Guide Clearance 0.055 to 0.085 mm 0.10 mm
[V3307-CR-TE4B / V3307-CR-TIE4B] 0.0022 to 0.0033 in. 0.0039 in.
• Valve Stem O.D. 6.960 to 6.975 mm –

0.2741 to 0.2746 in.
• Valve Guide I.D. 7.030 to 7.045 mm –

0.2768 to 0.2773 in.
Valve Clearance (Cold) 0.13 to 0.17 mm –
0.0052 to 0.0066 in
Intake Valve Timing Open 0.21 rad (12 °) –
[V2607-CR-TE4B / V2607-CR-TIE4B] before T.D.C.
Close 0.77 rad (44 °) –

after B.D.C.
Exhaust Valve Timing Open 0.86 rad (49 °) –
[V2607-CR-TE4B / V2607-CR-TIE4B] before B.D.C.
Close 0.30 rad (17 °) –

after T.D.C.
Intake Valve Timing Open 0.24 rad (14 °) –
[V2607-CR-E4B / V3307-CR-TE4B / before T.D.C.
V3307-CR-TIE4B]
Close 0.70 rad (40 °) –
after B.D.C.
Exhaust Valve Timing Open 0.87 rad (50 °) –
[V2607-CR-E4B / V3307-CR-TE4B / before B.D.C.
V3307-CR-TIE4B]
Close 0.24 rad (14 °) –
after T.D.C.
Valve Spring
[V2607-CR-E4B / V2607-CR-TE4B / Free Length 35.4 to 35.9 mm 34.9 mm
V2607-CR-TIE4B] 1.40 to 1.41 in. 1.37 in.
[V3307-CR-TE4B / V3307-CR-TIE4B] Free Length 35.1 to 35.6 mm 34.6 mm

1.39 to 1.40 in. 1.36 in.
Tilt – 1.0 mm
0.039 in.
1-S6

Valve Spring
[V2607-CR-E4B / V2607-CR-TE4B / Setting Load / 60.8 N / 29.7 mm 45.9 N / 29.7 mm
V2607-CR-TIE4B] Setting Length 6.20 kgf / 29.7 mm 4.68 kgf / 29.7 mm
13.7 lbf / 1.17 in. 10.3 lbf / 1.17 in.
[V3307-CR-TE4B / V3307-CR-TIE4B] Setting Load / 63.5 N / 31.5 mm 45.9 N / 31.5 mm

Setting Length 6.48 kgf / 31.5 mm 4.68 kgf / 31.5 mm
14.3 lbf / 1.24 in. 10.3 lbf / 1.24 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.054 mm 0.15 mm
V2607-CR-TIE4B]
• Rocker Arm Shaft O.D. 13.973 to 13.984 mm –

0.55012 to 0.55055 in.
• Rocker Arm I.D. 14.000 to 14.027 mm –

0.55119 to 0.55224 in.
Rocker Arm Shaft to Rocker Arm Oil Clearance 0.016 to 0.054 mm 0.15 mm
• Rocker Arm Shaft O.D. 14.973 to 14.984 mm –

0.58949 to 0.58992 in.
• Rocker Arm I.D. 15.000 to 15.027 mm –

0.59056 to 0.59161 in.
Valve Bridge Arm to Valve Bridge Shaft Oil Clearance 0.018 to 0.057 mm 0.15 mm
V2607-CR-TIE4B]
• Valve Bridge Arm I.D. 8.050 to 8.080 mm –

0.3170 to 0.3181 in.
• Valve Bridge Shaft O.D. 8.023 to 8.032 mm –

0.3159 to 0.3162 in.
Valve Bridge Arm to Valve Bridge Shaft Oil Clearance 0.018 to 0.057 mm 0.15 mm
• Valve Bridge Arm I.D. 9.050 to 9.080 mm –

0.3563 to 0.3574 in.
• Valve Bridge Shaft O.D. 9.023 to 9.032 mm –

0.3553 to 0.3555 in.
Push Rod Alignment – 0.25 mm
0.0098 in.
Tappet to Tappet Bore Oil Clearance 0.020 to 0.050 mm 0.07 mm
0.00079 to 0.0019 in. 0.003 in.
• Tappet Bore I.D. 10.000 to 10.015 mm –

0.39370 to 0.39429 in.
• Tappet O.D. 9.965 to 9.980 mm –

0.3924 to 0.3929 in.
1-S7

Camshaft Side Clearance – 0.10 mm
0.0039in.
Alignment – 0.01 mm
0.0004 in.
Cam Height Intake 32.70 mm 32.20 mm
[V2607-CR-E4B] 1.287 in. 1.268 in.
Exhaust 33.20 mm 32.70 mm

1.307 in. 1.287 in.
[V2607-CR-TE4B / V2607-CR-TIE4B] 1.283 in. 1.264 in.

1.299 in. 1.280 in.
[V3307-CR-TE4B / V3307-CR-TIE4B] 1.476 in. 1.457 in.

1.492 in. 1.472 in.
Camshaft Oil Clearance 0.050 to 0.091 mm 0.15 mm
V2607-CR-TIE4B]
• Camshaft Journal 1 O.D. 34.934 to 34.950 mm –

1.3754 to 1.3759 in.
• Cylinder Block Bore 1 I.D. 35.000 to 35.025 mm –

1.3780 to 1.3789 in.

1.6510 to 1.6515 in.

1.6536 to 1.6545 in.
Camshaft Oil Clearance 0.050 to 0.091 mm 0.15 mm

1.3754 to 1.3759 in.

1.3780 to 1.3789 in.

1.7297 to 1.7303 in.

1.7323 to 1.7332 in.
1-S8

Timing Gear
[V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B]
• Crank Gear to Cam Gear Backlash 0.0400 to 0.118 mm 0.22 mm
0.00158 to 0.00464 in. 0.0087 in.
• Cam Gear to Idle Gear Backlash 0.0400 to 0.159 mm 0.22 mm

0.00158 to 0.00625 in. 0.0087 in.
• Idle Gear to Supply Pump Gear Backlash 0.0400 to 0.168 mm 0.22 mm

0.00158 to 0.00661 in. 0.0087 in.
Timing Gear
[V3307-CR-TE4B / V3307-CR-TIE4B] Backlash 0.0410 to 0.139 mm 0.22 mm
• Crank Gear to Cam Gear 0.00162 to 0.00547 in. 0.0087 in.
• Cam Gear to Idle Gear Backlash 0.0410 to 0.145 mm 0.22 mm

0.00162 to 0.00570 in. 0.0087 in.
• Idle Gear to Supply Pump Gear Backlash 0.0410 to 0.139 mm 0.22 mm

0.00162 to 0.00547 in. 0.0087 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.025 to 0.096 mm 0.10 mm
V2607-CR-TIE4B]
• Idle Gear Bushing I.D. 35.000 to 35.055 mm –

1.3780 to 1.3801 in.
• Idle Gear Shaft O.D. 34.959 to 34.975 mm –

1.3764 to 1.3769 in.
Idle Gear Shaft to Idle Gear Bushing Oil Clearance 0.0250 to 0.106 mm 0.11 mm
• Idle Gear Bushing I.D. 47.000 to 47.065 mm –

1.8504 to 1.8529 in.
• Idle Gear Shaft O.D. 46.959 to 46.975 mm –

1.8488 to 1.8494 in.
Idle Gear Side Clearance 0.050 to 0.20 mm 0.90 mm
V2607-CR-TIE4B]
Idle Gear Side Clearance 0.15 to 0.25 mm 0.90 mm
Piston Pin Bore I.D. 26.000 to 26.013 mm 26.05 mm
V2607-CR-TIE4B]
Piston Pin Bore I.D. 28.000 to 28.013 mm 28.05 mm
[V3307-CR-TE4B / V3307-CR-TIE4B] 1.1024 to 1.1028 in. 1.104in.
Top Ring to Ring Groove Clearance 0.050 to 0.090 mm 0.15 mm
0.0020 to 0.0035 in. 0.0059 in.
Second Ring to Ring Groove Clearance 0.090 to 0.12 mm 0.20 mm
0.0036 to 0.0047 in. 0.0079 in.
Oil Ring to Ring Groove Clearance 0.020 to 0.060 mm 0.15 mm
0.00079 to 0.0023 in. 0.0059 in.
1-S9

Piston Ring Gap Top Ring 0.20 to 0.35 mm 1.25 mm
V2607-CR-TIE4B]
Second Ring 0.30 to 0.45 mm 1.25 mm
0.012 to 0.017 in. 0.0492 in.
Oil Ring 0.25 to 0.45 mm 1.25 mm

0.0099 to 0.017 in. 0.0492 in.
Piston Ring Gap Top Ring 0.25 to 0.40 mm 1.25 mm
Second Ring 0.30 to 0.45 mm 1.25 mm

0.012 to 0.017 in. 0.0492 in.
Oil Ring 0.25 to 0.45 mm 1.25 mm

0.0099 to 0.017 in. 0.0492 in.
Connecting Rod Alignment – 0.05 mm
0.002 in.
Piston Pin to Small End Bushing Oil Clearance 0.014 to 0.034 mm 0.15 mm
V2607-CR-TIE4B]
• Piston Pin O.D. 26.006 to 26.011 mm –
1.0239 to 1.0240 in.
• Small End Bushing I.D. 26.025 to 26.040 mm –

1.0246 to 1.0251 in.
Piston Pin to Small End Bushing Oil Clearance 0.020 to 0.040 mm 0.15 mm
• Piston Pin O.D. 28.006 to 28.011 mm –

1.1026 to 1.1027 in.
• Small End Bushing I.D. 28.031 to 28.046 mm –

1.1036 to 1.1041 in.
Crankshaft Side Clearance 0.15 to 0.35 mm 0.50 mm
0.0059 to 0.013 in. 0.020 in.
Alignment – 0.02 mm
0.0008 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.030 to 0.051 mm 0.20 mm
V2607-CR-TIE4B]
• Crankshaft Journal O.D. 72.977 to 72.990 mm –

2.8732 to 2.8736 in.
Crankshaft Journal to Crankshaft Bearing Oil Clearance 0.030 to 0.073 mm 0.20 mm
• Crankshaft Journal O.D. 79.977 to 79.990 mm –

3.1487 to 3.1492 in.
1-S10

Crank Pin to Crank Pin Bearing Oil Clearance 0.011 to 0.058 mm 0.20 mm
V2607-CR-TIE4B]
• Crank Pin O.D 46.980 to 46.991 mm –

1.8496 to 1.8500 in.
Crank Pin to Crank Pin Bearing Oil Clearance 0.017 to 0.048 mm 0.20 mm
• Crank Pin O.D 49.980 to 49.991 mm –

1.9678 to 1.9681 in.
Cylinder Bore I.D. 87.000 to 87.022 mm 87.15 mm
V2607-CR-TIE4B]
Cylinder Bore I.D. 94.000 to 94.022 mm 94.15 mm
Cylinder Bore (Oversize) I.D. 87.250 to 87.272 mm 87.40 mm
V2607-CR-TIE4B]
Cylinder Bore (Oversize) I.D. 94.500 to 94.522 mm 94.65 mm
1-S11
LUBRICATING SYSTEM
Engine Oil Pressure At Idle Speed – 50 kPa
[V2607-CR-E4B / V2607-CR-TE4B / 0.5 kgf/cm2
V2607-CR-TIE4B] 7 psi
At Rated Speed 250 to 440 kPa 150 kPa

2.5 to 4.5 kgf/cm2 1.5 kgf/cm2
36 to 64 psi 21 psi
Engine Oil Pressure At Idle Speed – 50 kPa
[V3307-CR-TE4B / V3307-CR-TIE4B] 0.5 kgf/cm2
7 psi
At Rated Speed 200 to 390 kPa 150 kPa

2.0 to 4.0 kgf/cm2 1.5 kgf/cm2
29 to 56 psi 21 psi
Engine Oil Pressure Switch Working Pressure 40 to 50 kPa –
0.4 to 0.6 kgf/cm2
6 to 8 psi
Inner Rotor to Outer Rotor Clearance 0.030 to 0.090 mm 0.3 mm
0.0012 to 0.0035 in. 0.01 in.
Outer Rotor to Pump Body Clearance 0.100 to 0.184 mm 0.3 mm
0.00394 to 0.00724 in. 0.01 in.
Inner Rotor to Cover Clearance 0.025 to 0.075 mm 0.225 mm
0.00099 to 0.0029 in. 0.00886 in.
Relief Valve Spring Free Length 60.0 to 60.5 mm 55.0 mm
V2607-CR-TIE4B]
Working Pressure 392 kPa –
4.00 kgf/cm2
56.9 psi
Relief Valve Spring Free Length 60.0 to 60.5 mm 55.0 mm
Working Pressure 294 kPa –

3.00 kgf/cm2
42.7 psi
1-S12
COOLING SYSTEM
Thermostat Valve Opening 80 to 84 °C –
[V2607-CR-E4B / V2607-CR-TE4B / Temperature 176 to 183 °F
V2607-CR-TIE4B]
Valve Full Opening 95 °C –
Temperature 203 °F
(Opened
Completely)
Thermostat Valve Opening 74.5 to 78.5 °C –
[V3307-CR-TE4B / V3307-CR-TIE4B] Temperature 166.1 to 173.3 °F
Valve Full Opening 90 °C –

Temperature 194 °F
(Opened
Completely)
Radiator Water Tightness No leak at specified –
pressure
Radiator Cap Air Leakage 10 seconds or more
90 → 60 kPa
0.9 → 0.6 kgf/cm2
10 → 9 psi
Fan Belt Tension 10 to 12 mm / 98 N –
0.40 to 0.47 in. / 98 N
(10 kgf, 22 lbf)
ELECTRICAL SYSTEM
Glow Plug Resistance Approx. 0.95 Ω –
Commutator O.D. 32.0 mm 31.4 mm
1.26 in. 1.24 in.
Mica Undercut 0.50 mm 0.2 mm
0.020 in. 0.0079 in.
Brush (Starter) Length 18.0 mm 11.0 mm
0.709 in. 0.433 in.
Rotor Coil Resistance 2.8 to 3.3 Ω –
Slip Ring O.D. 22.7 mm 22.1 mm
0.894 in. 0.870 in.
Brush (Alternator) Length 18.5 mm 5.0 mm
0.728 in. 0.20 in.
9Y1210674ENS0149US0
1-S13
3. TIGHTENING TORQUES
Use a torque wrench to tighten the screws, bolts and nuts to the specified torque. Tighten the screws, bolts and
nuts used, such as on the cylinder head in the correct sequence and torque.
9Y1210674ENS0003US0
[1] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR

GENERAL USE
If the tightening torque is not specified, refer to the table below for the none specified torques values.
Indication on
top of bolt No-grade or 4T 7T
Indication on
top of nut No-grade or 4T
Unit N·m kgf·m lbf·ft N·m kgf·m lbf·ft

M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
M8 18 to 20 1.8 to 2.1 13 to 15 24 to 27 2.4 to 2.8 18 to 20
M10 40 to 45 4.0 to 4.6 29 to 33 49 to 55 5.0 to 5.7 37 to 41
M12 63 to 72 6.4 to 7.4 47 to 53 78 to 90 7.9 to 9.2 58 to 66
9Y1210674ENS0004US0
1-S14
[2] TIGHTENING TORQUES OF SCREWS, BOLTS AND NUTS FOR

SPECIAL USE
NOTE
• For the screws, bolts and nuts with the mark "*", apply engine oil to their threads and seats before you
tighten.
• The alphabet "M" in Dimension × Pitch shows that the screw, bolt or nut dimensions are in the metric
system. The dimension is the nominal external diameter in mm of the threads. The pitch is the nominal
distance in mm between 2 threads.
Dimension ×
Item N·m kgf·m lbf·ft
Pitch
Glow lead mounting nut M4 × 0.7 0.98 to 1.7 0.10 to 0.18 0.73 to 1.3
Glow plug M8 × 1.0 7.7 to 9.3 0.78 to 0.95 5.7 to 6.8
Cylinder head cover screw M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Injection pipe retaining nut M12 × 1.5 30 to 40 3.1 to 4.0 23 to 29
Oil switch taper screw R 1/8 15 to 19 1.5 to 2.0 11 to 14
Supply pump mounting nut M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Injector clamp nut M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Supply pump gear mounting nut M14 × 1.5 59 to 68 6.0 to 7.0 44 to 50
Overflow pipe joint screw
M8 11 to 15 1.2 to 1.5 8.2 to 11
(Cylinder head side)
M10 7.9 to 12 0.80 to 1.3 5.8 to 9.4
(Common rail side)
M10 7.9 to 12 0.80 to 1.3 5.8 to 9.4
(Supply pump side)
Common rail mounting screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Coolant temperature sensor – 16 to 19 1.6 to 2.0 12 to 14
Camshaft position sensor mounting
– 8.0 to 12 0.82 to 1.2 5.9 to 8.8
screw
Crankshaft position sensor mounting
– 8.0 to 12 0.82 to 1.2 5.9 to 8.8
screw
Intake air temperature sensor – 30 to 39 3.0 to 4.0 22 to 28
Boost sensor mounting screw
M6 × 1.0 4 to 5 0.4 to 0.6 3 to 4
(Turbocharger model)
Air flow sensor mounting screw M4 × 0.7 1.17 to 1.77 0.120 to 0.180 0.863 to 1.30
Front cover mounting screw M8 × 1.25 30 to 34 3.0 to 3.5 22 to 25
Idle gear mounting screw M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
Mounting screw of crankshaft position
M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
pulsar gear
DPF bracket mounting screw M12 × 1.25 78 to 90 7.9 to 9.2 58 to 66
Reed valve of EGR valve M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
Exhaust manifold mounting nut M8 × 1.25 30 to 34 3.0 to 3.5 22 to 25
EGR cooler flange screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Case of oil separator – 9.50 to 10.5 0.969 to 1.07 7.01 to 7.74
Drain plug M22 × 1.5 45 to 53 4.5 to 5.5 33 to 39
Overflow pipe joint screw M6 × 1.0 9.81 to 11.2 1.00 to 1.15 7.24 to 8.31
*Crankshaft screw M16 × 1.5 255 to 274 26.0 to 28.0 188 to 202
Relief valve retaining screw M22 × 1.5 69 to 78 7.0 to 8.0 51 to 57
1-S15
Dimension ×
Pitch
*Flywheel screw M12 × 1.25 98.1 to 107 10.0 to 11.0 72.4 to 79.5
Camshaft set screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
B terminal nut of starter M8 × 1.25 9.8 to 11 1.0 to 1.2 7.3 to 8.6
Pulley nut of alternator M24 58.4 to 78.9 5.95 to 8.05 43.1 to 58.2
Oil pump cover screw M6 7.9 to 9.3 0.80 to 0.95 5.8 to 6.8
V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B
Dimension ×
Pitch
Rocker arm bracket screw M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
*Cylinder head mounting screw M13 × 1.25 147 to 156 15.0 to 16.0 109 to 115
Oil cooler joint screw M20 × 1.5 64 to 73 6.5 to 7.5 47 to 54
Flywheel housing mounting screw M12 × 1.25 78 to 90 7.9 to 9.2 58 to 66
Flywheel housing mounting screw (9T) M12 × 1.25 103 to 117 10.5 to 12.0 76.0 to 86.7
*Connecting rod screw M8 × 1.0 41 to 45 4.1 to 4.6 30 to 33
*Crankcase 2 mounting screw M13 × 1.25 128 to 137 13.0 to 14.0 94.1 to 101
Crankcase 2 flange screw M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
Screw of muffler flange (V2607-CR-E4) M8 × 1.25 24 to 27 2.4 to 2.8 18 to 20
Nut of muffler flange (V2607-CR-TE4) M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
Nut of muffler flange
M8 × 1.25 29.4 to 34.3 3.00 to 3.49 21.7 to 25.2
(V2607-CR-TIE4B)
DPF mounting bracket
– 16 to 20 1.7 to 2.0 12 to 14
(V2607-CR-E4B)
DPF mounting screw
M10 × 1.25 49.0 to 63.7 5.00 to 6.49 36.2 to 46.9
(V2607-CR-TE4B)
Muffler full assembly (DPF) mounting
screw M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
(V2607-CR-E4B / V2607-CR-TE4B)
Muffler full assembly (DOC) mounting
M10 × 1.25 60.8 to 70.8 6.20 to 7.21 44.9 to 52.2
screw (V2607-CR-TIE4B)
Temperature sensor
M12 × 1.25 25 to 34 2.5 to 3.5 18 to 25
(V2607-CR-E4B / V2607-CR-TE4B)
Differential pressure pipe
M12 × 1.0 16 to 22 1.6 to 2.3 12 to 16
(V2607-CR-E4B / V2607-CR-TE4B)
1-S16
V3307-CR-TE4B / V3307-CR-TIE4B
Dimension ×
Pitch
Rocker arm bracket screw M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
*Cylinder head mounting screw M14 × 1.5 187 to 196 19.0 to 20.0 138 to 144
Oil cooler joint screw M20 × 1.5 40 to 44 4.0 to 4.5 29 to 32
Flywheel housing mounting screw (9T) M12 × 1.25 103 to 117 10.5 to 12.0 76.0 to 86.7
*Connecting rod screw M9 × 1.0 69 to 73 7.0 to 7.5 51 to 54
*Crankcase 2 mounting screw M14 × 1.5 138 to 147 14.0 to 15.0 102 to 108
Crankcase 2 flange screw (9T) M10 × 1.25 59 to 63 6.0 to 6.5 44 to 47
Nut of muffler flange (V3307-CR-TE4B) M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
Nut of muffler flange
M8 × 1.25 29.4 to 34.3 3.00 to 3.49 21.7 to 25.2
(V3307-CR-TIE4B)
DPF mounting screw M10 × 1.25 49.0 to 63.7 5.00 to 6.49 36.2 to 46.9
Muffler full assembly (DPF) mounting
M10 × 1.25 49 to 55 5.0 to 5.7 37 to 41
screw (V3307-CR-TE4B)
Muffler full assembly (DOC) mounting
M10 × 1.25 60.8 to 70.8 6.20 to 7.21 44.9 to 52.2
screw (V3307-CR-TIE4B)
Temperature sensor
M12 × 1.25 25 to 34 2.5 to 3.5 18 to 25
(V2607-CR-E4B / V2607-CR-TE4B)
Differential pressure pipe
M12 × 1.0 16 to 22 1.6 to 2.3 12 to 16
(V2607-CR-E4B / V2607-CR-TE4B)
SCV mounting screw M6 × 1.0 6.90 to 10.8 0.704 to 1.10 5.09 to 7.96
Fuel temperature sensor – 17.6 to 26.5 1.80 to 2.70 13.0 to 19.5
9Y1210674ENS0150US0
1-S17
4. CHECKING, DISASSEMBLING AND SERVICING

[1] CHECKING AND ADJUSTING
(1) Engine Body
Compression pressure
1. After warming-up the engine, remove the air cleaner, muffler,
glow lead, and glow plugs.
2. Set a compression tester (1) (Code No.: 07909-30208) with the
adaptor (2) to the glow plug hole.
3. Crank the engine with the starter to operate the engine approx.
200 to 300 min-1 (rpm).
4. Measure a maximum value of the compression pressure. Do the
same steps twice for each cylinder.
NOTE
• Check the compression pressure with the specified valve
clearance.
• Always use a fully charged battery for you do this test.
• Variances in cylinder compression values must be less
than 10 %.
Factory 3.20 MPa / 250 min-1 (rpm)
specifica- 32.6 kgf/cm2 / 250 min-1 (rpm)
tion 464 psi / 250 min-1 (rpm)
V2607-CR-TE4B
2.20 MPa / 250 min-1 (rpm)
Allowable
22.4 kgf/cm2 / 250 min-1 (rpm)
limit
319 psi / 250 min-1 (rpm)
specifica- 40.0 kgf/cm2 / 250 min-1 (rpm)
Compression V2607-CR-E4B tion 569 psi / 250 min-1 (rpm)
pressure V3307-CR-TE4B 2.90 MPa / 250 min-1 (rpm)
Allowable
29.6 kgf/cm2 / 250 min-1 (rpm)
limit
421 psi / 250 min-1 (rpm)
specifica- 27 kgf/cm2 / 250 min-1 (rpm)
V2607-CR-TIE4 tion 380 psi / 250 min-1 (rpm)
V3307-CR-TIE4 1.6 MPa / 250 min-1 (rpm)
Allowable
16 kgf/cm2 / 250 min-1 (rpm)
limit
230 psi / 250 min-1 (rpm)
0.98 to 1.7 N·m

Glow lead mounting nut 0.10 to 0.18 kgf·m
0.73 to 1.3 lbf·ft
Tightening torque
7.7 to 9.3 N·m
Glow plug 0.78 to 0.95 kgf·m
5.7 to 6.8 lbf·ft
(1) Compression Tester (2) Glow Plug Adaptor

9Y1210674ENS0006US0
1-S18
Valve Clearance
IMPORTANT
• You must check and adjust the valve clearance when the
engine is cold.
1. Remove the injection pipes, glow lead, glow plugs and the
cylinder head cover.
2. Align the "1TC" mark line on the flywheel and projection on the
housing. Make sure that the No.1 piston (front cover side)
comes to the compression or overlap top dead center.
3. Check the subsequent valve clearance at the mark "1TC" with
a feeler gauge. If the clearance is out of the factory
specifications, adjust with the adjusting screw (1) and tighten
the lock nut (2) of the adjusting screw.
0.13 to 0.17 mm
Valve clearance (A) Factory specification
0.0052 to 0.0066 in.
NOTE
• After you adjust the valve clearance, tighten the lock nut (2)
of the adjusting screw.
Adjustable Cylinder Location of Piston IN. EX.
1st  
When No. 1 piston is at compression top 2nd 

dead center 3rd 
4th
1st
2nd 
When No. 1 piston is at overlap position
3rd 
4th  
9.81 to 11.2 N·m

7.24 to 8.31 lbf·ft
Tightening torque
30 to 40 N·m
23 to 29 lbf·ft
(1) Adjusting Screw A: Valve Clearance

(2) Lock Nut
9Y1210674ENS0007US0
1-S19
(2) Lubricating System

Engine Oil Pressure
1. Remove the engine oil pressure switch, and set the oil pressure
tester (Code No.: 07916-32032).
2. Operate the engine for warming-up.
3. Measure the oil pressure at the idle speed and rated speed.
4. If the oil pressure is less than the allowable limit, do a check
below.
• Engine oil level
• Oil pump
• Oil strainer
• Oil filter cartridge
• Oil passage
• Oil clearance
• Relief valve
(When reassembling)
• After you check the oil pressure of the engine, tighten its oil
pressure switch to the specified torque.
50 kPa
At idle Allowable
0.5 kgf/cm2
speed limit
7 psi
Engine oil pressure
Factory 250 to 440 kPa
[V2607-CR-E4B /
specifica- 2.5 to 4.5 kgf/cm2
V2607-CR-TE4B /
At rated tion 36 to 64 psi
V2607-CR-TIE4B]
speed 150 kPa
Allowable
1.5 kgf/cm2
limit
21 psi
50 kPa
At idle Allowable
0.5 kgf/cm2
speed limit
7 psi
Engine oil pressure Factory 200 to 390 kPa
[V3307-CR-TE4B / specifica- 2.0 to 4.0 kgf/cm2
V3307-CR-TIE4B] At rated tion 29 to 56 psi
speed 150 kPa
Allowable
1.5 kgf/cm2
limit
21 psi
15 to 19 N·m
Tightening torque Oil switch taper screw 1.5 to 2.0 kgf·m
11 to 14 lbf·ft
9Y1210674ENS0008US0
(3) Cooling System

Fan Belt Tension
1. Push the fan belt (1) halfway between the fan drive pulley and
measure the deflection (A).
the alternator mounting screw (2) and adjust its position.
10 to 12 mm
Deflection (A) Factory specification
0.40 to 0.47 in.
(1) Fan Belt (A) Deflection

(2) Alternator Mounting Screw
9Y1210674ENS0009US0
1-S20
Fan Belt Damage and Wear
1. Check the fan belt for damage.
2. If the fan belt has a damage, replace it.
3. Check if the fan belt is worn out and sunk in the pulley groove.
4. If it is, replace it.
(A) Good (B) Bad
9Y1210674ENS0010US0
Radiator Cap Air Leakage
CAUTION
• Remove the radiator cap only after you stop the engine for
a minimum of 10 minutes to decrease its temperature. If
not, hot water can gush out and cause injury.
1. Set a radiator tester and an adaptor on the radiator cap.
2. Apply the specified pressure 90 kPa (0.9 kgf/cm2, 10 psi).
3. Measure the time for the pressure to decrease to 60 kPa
(0.6 kgf/cm2, 9 psi).
4. If the measurement is less than the factory specification,
replace the radiator cap.
More than 10 seconds for
pressure decrease
Pressure decreasing
Factory specification from 90 to 60 kPa
time
(from 0.9 to 0.6 kgf/cm2,
from 10 to 9 psi)
9Y1210674ENS0011US0
Radiator Water Leakage
1. Fill a specified quantity of water into the radiator.
2. Set a radiator tester and an adaptor on the radiator. Increase
the water pressure to the specified pressure with the radiator
tester and adaptor.
3. Check the radiator for water leakage.
4. For water leakages from the pinhole, replace the radiator or
repair with the radiator cement. When water leak is too much,
replace the radiator.
Radiator water leakage No leak at specified
Factory specification
test pressure
NOTE
• The pressure of the leak test is different for each radiator
specification. Thus, refer to the test pressure of each
radiator specification to do the leakage test.
9Y1210674ENS0012US0
1-S21
Opening-temperature of Thermostat Valve
1. Push down the thermostat valve and put the thread between the
valve and the valve seat.
2. Put the thermostat and the thermometer in the container and
increase the temperature of the water gradually.
3. Take the thread, and float the thermostat in the water. As the
water temperature rises, the valve will open, and the thermostat
will separate from the thread. Measure the temperature at this
moment.
4. Continue to increase the temperature and read the temperature
when the valve opens approximately 8 mm (0.3 in.).
5. If the measurement is out of the factory specifications, replace
the thermostat.
V2607-CR-E4B
Factory
V2607-CR-TE4B 80 to 84 °C
specifica-
Thermostat's V2607-CR- 176 to 183 °F
tion
valve opening TIE4B
temperature V3307-CR-TE4B Factory
74.5 to 78.5 °C
V3307-CR- specifica-
166.1 to 173.3 °F
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 95 °C
Temperature at specifica-
V2607-CR- 203 °F
which thermostat tion
TIE4B
completely
opens V3307-CR-TE4B Factory
90 °C
194 °F
TIE4B tion
9Y1210674ENS0013US0
(4) Electrical System

CAUTION
• To prevent an accidental short circuit, attach the positive cable to the positive terminal before the
negative cable is attached to the negative terminal.
• Do not remove the battery cap while the engine operates.
• Keep electrolyte away from eyes, hands and clothes. If you are spattered with it, clean with water
immediately.
• Keep open sparks and flames away from the battery at all times. Hydrogen gas mixed with oxygen
becomes very explosive.
IMPORTANT
• Do not disconnect or remove the battery when you operate engine.
9Y1210674ENS0014US0
Battery Voltage
1. Stop the engine.
2. Measure the voltage with a circuit tester between the battery
terminals.
3. If the battery voltage is less than the factory specification, check
the battery specific gravity and charge the battery.
Battery voltage Factory specification More than 12 V
(1) Positive Terminal (2) Negative Terminal

9Y1210674ENS0015US0
1-S22
Battery Specific Gravity
CAUTION
• If battery acid (dilute sulfuric acid) gets on you it could
cause blindness or burns, or could cause corrosion of
machinery and tools so please be careful when handling.
• Wear safety glasses and rubber gloves when performing
battery maintenance and inspection (measuring specific
gravity, filling water, or charging).
• If the gas that is generated is ignited by an ignition source,
it may explode so be very careful with sparks and fire.
• Keep your body and face as far away from the battery as
you can when performing maintenance and inspection.
• Do not allow people who do not know how to handle a
battery or who do not sufficiently understand the danger
perform inspection or maintenance.
(Measurement items)
 Zero adjustment
1. Open the cover and drip water on the prism surface using the
included rod.
2. Close the cover.
3. Aim in a direction that is bright, look into the lens, and adjust the
focus until the gradations can be seen clearly.
4. If the boundary line is not on the gradation baseline (0 position),
turn the adjustment screw until it matches.
5. When zero adjustment is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.
 Measurement of test fluid
1. Open the cover and drip test fluid on the prism surface using the
included rod.
2. Close the cover.
3. Aim in a direction that is bright, look into the lens and read the
gradation of the blue boundary line.
4. When the measurement is complete, wipe the prism and cover
surface with a soft cloth or tissue paper.
(Reference)
Electrolyte specific gravity and amount of discharge.
Use the following table as a reference.
(A) Electrolyte Specific Gravity (C) Good
(B) Discharge (D) Charging is necessary.
NOTE
Temperature conversion of electrolyte specific gravity
• Battery electrolyte specific gravity changes based on
temperature.
• Insert the value identified on a specific gravity meter into
the following conversion equation for temperature
correction to learn an accurate specific gravity value.
(Standard temperature assumed to be 20 °C (68 °F))
D20 = Dt + 0.0007 (t - 20)
D20 = specific gravity value converted to standard
temperature of 20 °C (68 °F)
Dt = measured specific gravity value at the electrolyte
temperature t °C
9Y1210674ENS0146US0
1-S23
Motor Test
CAUTION
• Hold the starter to prevent its movement when you do a test
on the motor.
1. Disconnect the negative cable from the battery.
2. Disconnect the positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter C terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter body
and the battery negative terminal (3).
7. If the motor does not operate, starter is damaged.
Repair or replace the starter.
NOTE
• B terminal: It is the terminal that connects the cable from
the battery to the starter.
• C terminal: It is the terminal that connects the cable from
the motor to the magnet switch.
(1) C Terminal (3) Negative Terminal
(2) Positive Terminal
9Y1210674ENS0017US0
Magnetic Switch Test
1. Disconnect the negative cable from the battery.
2. Disconnect the positive cable from the battery.
3. Disconnect the leads from the starter B terminal.
4. Remove the starter from the engine.
5. Connect a jumper lead from the starter S terminal (1) to the
battery positive terminal (2).
6. Connect a jumper lead momentarily between the starter body
and the battery negative terminal (3).
7. If the pinion gear does not come out, the magnetic switch is
damaged. Repair or replace the starter.
NOTE
• B terminal: It is the terminal that connects the cable from
the battery to the starter.
• S terminal: It is the terminal that connects the cable from
the starter switch to the magnetic switch.
(1) S Terminal (3) Negative Terminal
(2) Positive Terminal
9Y1210674ENS0018US0
Magnetic Switch Continuity Test
1. Push in the plunger. Then check the continuity across the C
terminal (1) and the B terminal (2) with a circuit tester.
2. If it is not continuous or it shows a value, replace the magnetic
switch.
(1) C Terminal (2) B Terminal
9Y1210674ENS0020US0
1-S24
Alternator-on Unit Test
Before testing
• Before the alternator-on unit test, do a check of the list below :
– Battery terminal connections
– Circuit connection
– Fan belt tension
– Charge indicator lamp
– Fuses on the circuit
– Abnormal noise from the alternator
• Prepare full charged battery for the test.
NOTE
• Do not touch the engine parts that turns while the engine
operates.
Keep a safety distance from the engine parts that turn.
1. Start the engine.
2. When the engine operates, measure the voltage between
battery terminals. If the voltage is between 13.8 V and 14.8 V,
the alternator operates correctly.
3. If the results of alternator-on unit test are not in the factory
specifications, disassemble the alternator. Check each
component part to find out the problem. Refer to
"DISASSEMBLING AND ASSEMBLING" and "SERVICING" for
the alternator.
Regulating voltage at no 13.8 to 14.8 V
load at 25 °C (77 °F)
9Y1210674ENS0021US0
Glow Plug Continuity
1. Remove the glow plug (2).
2. Measure the resistance with a circuit tester between the glow
plug terminal and the glow plug housing.
3. If the measurement does not show the factory specification, the
glow plug (2) is damaged.
NOTE
• Adjust the direction of the ditch to the terminal side when
the seal (1) is installed in the glow plug (2).
Resistance Factory specification Approx. 0.95 Ω
(1) Seal (2) Glow Plug

9Y1210674ENS0022US0
1-S25
(5) Turbocharger
Exhaust Gas Leakage of Turbine Side
1. Check the exhaust port (3) and the inlet port (5) side of the
turbine housing (1) for exhaust gas leakage.
2. If you find a gas leakage, tighten the screws and nuts again or
replace the gasket (2) / (4) / (6) with a new one.
(1) Turbine Housing (4) Gasket
(2) Gasket (5) Inlet Port
(3) Exhaust Port (6) Gasket
9Y1210674ENS0023US0
Air Leakage of Compressor Side

1. Check the inlet hose (1) of the compressor cover (3) for air
leakage.
2. Check the suction side of the inlet hose for loose connections or
cracks.
3. If you find an air leakage, change the clamps (2) and / or the
inlet hose.
(1) Inlet Hose (3) Compressor Cover
(2) Clamp Band
9Y1210674ENS0024US0
Radial Clearance
1. If the wheel touches the housing, replace the turbocharger
assembly with a new one.
9Y1210674ENS0025US0
1-S26
[2] DISASSEMBLING AND ASSEMBLING

(1) Draining Engine Oil and Coolant
Draining Engine Oil
1. Start and increase the temperature of the engine for
approximately 5 minutes.
3. Remove the drain plug (1) to drain the oil.
4. After you drain, tighten the drain plug (1).
(When reassembling)
• Fill the engine oil until the upper line on the dipstick (2).
IMPORTANT
• Do not mix different types of oil.
• Use the correct SAE Engine Oil by reference to the ambient
temperature.
(1) Drain Plug (2) Dipstick
9Y1210674ENS0026US0
Draining Coolant
CAUTION
• Do not remove the radiator cap while you operate or
immediately after you stop the engine. If not, hot water can
flow out from the radiator. Only open the cap after more
than 10 minutes for the temperature of the radiator to
decrease.
1. Prepare a bucket.
2. Open the drain valve (2) to drain the coolant.
3. After you drain, close the drain valve (2).
(1) Radiator Cap (2) Drain Valve
9Y1210674ENS0112US0
1-S27
(2) External Components

CRS Intermediate Harness
1. Disconnect the ECU intermediate harness.
2. Remove the injector intermediate harness from the bracket.
3. Remove the engine intermediate harness from the bracket.
(When reassembling)
• Make sure that bracket is installed correct position.
• Make sure to install wire and clamp to specified position.
(1) ECU Intermediate Harness (3) Injector Intermediate Harness (6) Glow Plug (9) Engine ECU
(OEM Side Harness) (Engine Side Harness) (7) Engine (10) OEM Designed Interface
(2) Engine Intermediate Harness (4) Starter (8) Relay (11) Battery
(Engine Side Harness) (5) Alternator
9Y1210674ENS0027US0
1-S28
[A] Engine Intermediate Harness (Engine Side Harness)
V2607-CR-E4B
(1) Oil Pressure Switch (6) CAN Connector (4P) (10) Camshaft Position (G) Sensor (13) Engine Intermediate
Connector (1P) (7) Intake Air Temperature Connector (3P) Connector
(2) SCV (Suction Control Valve) Sensor Connector (2P) (11) Crankshaft Position (NE) (14) Rail Pressure Sensor
Connector (2P) (8) Intake Throttle Valve Sensor Connector (3P) Connector (3P)
(3) Fuel Temperature Sensor Connector (6P) (12) Resistor 120 Ω (2P) /
Connector (2P) (9) Coolant Temperature Sensor Resistor 1.1 kΩ (2P) (a) to (h): Clamp
(4) EGR Valve Connector (4P) Connector (2P)
(5) CAN Connector (4P)
9Y1210674ENS0028US0
V2607-CR-TE4B / V3307-CR-TE4B
(1) Oil Pressure Switch (6) CAN Connector (4P) (11) Camshaft Position (G) Sensor (14) Engine Intermediate
Connector (1P) (7) CAN Connector (4P) Connector (3P) Connector
(2) SCV (Suction Control Valve) (8) Intake Air Temperature (12) Crankshaft Position (NE) (15) Rail Pressure Sensor
Connector (2P) Sensor Connector (2P) Sensor Connector (3P) Connector (3P)
(3) Fuel Temperature Sensor (9) Intake Throttle (13) Resistor 120 Ω (2P) /
Connector (2P) Valve?Connector (6P) Resistor 1.1 kΩ (2P) (a) to (h): Clamp
(4) EGR Valve Connector (4P) (10) Coolant Temperature Sensor
(5) Boost Pressure Sensor Connector (2P)
Connector (3P)
9Y1210674ENS0113US0
1-S29
V2607-CR-TIE4B / V3307-CR-TIE4B
(1) Oil Pressure Switch (5) Boost Pressure Sensor (10) Camshaft Position (G) Sensor (13) Engine Intermediate
Connector (1P) Connector (3P) Connector (3P) Connector
(2) SCV (Suction Control Valve) (6) CAN Connector (4P) (11) Crankshaft Position (NE) (14) Rail Pressure Sensor
Connector (2P) (7) CAN Connector (4P) Sensor Connector (3P) Connector (3P)
(3) Fuel Temperature Sensor (8) Intake Air Temperature (12) Resistor 120 Ω (2P) /
Connector (2P) Sensor Connector (2P) Resistor 1.1 kΩ (2P) (a) to (h): Clamp
(4) EGR Valve Connector (4P) (9) Coolant Temperature Sensor
Connector (2P)
9Y1210674ENS0152US0
1-S30
[B] Injector Intermediate Harness (Engine Side Harness)
V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B / V3307-CR-TE4B / V3307-CR-TIE4B
(1) Injector #4 Connector (2P) (a) to (d): Clamp

(2) Injector #3 Connector (2P)
(5) Injector Intermediate Connector
(12P)
9Y1210674ENS0114US0
[C] DPF Intermediate Harness (Engine Side Harness)

V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B
(1) DPF Intermediate Connector (16P) (a) to (d): Clamp

(2) DPF Temperature Sensor (T0) (2P)
(5) Differential Pressure Sensor (ΔP)
(3P)
9Y1210674ENS0115US0
Air Cleaner and Others

1. Remove the air cleaner.
2. Remove the fan (2), fan belt (3), alternator (4) and starter (5).
3. Remove the oil separator assembly (1), wire harness bracket
(6) and oil separator bracket (7).
(When reassembling)
• Check for cracks on the belt surface.
IMPORTANT
• After you assemble the fan belt, adjust the fan belt tension.
• Do not put the fan in the incorrect direction. Install the fan
so that the parts number (8) of the fan is toward the front
side. (radiator side)
(1) Oil Separator Assembly (5) Starter
(2) Fan (6) Wire Harness Bracket
(3) Fan Belt (7) Oil Separator Bracket
(4) Alternator (8) Parts Number
9Y1210674ENS0029US0
1-S31
Muffler Full Assembly (DPF) (V2607-CR-E4B)
IMPORTANT
a new one.
NOTE
parking brake.
preparing the DPF cleaning order from.
(Diagmaster).
the bracket.
5. Remove the 4 screws (1) of muffler flange (2).
7. Remove the muffler full assembly (DPF) (14).
8. Remove the DPF bracket (16).
(1) Screw of Muffler Flange (8) Differential Pressure Sensor
(2) Muffler Flange (9) Temperature Sensor (T2)
(4) Connector of Temperature Sensor (11) Differential Pressure Pipe
(T2) (12) Temperature Sensor (T1)
(5) Connector of Temperature Sensor (13) Temperature Sensor (T0)
(T1) (14) Muffler Full Assembly (DPF)
(6) Connector of Temperature Sensor (15) Muffler Full Assembly (DPF)
(T0) Mounting Screw
(7) Differential Pressure Sensor (16) DPF Bracket
Bracket
(To be continued)
1-S32
(Continued)
(When reassembling)
• Replace the gaskets with new ones.
it.
• When replacing the differential pressure pipe (10), (11), apply a
correct position.
24 to 27 N·m
Screw of muffler flange 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
49 to 55 N·m
Tightening torque 5.0 to 5.7 kgf·m
mounting screw
37 to 41 lbf·ft
78 to 90 N·m
DPF bracket mounting
7.9 to 9.2 kgf·m
screw
58 to 66 lbf·ft
(1) Screw of Muffler Flange (8) Differential Pressure Sensor

(T2) (12) Temperature Sensor (T1)
(T0) Mounting Screw
Bracket
9Y1210674ENS0030US0
1-S33
DPF (If necessary) (V2607-CR-E4B)
NOTE
parking brake.
(Diagmaster).
1. Remove the tube (5), (6) from the differential pressure pipe (2),
(3).
3. Loosen the DPF mounting bracket (1), (4) and remove the DPF
(10).
(1) DPF Mounting Bracket (9) Gasket
(2) Differential Pressure Pipe (10) DPF
(3) Differential Pressure Pipe (11) Gasket
(4) DPF Mounting Bracket (12) Catalyst (DOC)
(5) Tube (13) Temperature Sensor (T0)
(8) Body (DPF Outlet)
(To be continued)
1-S34
(Continued)
(When reassembling)
• Replacing the gaskets (9), (11) with new ones.
it.
correct position.
16 to 20 N·m
DPF mounting bracket 1.7 to 2.0 kgf·m
12 to 14 lbf·ft
25 to 34 N·m
Tightening torque Temperature sensor 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
16 to 22 N·m
12 to 16 lbf·ft
(1) DPF Mounting Bracket (9) Gasket

(2) Differential Pressure Pipe (10) DPF
(3) Differential Pressure Pipe (11) Gasket
(4) DPF Mounting Bracket (12) Catalyst (DOC)
(8) Body (DPF Outlet)
9Y1210674ENS0031US0
1-S35
Muffler Full Assembly (DPF) (V2607-CR-TE4B,
V3307-CR-TE4B)
IMPORTANT
a new one.
NOTE
parking brake.
(Diagmaster).
the bracket.
7. Remove the muffler full assembly (DPF) (12).
8. Remove the DPF bracket (16).
(1) Nut of Muffler Flange (8) Differential Pressure Sensor
(3) Clamp (10) Temperature Sensor (T1)
(T1) Mounting Screw
Bracket
(To be continued)
1-S36
(Continued)
(When reassembling)
it.
• When replacing the differential pressure pipe (14), (15), apply a
correct position.
49 to 55 N·m
37 to 41 lbf·ft
49 to 55 N·m
mounting screw
37 to 41 lbf·ft
78 to 90 N·m
7.9 to 9.2 kgf·m
screw
58 to 66 lbf·ft
(1) Nut of Muffler Flange (8) Differential Pressure Sensor

(3) Clamp (10) Temperature Sensor (T1)
(T1) Mounting Screw
Bracket
9Y1210674ENS0147US0
1-S37
DPF (If necessary) (V2607-CR-TE4B, V3307-CR-TE4B)
NOTE
parking brake.
(Diagmaster).
1. Remove the tube (3), (5) from the differential pressure pipe (4),
(6).
3. Loosen the DPF mounting screw (1), (2) and remove the DPF
(9).
(1) DPF Mounting Screw (9) DPF
(2) DPF Mounting Screw (10) Collar (DPF)
(3) Tube (11) Catalyst (DOC)
(4) Differential Pressure Pipe (12) Temperature Sensor (T0)
(5) Tube (13) Gasket
(8) Body (DPF Outlet) (16) Gasket
(17) Temperature Sensor (T2)
(To be continued)
1-S38
(Continued)
(When reassembling)
• Replacing the gaskets (13), (15), (16) with new ones.
it.
correct position.
49.0 to 63.7 N·m
DPF mounting screw 5.00 to 6.49 kgf·m
36.2 to 46.9 lbf·ft
25 to 34 N·m
Tightening torque Temperature sensor 2.5 to 3.5 kgf·m
18 to 25 lbf·ft
16 to 22 N·m
12 to 16 lbf·ft
(1) DPF Mounting Screw (9) DPF

(2) DPF Mounting Screw (10) Collar (DPF)
(3) Tube (11) Catalyst (DOC)
(5) Tube (13) Gasket
(8) Body (DPF Outlet) (16) Gasket
(17) Temperature Sensor (T2)
9Y1210674ENS0148US0
1-S39
Muffler Full Assembly (DOC) (V2607-CR-TIE4B,
V3307-CR-TIE4B)
IMPORTANT
• Since the DOC that was dropped or given a shock cannot
be reused even if there is no damage outwardly, replace it
with a new one.
NOTE
parking brake.
• As the DOC muffler full assembly is hot just after the
engine shutdown, make sure to start operation after it gets
cool.
• Make sure not to damage the DOC muffler full assembly by
2. Remove the muffler full assembly (DOC) mounting screws (4).
3. Remove the muffler full assembly (DOC) (3).
4. Remove the bracket (5).
(When reassembling)
it.
• Tighten bolts and nuts to their specified torque.
29.4 to 34.3 N·m
21.7 to 25.2 lbf·ft
60.8 to 70.8 N·m
Muffler full assembly (DOC)
mounting screw
44.9 to 52.2 lbf·ft
78 to 90 N·m
7.9 to 9.2 kgf·m
screw
58 to 66 lbf·ft
(1) Nut of Muffler Flange (4) Muffler Full Assembly (DOC)

(2) Muffler Flange Mounting Screw
(3) Muffler Full Assembly (DOC) (5) Bracket
9Y1210674ENS0151US0
1-S40
(3) Turbocharger and EGR

CAUTION
• While the engine operates or just after it stops, do not touch the hot turbocharger.
NOTE
• When you remove or install the turbocharger assembly, do not let dust, dirt and other unwanted materials
in the oil pipes.
• After you replace the turbocharger assembly, fill clean engine oil through the oil filter port of the
turbocharger.
• Before you start the engine, make sure that the air cleaner is in the correct position.
9Y1210674ENS0032US0
Turbocharger
1. Remove the inlet hose (2).
2. Remove the muffler flange (3).
3. Remove the oil pipe (5).
4. Remove the return pipe (4).
5. Remove the turbocharger assembly (1).
(When reassembling)
• Fill clean engine oil through the oil filter port of the turbocharger.
• Do not to let dust, dirt and other unwanted materials in the oil
pipes.
NOTE
• Put tape or cover on all openings to prevent damage in the
oil holes in the turbocharger by unwanted materials.
(1) Turbocharger Assembly (4) Return Pipe
(2) Inlet Hose (5) Oil Pipe
(3) Muffler Flange
9Y1210674ENS0033US0
EGR Cooler
1. Disconnect the EGR cooler pipe (1), (3).
2. Remove the EGR cooler (2).
24 to 27 N·m
Tightening torque EGR cooler flange screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
(1) EGR Cooler Pipe (3) EGR Cooler Pipe

(2) EGR Cooler
9Y1210674ENS0116US0
EGR Valve
1. Disconnect the cooler pipe (2) of EGR valve.
2. Remove the EGR valve (1).
NOTE
• Do not disassemble the EGR valve assembly.
(When reassembling)
(1) EGR Valve (2) Cooler Pipe
9Y1210674ENS0035US0
1-S41
Intake Throttle Valve
1. Remove the cover (1) and the air cleaner flange (2).
2. Remove the intake throttle valve (3).
NOTE
• Do not disassemble the intake throttle valve.
(When reassembling)
(1) Cover (3) Intake Throttle Valve
(2) Air Cleaner Flange
9Y1210674ENS0034US0
(4) Common Rail

Common Rail and Injection Pipes
CAUTION
• Do not loosen the injection pipe when the fuel is under high
pressure (within five minutes of stopping the engine).
NOTE
• Please replace the rail assembly, if the exchange of the
pressure limiter or the rail pressure sensor is necessary.
• Do not remove the pressure limiter (5) and rail pressure
sensor (2) from the common rail (6).
• When removing the common rail (6), do not hold it by the
pressure limiter (5) and rail pressure sensor (2).
1. Remove the injection pipe (3).
2. Remove the overflow pipe (4).
3. Remove the injection pipes (1).
4. Remove the common rail (6).
IMPORTANT
• Store the injection pipes (1), (3) so it does not get any dust
in it.
• Store the common rail (6) so it does not get any dust in it.
(When reassembling)
NOTE
• Tighten the injection pipes securely to their specified
torques.
24 to 27 N·m
Common rail mounting
2.4 to 2.8 kgf·m
screw
18 to 20 lbf·ft
30 to 40 N·m
23 to 29 lbf·ft
11 to 15 N·m
(Cylinder head side) M8
8.2 to 11 lbf·ft
7.9 to 12 N·m
0.80 to 1.3 kgf·m
(Common rail side) M10
5.8 to 9.4 lbf·ft
7.9 to 12 N·m
0.80 to 1.3 kgf·m
(Supply pump side) M10
5.8 to 9.4 lbf·ft
(1) Injection Pipe (4) Overflow Pipe

(2) Rail Pressure Sensor (5) Pressure Limiter
(3) Injection Pipe (6) Common Rail
9Y1210674ENS0036US0
1-S42
Coolant Temperature Sensor
1. Remove the coolant temperature sensor (1).
(When reassembling)
16 to 19 N·m
Coolant Temperature
Sensor
12 to 14 lbf·ft
(1) Coolant Temperature Sensor

9Y1210674ENS0037US0
Camshaft Position Sensor

1. Remove the camshaft position sensor mounting screw.
2. Remove the camshaft position sensor (1).
(When reassembling)
• Replace the O-ring with a new one.
8.0 to 12 N·m
Camshaft position sensor
mounting screw
5.9 to 8.8 lbf·ft
(1) Camshaft Position Sensor

9Y1210674ENS0038US0
Crankshaft Position Sensor
1. Remove the crankshaft position sensor mounting screw (2).
2. Remove the crankshaft position sensor (1).
(When reassembling)
• Replace the O-ring with a new one.
IMPORTANT
• If you drop the sensor, do not reuse it.
8.0 to 12 N·m
Crankshaft position sensor
mounting screw
5.9 to 8.8 lbf·ft
(1) Crankshaft Position Sensor (2) Crankshaft Position Sensor

Mounting Screw
9Y1210674ENS0039US0
Intake Air Temperature Sensor
1. Remove the intake air temperature sensor (1).
(When reassembling)
30 to 39 N·m
Intake air temperature
sensor
22 to 28 lbf·ft
(1) Intake Air Temperature Sensor

9Y1210674ENS0040US0
1-S43
Boost Sensor
IMPORTANT
• Be careful not to damage the sensor when removing the
hose from the boost sensor.
1. Remove the hose (3) from the boost sensor (1).
2. Remove the boost sensor mounting screw (2).
3. Remove the boost sensor (1).
(When reassembling)
• If the hose is damaged, replace it with a new hose.
4 to 5 N·m
Boost sensor mounting
screw
3 to 4 lbf·ft
(1) Boost Sensor (3) Hose

(2) Boost Sensor Mounting Screw
9Y1210674ENS0041US0
(5) Cylinder Head and Valves

Cylinder Head Cover and Glow Plug
1. Remove the glow lead (2) and the glow plugs (1).
2. Remove the cylinder head cover (3).
(When reassembling)
• Check to see that the cylinder head cover gasket is not
detective.
• Tighten the head cover mounting screws to specified torque.
• Do not damage injector QR code tags (4) when installing
cylinder head cover (3).
• Replace the gasket of cylinder head cover with a new one.
• Adjust the direction of the ditch to the terminal side when the
seal (5) is installed in the glow plug (1).
• After installing the glow plug (1), make sure that the seal (5) was
set to the specified position.
9.81 to 11.2 N·m
7.24 to 8.31 lbf·ft
0.98 to 1.7 N·m
Tightening torque Glow lead mounting nut 0.10 to 0.18 kgf·m
0.73 to 1.3 lbf·ft
7.7 to 9.3 N·m
Glow plug 0.78 to 0.95 kgf·m
5.7 to 6.8 lbf·ft
(1) Glow Plug (A) Good

(2) Glow Lead (B) Bad
(3) Cylinder Head Cover
(4) Injector QR Code Tag
(5) Seal
9Y1210674ENS0042US0
1-S44
Overflow Pipe and Injectors
1. Remove the overflow pipe (1).
2. Remove the injector clamp (3).
3. Remove the injector (2) and its gasket (6).
IMPORTANT
• Do not disassemble the injector (2).
• Do not remove the injector QR code tag (8).
• Do not damage the injector QR code tag (8).
• Do not get the injectors out of order. If the injectors get out
of order, it is necessary to perform injector correction
(writing the injector ID codes (7) to the ECU).
• Store the injectors so they do not get any dust in them.
(When reassembling)
• Apply a thin layer of engine oil to an O-ring (9) when you install
the injector.
• Replace the injectors' gaskets (6) with new ones.
• When attaching the overflow pipe (1) to the injector, replace the
gasket (5) with a new one.
• Install the overflow pipe joint screw (4).
• Tighten the injector clamp nuts securely to their specified
torques.
• Tighten the overflow pipe joint screws (4) securely to their
specified torques.
• After installing the overflow pipe, in order to check the fuel
leakage, add pressure by air from the fuel pipe joint, and check
the fuel leakage of overflow pipe and gasket (5).
• In case there is fuel leakage, replace the gasket (5), then check
the fuel leakage again.
NOTE
• If you replace the injectors, it is necessary to perform
injector correction (writing the injector ID codes (7) to the
ECU).
24 to 27 N·m
Injector clamp nut 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
9.81 to 11.2 N·m
1.00 to 1.15 kgf·m
(M6 × 1.0)
7.24 to 8.31 lbf·ft
(1) Overflow Pipe (6) Gasket

(2) Injector (7) Injector ID Code
(3) Injector Clamp (8) Injector QR Code Tag
(4) Overflow Pipe Joint Screw (9) O-ring
(5) Gasket
9Y1210674ENS0043US0
1-S45
Check the Fuel Leakage of the Overflow Pipe
1. Connect the fuel hose of air pressure adjustment equipment to
the fuel tube (3).
2. Tighten the valve (4).
3. Connect the air hose to the air pressure adjustment equipment.
4. Adjust air pressure of the regulator (1) between 0.03 and
0.05 MPa (0.3 and 0.5 kgf/cm2, 5 and 7 psi).
5. Open the valve (4) gradually, then add 0.03 MPa (0.3 kgf/cm2,
4 psi) pressure.
6. Tighten the valve (4).
7. Check the decreased pressure after 4 seconds.
NOTE
• If the decreased pressure is higher than 0.001 MPa
(0.01 kgf/cm2, 0.1 psi), it means that there is fuel leakage.
Replace the gasket (5), then check the fuel leakage again.
Decreased pressure after 4 seconds is lower than
Leakage Check
0.001 MPa (0.01 kgf/cm2, 0.1 psi)
Specification of components
Parts Name Specification or Code No.
0.030 to 0.86 MPa
Regulator (1) 0.31 to 8.7 kgf/cm2
4.4 to 120 psi
0 to 0.06 MPa
Pressure Gauge (6) 0 to 0.6 kgf/cm2
0 to 8 psi
(1) Regulator (4) Valve

(2) Overflow Pipe (5) Gasket
(3) Fuel Tube (6) Pressure Gauge
9Y1210674ENS0044US0
1-S46
Rocker Arm, Push Rod and Valve Bridge Arm
1. Remove the rocker arm (1) as a unit.
2. Remove the push rods (2).
3. Remove the valve bridge arm (3).
(When reassembling)
• When installing the push rod (2), mount it securely in the groove
of the tappet.
• When installing the valve bridge arm (3), apply engine oil to the
valve bridge shaft sufficiently and check whether to move
smoothly.
• When installing the valve bridge arm (3), face the mark (4) to
intake side.
IMPORTANT
• After installing the rocker arm, adjust the valve clearance.
V2607-CR-E4B
24 to 27 N·m
V2607-CR-TE4B
Rocker 2.4 to 2.8 kgf·m
V2607-CR-
arm 18 to 20 lbf·ft
Tightening torque TIE4B
bracket
screw V3307-CR-TE4B 49 to 55 N·m
V3307-CR- 5.0 to 5.7 kgf·m
TIE4B 37 to 41 lbf·ft
(1) Rocker Arm (3) Valve Bridge Arm

(2) Push Rod (4) Mark
9Y1210674ENS0045US0
Injector Oil Seal and Injection Pipe Oil Seal (If necessary)
1. Remove the injector oil seal (2) and injection pipe oil seal (3)
from cylinder head cover (1).
(When reassembling)
• When installing the injector oil seal (2) and injection pipe oil seal
(3), use the new one.
(1) Cylinder Head Cover (3) Injection Pipe Oil Seal
(2) Injector Oil Seal
9Y1210674ENS0046US0
1-S47
Cylinder Head
1. Remove the inlet manifold (1) and exhaust manifold (2).
2. Remove the cylinder head mounting screw in the sequence of
(j) to (a), and remove the cylinder head (3).
3. Remove the cylinder head gasket (4).
(When reassembling)
• Replace the cylinder head gasket (4) with a new one.
• When mounting the gasket, set it to the knock pin hole. Be
careful not to mount it reversely.
• The cylinder head should be free of scratches and dust.
• Be careful for handling the gasket not to damage it.
• Install the cylinder head.
• Tighten the cylinder head mounting screw gradually in the
sequence of (a) to (j) after applying engine oil.
• Be sure to adjust the valve clearance. (Refer to the "Valve
Clearance")
• It is not necessary to retighten the cylinder head mounting
screw after operating the engine for 30 minutes.
IMPORTANT
• When replacing the piston, piston pin bushing, connecting
rod or crank pin bearing, select the cylinder head gasket
thickness to meet with the top clearance refer to the "To
Select the Cylinder Head Gasket".
V2607-CR-E4B
147 to 156 N·m
V2607-CR-TE4B
Cylinder 15.0 to 16.0 kgf·m
V2607-CR-
head 109 to 115 lbf·ft
TIE4B
mounting
Tightening screw V3307-CR-TE4B 187 to 196 N·m
torque V3307-CR- 19.0 to 20.0 kgf·m
30 to 34 N·m
Exhaust manifold mounting
3.0 to 3.5 kgf·m
nut
22 to 25 lbf·ft
(1) Inlet Manifold A: Front Cover Side

(2) Exhaust Manifold B: Flywheel Housing Side
(3) Cylinder Head
(4) Cylinder Head Gasket
9Y1210674ENS0047US0
1-S48
To Select the Cylinder Head Gasket (for V2607-CR-E4B /
 Replacement of Cylinder Head Gasket
1. Make sure to note the hole (a), (b) or (c) of cylinder head gasket
(1) in advance.
2. Replace the same hole (a), (b) or (c) as the original cylinder
head gasket (1).
 To Select the Cylinder Head Gasket
• When replacing the piston, piston pin bushing, connecting rod
or crank pin bearing, select the cylinder head gasket (1)
thickness to meet with the top clearance refer to the "To Select
the Cylinder Head Gasket".
1. Measure the piston head's protrusion from the crankcase
cylinder face 4 spots per each piston using the dial gauge as
shown in figure, and get the average of the measurements.
2. Use the table below to select an applicable cylinder head gasket
(1).
Thickness of cylinder Piston Head's
Hole of head gasket protrusion from the
Cylinder Code
Before After level of crankcase
Head Number
tighten- tighten- cylinder face.
Gasket
ing ing (average of 4 pistons)
2 holes 1.30 mm 1.20 mm 0.451 to 0.550 mm

1J700-03330
(a) 0.0512 in. 0.0472 in. 0.0178 to 0.0216 in.
1.20 mm 1.10 mm 0.351 to 0.450 mm
1 hole (b) 1J700-03320
0.0472 in. 0.0433 in. 0.0139 to 0.0177 in.
Without 1.10 mm 1.00 mm 0.250 to 0.350 mm
1J700-03310
hole (c) 0.0433 in. 0.0394 in. 0.00985 to 0.0137 in.
(1) Cylinder Head Gasket (a) 2 Holes (2 Through Holes)

(2) Points of Measurement (b) 1 Hole (1 Through Hole)
A: Flywheel Housing Side (c) Without Hole (0 Through Hole)
B: Front Cover Side
C: Hole of Cylinder Head Gasket
9Y1210674ENS0048US0
1-S49
To Select the Cylinder Head Gasket (for V3307-CR-TE4B /
V3307-CR-TIE4B)
 Replacement of Cylinder Head Gasket
1. Make sure to note the notch (a), (b) or (c) of cylinder head
gasket (1) in advance.
2. Replace the same notch (a), (b) or (c) as the original cylinder
head gasket (1).
 To Select the Cylinder Head Gasket
• When replacing the piston, piston pin bushing, connecting rod
or crank pin bearing, select the cylinder head gasket (1)
thickness to meet with the top clearance refer to the "To Select
the Cylinder Head Gasket".
1. Measure the piston head's protrusion or recessing from the
crankcase cylinder face 4 spots per each piston using the dial
gauge as shown in figure, and get the average of the
measurements.
2. Use the table below to select an applicable cylinder head gasket
(1).
Thickness of cylinder Piston Head's
Notch of head gasket protrusion from the
Cylinder Code
Before After level of crankcase
Head Number
tighten- tighten- cylinder face.
Gasket
ing ing (average of 4 pistons)
0.2510 to 0.3425 mm
Without 1.10 mm 1.00 mm
1J770-03610 0.009882 to
notch (a) 0.0433 in. 0.0394 in.
0.01348 in.
1 notch 1.00 mm 0.900 mm 0.151 to 0.250 mm
1J770-03600
(b) 0.0394 in. 0.0354 in. 0.00595 to 0.00984 in.
2
0.900 mm 0.800 mm 0.0775 to 0.150 mm
notches 1J770-03310
0.0354 in. 0.0315 in. 0.00306 to 0.00590 in.
(c)
(1) Cylinder Head Gasket (a) Without Notch

(2) Points of Measurement (b) 1 Notch
A: Flywheel Housing Side (c) 2 Notches
B: Front Cover Side
C: Notch of Cylinder Head Gasket
9Y1210674ENS0049US0
1-S50
Valve
1. Push the valve spring (3) with the valve spring retainer (2) and
remove the valve spring collets (1).
2. Remove the valve spring (3) and valve (5).
(When reassembling)
• Clean the valve stem and valve guide hole, and apply engine oil
sufficiently.
• After you install the valve spring collets (1), lightly tap the stem
tip to attach it correctly with the plastic hammer.
[V3307-CR-TE4B / V3307-CR-TIE4B]
• Install the valve spring (3) with its smaller pitch (7) end
downward (at the cylinder head side "B").
(1) Valve Spring Collet (6) Large Pitch
(2) Valve Spring Retainer (7) Smaller Pitch
(3) Valve Spring
(4) Valve Stem Seal A: Valve Spring Retainer Side
(5) Valve B: Cylinder Head Side
9Y1210674ENS0050US0
(6) Thermostat
Thermostat Assembly
1. Remove the thermostat cover mounting screws, and remove
the thermostat cover (1).
2. Remove the thermostat assembly (3).
(When reassembling)
• Replace the gasket with a new one.
• Attach the thermostat assembly with its hole (4) facing toward
the front cover side.
(1) Thermostat Cover (3) Thermostat Assembly
(2) Thermostat Cover Gasket (4) Hole
9Y1210674ENS0051US0
1-S51
(7) SCV
Removal of SCV
1. Carefully wash circumference of the SCV (1) in advance with
cleaning solution, nylon brush, air blow, etc.
2. Remove fittings around the SCV (1) that disturb removing and
the harness connector of the SCV.
3. Loosen the SCV mounting screw (2) with hexagon wrench
(5 mm-square) and remove them (2 places).
4. Install a guide pin (refer to the "SPECIAL TOOL") in the SCV
mounting screw (2) attaching portion manually.
5. Pull the SCV (1) straight along with the guide pin (3).
NOTE
• No foreign materials shall be attached inside the supply
pump and on the SCV mounting surface during SCV
replacement. After removal, keep the removed part of
supply pump side without wipe with waste cloth.
• Do not work with slanted and insufficient installation of
hexagon wrench. (Do not crush the hexagon socket.)
• Used SCV and O-ring shall not be reused.
• Confirm that no O-ring remains at the supply pump body
side. To be removed if remained.
(1) Suction Control Valve (SCV) (3) Guide Pin
(2) SCV Mounting Screw
9Y1210674ENS0153US0
1-S52
Installation of SCV
1. Apply clean silicon grease on the O-ring (1) and set into the
O-ring groove of housing. If the gasket is attached in the kit,
replace the gasket. (May not included depending on
specification.)
2. Apply clean silicon grease on the O-ring of the SCV (2) tip.
3. Turn the connector of the SCV in the same direction at
installation and install the SCV (2) straight along with the guide
pin without twisting.
4. After installation of the SCV (2), remove the guide pin installed
with pressing the SCV and tighten the SCV mounting screw
temporary. Hand tighten the two bolts alternately so as to hit the
seat surface evenly (so as not to tighten unevenly).
5. Tighten finally the SCV mounting screw with hexagon wrench
(5 mm-square) and torque wrench with specified torque value.
6. Install the harness connector of the SCV and removed parts as
before.
7. After completion of works, confirm that the parts are replaced
correctly by execution of dispersion of pumps of diagnosis tool
(Diagmaster), and that there is no fuel leak with visual check.
NOTE
• To be no foreign materials and scratches on the Oring
groove and the SCV mounting surface. To be no adhesion
of foreign materials during grease application.
• The O-ring shall not be jammed between the pump housing
and the SCV to prevent fuel leak and malfunction due to
burr of the O-ring.
• Install the SCV surely until the SCV hits the supply pump
housing.
• The bolts shall not be tightened over the specified torque
value to prevent bolt damage due to excessive torque.
• To be no foreign materials inside the SCV connector to
prevent malfunction, open circuit, and short circuit. If there
are foreign materials, remove them surely with air blow,
etc. The wire harness of the SCV shall be wired with the
route of installation to ensure no excessive looseness and
tension.
• When replacing the SCV with a new one, use the diagnosis
tool to conduct learning of discrepancies in the new SCV.
6.90 to 10.8 N·m
Tightening torque SCV mounting screw 0.704 to 1.10 kgf·m
5.09 to 7.96 lbf·ft
(1) O-ring (2) Suction Control Valve (SCV)

9Y1210674ENS0154US0
1-S53
(8) Fuel Temperature Sensor

Removal of Fuel Temperature Sensor
1. Carefully wash circumference of the fuel temperature sensor (1)
in advance with cleaning solution, nylon brush, air blow, etc.
2. Remove fittings around the fuel temperature sensor (1) that
disturb removing and the harness connector of the fuel
temperature sensor.
3. After slight turning the fuel temperature sensor (1)
counterclockwise with the crow foot wrench (3) to loose, wash
the fuel temperature sensor (1) joint again to remove foreign
materials such as paint chips generated during loosening.
4. Remove the fuel temperature sensor (1) from the supply pump
body.
NOTE
• To be no foreign materials in the supply pump.
• Used fuel temperature sensor and O-ring shall not be
reused.
• Confirm that no O-ring remains at the supply pump body
side. To be removed if remained.
• After removal of the fuel temperature sensor, installation of
the fuel temperature sensor shall be conducted at once.
(1) Fuel Temperature Sensor (3) Crow Foot Wrench
(2) Supply Pump (Spanner Type 19 mm)
9Y1210674ENS0155US0
Installation of Fuel Temperature Sensor
1. Install the O-ring in the fuel temperature sensor (1).
2. Install the fuel temperature sensor (1) in the fuel temperature
sensor attaching portion of the supply pump (2) manually by
turning clockwise.
3. Tighten finally the fuel temperature sensor (1) by turning
clockwise with crow foot wrench (3) with specified torque value.
4. Install the harness connector of the fuel temperature sensor (1)
and removed parts as before.
5. After completion of works, confirm that the parts are replaced
correctly by execution of dispersion of pumps of diagnosis tool
(Diagmaster), and that there is no fuel leak with visual check.
NOTE
• To be no foreign materials and scratches on the fuel
temperature sensor mounting surface. To be no adhesion
of foreign materials on the O-ring.
• Install the combustion temperature sensor to the supply
pump after confirming that the O-ring is installed in the fuel
temperature sensor correctly.
• Do not tighten the fuel temperature sensor with holding the
connector to prevent the damage of connector.
• To be no foreign materials inside the fuel temperature
sensor connector to prevent malfunction, open circuit, and
short circuit. If there are foreign materials, remove them
surely with air blow, etc. The wire harness of the fuel
temperature sensor shall be wired with the route of
installation to ensure no excessive looseness and tension.
17.6 to 26.5 N·m
Tightening torque Fuel temperature sensor 1.80 to 2.70 kgf·m
13.0 to 19.5 lbf·ft
(1) Fuel Temperature Sensor (3) Crow Foot Wrench

(2) Supply Pump (Spanner Type 19 mm)
9Y1210674ENS0156US0
1-S54
(9) Supply Pump

Supply Pump
CAUTION
• Do not loosen the injection pipe when the fuel is under high
pressure (within five minutes of stopping the engine).
1. Remove the window cover (1) from the flywheel housing (2).
2. Put the piston of the number 4 cylinder at TDC.
NOTE
• When positioning the piston of the 4th cylinder to TDC,
rotate the flywheel counterclockwise and align the TC mark
(4) on the flywheel with the mark (3) on the housing of the
flywheel. If the supply pump gear timing mark (8) meshes
with idle gear (6), then the piston of the 4th cylinder is TDC.
If they do not mesh, rotate the flywheel counterclockwise
one revolution.
3. Make a temporary mark (5) with a white paint marker pen on the
tooth of idle gear (6).
NOTE
• This mark is extremely useful during reassembly of the
supply pump gear and idle gear (6) to get the timing right.
4. Fix the flywheel in place.
5. Loosen the supply pump gear's mounting nut (9).
6. Remove the supply pump (10).
NOTE
• Do not disassemble the supply pump.
• Store the supply pump so it does not get any dust in it.
(1) Window Cover (7) Supply Pump Gear
(2) Flywheel Housing (8) Timing Mark
(3) Mark (9) Supply Pump Gear Mounting Nut
(4) TC Mark (10) Supply Pump
(5) Mark (11) Supply Pump Mounting Nut
(6) Idle Gear
(To be continued)
1-S55
(Continued)
(When reassembling)
• Align the alignment marks of the supply pump gear (7) and idle
gear (6).
• Replace the O-ring of the supply pump (10) with a new one.
• Install the supply pump (10).
• Tighten the supply pump mounting nut (11).
• Tighten the supply pump gear mounting nut (9) to its specified
torque.
• Mount the window cover (1).
NOTE
• When replacing the supply pump with a new one, use the
diagnosis tool to conduct "Supply Pump Learning" in the
new supply pump.
24 to 27 N·m
Supply pump mounting nut 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
59 to 68 N·m
Supply pump gear
6.0 to 7.0 kgf·m
mounting nut
44 to 50 lbf·ft
(1) Window Cover (a) 1 dot on the center of the valley

(6) Idle Gear between 2 teeth
(7) Supply Pump Gear (b) 1 dot on the tooth center
(9) Supply Pump Gear Mounting Nut (c) 1 dot on the tooth center
(10) Supply Pump (d) 2 dots on the tooth center
(11) Supply Pump Mounting Nut (e) 1 dot on the center of the valley
(12) Cam Gear between 2 teeth
(13) Crankshaft Gear (f) 1 dot on the tooth center
(g) 1 dot on the tooth center
(h) 1 dot on the center of the valley
between 2 teeth
(i) 2 dots on the tooth center
(j) 2 dots on the center of the valley
between 2 teeth
(k) 3 dots on the center of the valley
between 2 teeth
(l) "3" on the tooth center
[A] Alignment Marks for

V2607-CR-E4B, V2607-CR-TE4B
and V2607-CR-TIE4B
[B] Alignment Marks for
V3307-CR-TE4B and
V3307-CR-TIE4B
9Y1210674ENS0052US0
1-S56
Supply Pump Gear and Crankshaft Position Pulsar Gear (If
necessary)
1. Remove the supply pump gear (1) and crankshaft position
pulsar gear (4) with gear puller (2) from the supply pump (3).
2. Remove the mounting screws of crankshaft position pulsar gear
(4).
3. Remove the crankshaft position pulsar gear (4).
(When reassembling)
• Install the crankshaft position pulsar gear (4) to the supply pump
gear (1).
• Align each pitch (a) and (b) of the crankshaft position pulsar
gear (4) and the supply pump gear (1)
Mounting screw of 9.81 to 11.2 N·m
Tightening torque crankshaft position pulsar 1.00 to 1.15 kgf·m
gear 7.24 to 8.31 lbf·ft
(1) Supply Pump Gear (a) Large Pitch

(2) Gear Puller (b) Small Pitch
(3) Supply Pump
(4) Crankshaft Position Pulsar Gear
(5) Supply Pump Gear Mounting Nut
9Y1210674ENS0117US0
1-S57
Fan Drive Pulley
1. Mount a flywheel stopper (1) on the flywheel (2).
2. Remove the crankshaft screw (4).
3. Remove the fan drive pulley (3).
(When reassembling)
• Tighten the crankshaft screw (4) to specified torque after
applying engine oil.
255 to 274 N·m
Tightening torque Crankshaft screw 26.0 to 28.0 kgf·m
188 to 202 lbf·ft
(1) Stopper (3) Fan Drive Pulley

(2) Flywheel (4) Crankshaft Screw
9Y1210674ENS0118US0
(10) Water Pump and Oil Cooler

Water Pump (If necessary)
1. Remove the water pump (1).
(When reassembling)
• When mounting the water pump (1), use the new water pump
gasket.
(1) Water Pump
9Y1210674ENS0119US0
Oil Cooler
1. Remove the water pipe (2).
2. Remove the oil filter cartridge (1).
3. Remove the oil cooler joint screw (3).
4. Remove the oil cooler (4).
V2607-CR-E4B
64 to 73 N·m
V2607-CR-TE4B
6.5 to 7.5 kgf·m
V2607-CR-
Tightening Oil cooler 47 to 54 lbf·ft
TIE4B
torque joint screw
V3307-CR-TE4B 40 to 44 N·m
V3307-CR- 4.0 to 4.5 kgf·m
(1) Oil Filter Cartridge (3) Oil Cooler Joint Screw

(2) Water Pipe (4) Oil Cooler
9Y1210674ENS0120US0
1-S58
(11) Front Cover

Front Cover
1. Remove the front cover (1).
(When reassembling)
• Make sure that the front cover gasket (4) set in position.
• Make sure that the liquid gasket coating surface is free of water,
dust and oil in order to keep sealing effect.
NOTE
• Assemble the adhesive-applied parts within ten minutes.
• Apply a liquid gasket (Three Bond 1217H or equivalent) (5)
to the seam between crankcase 1 (3) and crankcase 2 (2).
30 to 34 N·m
Front cover mounting
screw
22 to 25 lbf·ft
(1) Front Cover (4) Front Cover Gasket

(2) Crankcase 2 (5) Liquid Gasket
(3) Crankcase 1
9Y1210674ENS0121US0
Relief Valve
1. Remove the relief valve retaining screw (5).
2. Remove the relief valve (2), the spring (3) and the packing (4).
69 to 78 N·m
Tightening torque Relief valve retaining screw 7.0 to 8.0 kgf·m
51 to 57 lbf·ft
(1) Front Cover (4) Packing

(2) Relief Valve (5) Relief Valve Retaining Screw
(3) Spring
9Y1210674ENS0122US0
1-S59
(12) Flywheel and Timing Gears

Flywheel
1. Install the stopper (1) to the flywheel (2) so that the flywheel (2)
does not turn.
NOTE
• Do not use an impact wrench. Serious damage will occur.
• There is one positioning pin in the crankshaft gear and it is
installed in the flywheel (2).
2. Remove the flywheel screws (3) and set the flywheel guide
screws (4).
[V2607-CR-E4B / V2607-CR-TE4B / V2607-CR-TIE4B]
3. Remove the flywheel (2).
3. Remove the flywheel (2) with jack-up screws (5).
(When reassembling)
• Apply engine oil to the flywheel screws (3).
• Before fitting the flywheel (2) and the crankshaft gear together,
wipe oil, dust and other foreign substances off their mating
faces.
• The flywheel (2) and the crankshaft gear are fitting together in
just one position. Make sure they are tightly fit and drive the
screws.
98.1 to 107 N·m
Tightening torque Flywheel screw 10.0 to 11.0 kgf·m
72.4 to 79.5 lbf·ft
(1) Stopper (4) Flywheel Guide Screw

(2) Flywheel (5) Jack-up Screw
(3) Flywheel Screw
9Y1210674ENS0123US0
1-S60
Measuring Angular Deviation between Crankshaft TDC and
Crank Position Sensor Detected TDC
1. Remove the cylinder head cover, an injector and rocker arm.
2. Bring the piston of cylinder 4 to TDC.
3. Remove the #4 exhaust valve bridge arm and valve spring.
4. Insert a small O-ring (5) so the valve does not fall into the
cylinder.
5. Set a dial gauge (3) on the tip of the valve (4).
6. Turn the flywheel counterclockwise and measure the position
where the tip of the valve is the highest.
7. Stop the flywheel at the position where the tip of the valve is the
highest.
8. Put a tri-square (6) on the flywheel housing (7) and flywheel (8)
and draw a reference line (9).
IMPORTANT
• Do not drop the valve (4) into the cylinder.
• When measuring the highest position of the tip of the valve,
do not rotate the flywheel clockwise. If you go past the
highest point of the valve, back the flywheel up slightly and
measure the highest point of the valve.
• The reference line (9) indicates the TDC of the crankshaft.
(1) TC Mark (Flywheel Housing) (6) Tri-square
(2) TC Mark (Flywheel) (7) Flywheel Housing
(3) Dial Gauge (8) Flywheel
(4) Valve (9) Reference Line
(5) O-ring
(To be continued)
1-S61
(Continued)
9. Connect a connector of the rotation sensor signal interface unit
(10) (see page G-54) to the crankshaft position sensor (14).
10. Connect each clip of the rotation sensor signal interface unit
(10) to the same test lead color of the tester (11).
11. Switch on the rotation sensor signal interface unit (10).
12. Turn the flywheel and make sure that the voltage of the
crankshaft position sensor goes from 0 → 5 V or 5 → 0 V.
13. Rotate the flywheel and align the crankshaft position sensor to
the part of the pulsar gear (15) that is missing teeth (17).
14. The 14th tooth (16) from the missing teeth is the standard.
15. Slowly turn the flywheel counterclockwise and stop the flywheel
at the point where the needle of the tester changes momentarily
from 0 → 5 V, the 14th tooth.
16. That point is where the crankshaft position sensor detects TDC.
17. Set the tri-square (6) on the reference line (9) on the flywheel
housing side and mark the detection point of crankshaft position
sensor TDC (19) on the flywheel.
18. Measure the interval (20) between the crankshaft TDC (18) and
the detection point of crankshaft position sensor TDC (19).
19. Calculation of fuel injection timing correction 1.0 mm (0.039 in.):
0.321 °.
Corrected angle = 0.321 ° X actual interval
20. Overwrite the injection timing correction value in the ECU.
NOTE
• Using analog tester is easier to see the voltage change.
IMPORTANT
• When the crankshaft position sensor detects the teeth of
the pulsar gear, the tester indicates 0 V.
• The position where the needle of the tester changes
momentarily from 0 → 5 V is the detection point of
crankshaft position sensor TDC (19).
• The reference line indicates the crankshaft TDC (18) of the
crankshaft. If the detected TDC is ahead of the crankshaft
TDC, it is considered minus. If the detected TDC lags
behind the crankshaft TDC, it is considered plus.
(10) Rotation Sensor Signal Interface (17) Missing Teeth
Unit (18) Crankshaft TDC
(11) Tester (19) Detection Point of Crankshaft
(12) Ground Terminal Position Sensor TDC
(13) Output Terminal (20) Interval
(14) Crankshaft Position Sensor
(15) Pulsar Gear
(16) 14th Tooth
9Y1210674ENS0111US0
1-S62
Flywheel Housing (for V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B)
1. Remove the outside flywheel housing mounting screws (1).
2. Remove the inside flywheel housing mounting screws (2).
3. Remove the flywheel housing (4).
(When reassembling)
• Apply engine oil to the flywheel housing oil seal (6).
• Set the flywheel guide screws (5) and the flywheel housing
guide jig (7) to the crankshaft gear (3). (Refer to "5. SPECIAL
TOOLS"at "GENERAL" section.)
• Apply a liquid gasket (Three Bond 1217H or equivalent) (10) to
the seam between crankcase 1 (8) and crankcase 2 (9), and set
gasket.
• Make sure that the bearing 1 (11) and the bearing 2 (12) set in
position.
78 to 90 N·m
Flywheel housing mounting
7.9 to 9.2 kgf·m
screw (7T screw)
58 to 66 lbf·ft
Tightening torque
103 to 117 N·m
10.5 to 12.0 kgf·m
screw (9T screw)
76.0 to 86.7 lbf·ft
(1) Flywheel Housing Mounting Screw (6) Oil Seal

(Outside) (7T) (7) Jig
(2) Flywheel Housing Mounting Screw (8) Crankcase 1
(Inside) (9T) (9) Crankcase 2
(3) Crankshaft Gear (10) Liquid Gasket
(4) Flywheel Housing (11) Bearing 1
(5) Flywheel Guide Screw (12) Bearing 2
9Y1210674ENS0124US0
1-S63
Flywheel Housing (for V3307-CR-TE4B / V3307-CR-TIE4B)
1. Remove the outside flywheel housing mounting screws (2).
2. Remove the inside flywheel housing mounting screws (4).
3. Remove the flywheel housing (3).
(When reassembling)
• Apply engine oil to the flywheel housing oil seal (6).
• Set the flywheel guide screw (5) and the flywheel housing guide
jig (7) to the crankshaft gear (1). (Refer to "5. SPECIAL TOOLS"
at "GENERAL" section.)
• Apply a liquid gasket (Three Bond 1217H or equivalent) (10) to
the seam between crankcase 1 (8) and crankcase 2 (9).
For Side PTO Model (Option)
• Install the inside roller bearing (12) of the camshaft (11) in the
outside roller bearing (13) of the flywheel housing (14).
103 to 117 N·m
screw (9T)
76.0 to 86.7 lbf·ft
(1) Crankshaft Gear (7) Jig

(2) Flywheel Housing Mounting Screw (8) Crankcase 1
(Outside) (9T) (9) Crankcase 2
(3) Flywheel Housing (10) Liquid Gasket
(4) Flywheel Housing Mounting Screw (11) Camshaft
(Inside) (9T) (12) Roller Bearing (Inside)
(5) Flywheel Guide Screw (13) Roller Bearing (Outside)
(6) Oil Seal (14) Flywheel Housing
9Y1210674ENS0125US0
1-S64
Camshaft and Idle Gear (for V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B)
1. Rotate the cylinder head side of the engine crankcase to the
lower side.
2. Remove the idle gear mounting screws (6) and draw out the idle
gear (2).
3. Remove the camshaft set screws (5) and draw out the cam gear
(4).
NOTE
• If the cylinder head side of the engine crankcase does not
become lower side, the tappets drop and become the
trouble to the camshaft. The camshaft will not be able to be
drawn out.
(When reassembling)
• When installing the idle gear (2) and cam gear (4), be sure to
place the 4th cylinder piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the idle gear last.
• Mount the supply pump gear (1) after installing the flywheel
housing.
• Make sure the idle gear shaft (11) is clean.
• Apply oil to the idle gear shaft (11) and set the crankcase 1 (7).
• Set the idle gear (12) and the collar (9) with the oil groove (10)
facing crankcase 1 side.
24 to 27 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
49 to 55 N·m
Idle gear mounting screw 5.0 to 5.7 kgf·m
37 to 41 lbf·ft
(1) Supply Pump Gear (8) Spring Pin

(2) Idle Gear (9) Collar
(3) Crank Gear (10) Oil Groove
(4) Cam Gear (11) Idle Gear Shaft
(5) Camshaft Set Screw (12) Idle Gear
(6) Idle Gear Mounting Screw
(7) Crankcase 1
9Y1210674ENS0126US0
1-S65
Camshaft and Idle Gear (for V3307-CR-TE4B / V3307-CR-TIE4B)
1. Rotate the cylinder head side of the engine crankcase to the
lower side.
2. Remove the idle gear mounting screws (6) and draw out the idle
gear (2).
3. Remove the camshaft set screws (5) and draw out the cam gear
(4).
NOTE
• If the cylinder head side of the engine crankcase does not
become lower side, the tappets drop and become the
trouble to the camshaft. The camshaft will not be able to be
drawn out.
(When reassembling)
• When installing the idle gear (2) and cam gear (4), be sure to
place the 4th cylinder piston at the top dead center in
compression then, align all mating marks on each gear to
assemble the timing gears, set the idle gear last.
• Mount the supply pump gear (1) after installing the flywheel
housing.
• Make sure the idle gear shaft (9) is clean.
• Apply oil to the idle gear shaft (9) and set the crankcase 1 (7).
24 to 27 N·m
Camshaft set screw 2.4 to 2.8 kgf·m
18 to 20 lbf·ft
Tightening torque
49 to 55 N·m
Idle gear mounting screw 5.0 to 5.7 kgf·m
37 to 41 lbf·ft
(1) Supply Pump Gear (6) Idle Gear Mounting Screw

(2) Idle Gear (7) Crankcase 1
(3) Crank Gear (8) Collar
(4) Cam Gear (9) Idle Gear Shaft
(5) Camshaft Set Screw (10) Idle Gear
9Y1210674ENS0127US0
1-S66
(13) Piston and Connecting Rod

Oil Pan and Oil Strainer
1. Remove the oil pan mounting screws (1) and remove the oil pan
(2).
2. Remove the oil strainer mounting screws (4), and remove the oil
strainer (5).
(When reassembling)
• Install the oil strainer (5), using care not to damage the O-ring
(3).
• Apply liquid gasket (Three Bond 1217H or equivalent) (6) to the
crankcase 2 (7) as shown in the figure.
• Carefully apply the adhesive evenly.
NOTE
• When mounting the adhesive-applied parts, be careful to fit
them to the mating parts.
• To avoid uneven tightening, tighten mounting screws (1) in
diagonal order from the center.
• After cleaning the oil strainer (5), install it.
• Attach the oil pan (2) so that the drain plugs (8) will
approach the flywheel housing side (B).
(1) Oil Pan Mounting Screw (6) Liquid Gasket
(2) Oil Pan (7) Crankcase 2
(3) O-ring (8) Drain Plug
(4) Oil Strainer Mounting Screw A: Front Cover Side
(5) Oil Strainer B: Flywheel Housing Side
9Y1210674ENS0128US0
Tappet
1. Remove the tappets (1) from the tappet bore (2) of the
crankcase 1 (3) using magnetic tool.
(When reassembling)
• Before installing the tappets (1), apply engine oil thinly around
them.
NOTE
• Mark the cylinder number to the tappets (1) to prevent
interchanging.
(1) Tappet (3) Crankcase 1
(2) Tappet Bore
9Y1210674ENS0129US0
1-S67
Connecting Rod Cap
1. Remove the connecting rod screws (1) from connecting rod cap.
2. Remove the connecting rod caps.
(When reassembling)
• Align the marks (a) with each other. (Face the marks toward the
injection pump.)
• Apply engine oil to the connecting rod screws (1) and lightly
screw it in by hand, then tighten it to the specified torque.
If the connecting rod screw (1) won't be screwed in smoothly,
clean the threads.
If the connecting rod screw (1) is still hard to screw in, replace it.
• When using the existing crank pin metal again, put tally marks
on the crank pin metal and the connecting rod in order to keep
their positioning.
NOTE
• At the time of reassembling the connecting rod caps, use a
combination of the connecting rod screws with the same
specified tightening torque.
V2607-CR-E4B
41 to 45 N·m
V2607-CR-TE4B
4.1 to 4.6 kgf·m
V2607-CR-
Tightening Connecting 30 to 33 lbf·ft
TIE4B
torque rod screw
V3307-CR-TE4B 69 to 73 N·m
V3307-CR- 7.0 to 7.5 kgf·m
(1) Connecting Rod Screw (a) Mark

9Y1210674ENS0130US0
1-S68
Piston
1. Completely clean carbon in the cylinders.
2. Turn the flywheel and set a piston to the top dead center.
3. Pull out the piston upward by lightly tapping it from the bottom
of the crankcase with the grip of a hammer.
(When reassembling)
• Before inserting the piston into the cylinder, apply enough
engine oil to the cylinder.
• When inserting the piston into the cylinder, face the mark (4) on
the connecting rod to the injection pump.
IMPORTANT
• Do not change the combination of cylinder and piston.
Make sure of the position of each piston by marking. For
example, mark "1" on the No. 1 position.
• When inserting the piston into the cylinder, place the gap
of each piston ring like the figure.
• Carefully insert the pistons using a piston ring compressor
(1). Otherwise, their chrome-plated section of piston rings
may be scratched, causing trouble inside the liner.
• When inserting the piston in place, be careful not to get the
molybdenum disulfide coating (3) torn off its skirt. This
coating is useful in minimizing the clearance with the
cylinder liner. Just after the piston pin has been
press-fitted, in particular, the piston is still hot and the
coating is easy to peel off. Wait until the piston cools down.
(1) Piston Ring Compressor (A) Top Ring Gap
(2) Piston (B) Second Ring Gap
(3) Molybdenum Disulfide Coating (C) Oil Ring Gap
(4) Mark (D) Piston Pin Hole
(E) Injection Pump Side
(a) 2.09 rad (120 °)
(b) 0.79 rad (45 °) A: V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B
B: V3307-CR-TE4B /
V3307-CR-TIE4B
9Y1210674ENS0131US0
1-S69
Piston Ring and Connecting Rod
1. Remove the piston rings using a piston ring tool.
2. Remove the piston pin (7), and separate the connecting rod (6)
from the piston (5).
(When reassembling)
• Be sure to fix the crank pin bearing I.D.color (B) and the
connecting rod I.D.color (A) are same colors.
• When installing the ring, assemble the rings so that the
manufacture's mark (12) near the gap faces the top of the piston
(5).
• When installing the oil ring (3) onto the piston (5), place the
expander joint (10) on the opposite side of the oil ring gap (11).
• Apply engine oil to the piston pin (7).
• When installing the piston pin (7), immerse the piston (5) in
80 °C (176 °F) oil for 10 to 15 minutes and insert the piston pin
(7) to the piston (5).
• Assemble the piston (5) to the connecting rod (6) with the ↑ mark
(8) and the connecting rod numbering mark (9) facing same
side.
• The end faces of the oil ring (3) are plated with hard chrome. In
putting the piston (5) into the cylinder, be careful not to get the
oil ring (3) scratched by the cylinder. Use the piston ring fitter to
tighten up the oil ring (3). If the ring's planting is scratched, it
may get stuck on the cylinder wall, causing a serious trouble.
IMPORTANT
• Mark the same number on the connecting rod (6) and the
piston (5) so as not to change the combination.
(1) Top Ring (10) Expander Joint
(2) Second Ring (11) Oil Ring Gap
(3) Oil Ring (12) Manufacture's Mark
(4) Piston Pin Snap Pin
(5) Piston (A) Connecting Rod ID Color:
(6) Connecting Rod Blue or without Color
(7) Piston Pin (B) Crank Pin Bearing ID Color:
(8) Mark (↑) Blue or without Color
(9) Numbering Mark
9Y1210674ENS0133US0
1-S70
(14) Crankshaft and Crankcase

Crankshaft and Crankcase
1. Remove the crankcase 2 mounting screw and crankcase 2
flange screw in the order of Z to A.
2. Remove the crankcase 2 (1) from the crankcase 1 (2).
3. Remove the crankshaft (3).
(1) Crankcase 2 (a) Front Cover Side
(2) Crankcase 1 (b) Flywheel Housing Side
(3) Crankshaft A to J: Crankcase 2 Mounting Screw
K to Z: Crankcase 2 Flange Screw
(To be continued)
1-S71
(Continued)
(When reassembling)
• Make sure the crankcase 1 (4) and 2 (1) are clean.
• Reassemble the crankshaft bearing (3) into crankcase 1 (4) and
2 (1).
• Reassemble the thrust bearing (2), with the oil groove facing
outside, into both flywheel housing edge journal side of the
crankcase 1 (4) and 2 (1).
• Apply oil to the thrust bearing and set the crankshaft (6).
• Apply liquid gasket (Three Bond 1217H or equivalent) (5) to the
crankcase 1 as shown in the figure.
• Carefully apply the adhesive evenly.
• Match the crankcase 1 (4) and 2 (1), referring to the flywheel
housing's contoured face.
• Tighten the crankcase 2 mounting screws (A to J) and the
crankcase 2 flange screws (K to Z) loosely after applying engine
oil.
• Tighten up the jig (7) to the specified torque same as the
flywheel housing screw. (Refer to "5. SPECIAL TOOLS" at
"GENERAL" section.) This helps to minimize the level
difference between the crankcase 1 (4) and the crankcase 2 (1)
(at the flywheel side). Possible gap must be 0.05 mm (0.002 in.)
or smaller.
• Tighten the crankcase 2 mounting screw and the crankcase 2
flange screw in the order of A to Z. (Refer to previous page.)
NOTE
• When mounting the adhesive-applied parts, be careful to fit
them to the mating parts.
V2607-CR-E4B
128 to 137 N·m
V2607-CR-TE4B
13.0 to 14.0 kgf·m
Crankcase 2 V2607-CR-
94.1 to 101 lbf·ft
mounting TIE4B
screw (A to J) V3307-CR-TE4B 138 to 147 N·m
V3307-CR- 14.0 to 15.0 kgf·m
Tightening TIE4B 102 to 108 lbf·ft
torque V2607-CR-E4B
49 to 55 N·m
V2607-CR-TE4B
5.0 to 5.7 kgf·m
Crankcase 2 V2607-CR-
37 to 41 lbf·ft
flange screw TIE4B
(K to Z) V3307-CR-TE4B 59 to 63 N·m
V3307-CR- 6.0 to 6.5 kgf·m
(1) Crankcase 2 (6) Crankshaft

(2) Thrust Bearing (7) Jig
(3) Crankshaft Bearing
(4) Crankcase 1 A: V2607-CR-E4B / V2607-CR-TE4B /
(5) Liquid Gasket V2607-CR-TIE4B
B: V3307-CR-TE4B /
V3307-CR-TIE4B
9Y1210674ENS0134US0
1-S72
(15) Starter
Disassembling Motor
1. Disconnect the solenoid switch (3).
2. Remove the 2 through screws (9) and the 2 brush holder lock
screws. Remove the rear end frame (13) and the brush holder
(12). Disconnect the armature (10) and the yoke (11). Remove
also the ball (7) from the tip of the armature.
3. Remove the set of packings (8), the 4 planetary gears and
another packing.
4. Remove the shaft assembly. Take note of the position of the
lever.
IMPORTANT
• Before disconnecting the yoke, put tally marks on the yoke
and the front bracket.
• Take note of the positions of the set of packings and the
setup bolt.
• Apply grease to the gears, bearings, shaft's sliding part and
ball.
NOTE
• Do not damage to the brush and commutator.
(When reassembling)
• Apply grease to the parts indicated in the figure.
9.8 to 11 N·m
Tightening torque B terminal nut 1.0 to 1.2 kgf·m
7.3 to 8.6 lbf·ft
(1) Gear (8) Set of Packings

(2) Front Bracket (9) Through Screws
(3) Solenoid Switch (10) Armature
(4) Overrunning Clutch (11) Yoke
(5) Internal Gear (12) Brush Holder
(6) Planetary Gear (13) Rear End Frame
(7) Ball
9Y1210674ENS0053US0
1-S73
(16) Alternator
Front Bracket
1. Remove the 4 screws (3).
2. Separate the front bracket (1) and the rear bracket (2) from each
other.
IMPORTANT
• Put a tally line on the front bracket (1) and the rear bracket
(2) for reassembling them later.
(1) Front Bracket (3) Screw
(2) Rear Bracket
9Y1210674ENS0054US0
Pulley
1. Hold the rotor (base of the claw) in a vise. Loosen the lock nut
using a M24 box wrench.
58.4 to 78.9 N·m
Tightening torque Alternator pulley nut 5.95 to 8.05 kgf·m
43.1 to 58.2 lbf·ft
9Y1210674ENS0055US0
Rotor
1. Remove the 4 screws and remove the bearing retainer.
2. Temporarily install the nut on the pulley screw, and remove the
rotor.
9Y1210674ENS0056US0
Brush
1. When the rotor is removed, the 2 brushes are found to stretch
out of the shaft hole.
9Y1210674ENS0057US0
1-S74
Reassembling the Brush
1. Fit the brush with its sliding face in the clockwise direction when
viewed from front.
IMPORTANT
• Be sure to keep the 2 brushes deep in the brush holder.
Otherwise the rotor and the rear section can not be fitted
into the position.
• Use a 4.0 mm (0.16 in.) hex. wrench to push the brushes
into place.
• Using a pin-pointed (2.0 mm (0.079 in.)) punch, keep the
brushes from popping out.
2. Match the tally line of the front section with that of the rear
section.
3. Tighten the 4 screws, and draw out the pin-pointed punch out of
the brush holder.
(1) Marking
9Y1210674ENS0058US0
Bearing at Slip Ring Side

1. Lightly secure the rotor (1) with a vise to prevent damage, and
remove the bearing (2) with a puller (3).
(1) Rotor (3) Puller
(2) Bearing
9Y1210674ENS0059US0
1-S75
[3] SERVICING
(1) Cylinder Head and Valves
Top clearance
1. Remove the cylinder head.
2. With the piston at TDC, use grease to affix three or four
plastigauges (1) of a diameter 1.5 mm (0.059 in.) × 5.0 to
7.0 mm (0.20 to 0.27 in.) long to the crown of the piston; keep
the gauges away from the intake valve and combustion
chamber fittings.
3. Take the piston to an intermediate position, install the cylinder
head and tighten the head bolts to the specified torque.
4. Turn the crankshaft so the piston goes through TDC.
5. Remove the cylinder head and compare the width of the
crushed plastigauges (2) with the scale (3).
6. If they are out of spec, check the oil clearance of the crank pin,
journal and piston pins
NOTE
• Top clearance = Width of the crushed plastigauge (2)
0.60 to 0.80 mm
Top clearance Factory Specification
0.024 to 0.031 in.
V2607-CR-E4B
147 to 156 N·m
V2607-CR-TE4B
15.0 to 16.0 kgf·m
Cylinder head V2607-CR-
Tightening 109 to 115 lbf·ft
mounting TIE4B
torque
screw V3307-CR-TE4B 187 to 196 N·m
V3307-CR- 19.0 to 20.0 kgf·m
(1) Plastigauge (3) Scale

(2) Crushed Plastigauge
9Y1210674ENS0060US0
Cylinder Head Surface Flatness
1. Clean the cylinder head surface.
2. Place a straightedge on the cylinder head's four sides "A", "B",
"C" and "D" and two diagonal "E" and "F" as shown in the
figure. Measure the clearance with a feeler gauge.
3. If the measurement is more than the allowable limit, make it
straight with a surface grinder.
IMPORTANT
• Check the valve recessing after you correct.
Cylinder head surface 0.05 mm
Allowable limit
flatness 0.002 in.
9Y1210674ENS0061US0
1-S76
Cylinder Head Flaw
1. Prepare an air spray red check.
2. Clean the surface of the cylinder head with detergent (2).
3. Apply some red permeative liquid (1) on the cylinder head
surface. After you apply, do not touch it for 5 to 10 minutes.
4. Clean away the red permeative liquid on the cylinder head
surface with detergent (2).
5. Apply the white developer (3) on the cylinder head surface.
6. If you found a red flaw, replace the cylinder head.
(1) Red Permeative Liquid (3) White Developer
(2) Detergent
9Y1210674ENS0062US0
Valve Recessing
1. Clean the cylinder head surface, valve face and valve seat.
2. Set the valve into the valve guide.
3. Measure the valve recessing with a depth gauge.
4. If the measurement is more than the allowable limit, replace the
valve. If it stays more than the allowable limit after you replace
the valve, replace the cylinder head.
(recessing)
Factory specification 0.65 to 0.85 mm
0.026 to 0.033 in.
Valve recessing
(recessing)
Allowable limit 1.20 mm
0.0472 in.
(1) Cylinder Head Surface (A) Recessing

(B) Protrusion
9Y1210674ENS0063US0
Valve Lapping
1. Apply the compound equally to the valve lapping surface.
2. Put the valve into the valve guide. Lap the valve on its seat with
a valve lapping tool.
3. After you lap the valve, clean away the compound and apply oil,
then lap the valve again with oil.
4. Apply Prussian Blue to the contact surface to measure the
seated rate. If the seated rate is less than 70 %, lap the valve
again.
IMPORTANT
• After you complete the valve lapping and assemble the
valve, check the valve recessing and adjust the valve
clearance.
(1) Good (3) Bad
(2) Bad
9Y1210674ENS0064US0
1-S77
Clearance between Valve Stem and Valve Guide
1. Remove carbon from the valve guide section.
2. Measure the valve stem O.D. with an external micrometer.
3. Measure the valve guide I.D. with a small hole gauge. Calculate
the clearance.
4. If the clearance is more than the allowable limit, replace the
valves. If the clearance stays more than the allowable limit,
replace the valve guide also.
Factory
V2607-CR-E4B 0.030 to 0.057 mm
specifica-
V2607-CR-TE4B 0.0012 to 0.0022 in.
tion
V2607-CR-
Clearance Allowable 0.10 mm
TIE4B
between limit 0.0039 in.
valve stem
and guide Factory
0.055 to 0.085 mm
(Intake) V3307-CR-TE4B specifica-
0.0022 to 0.0033 in.
V3307-CR- tion
TIE4B Allowable 0.10 mm
limit 0.0039 in.
Factory
V2607-CR-E4B 0.045 to 0.072 mm
specifica-
V2607-CR-TE4B 0.0018 to 0.0028 in.
tion
V2607-CR-
Clearance Allowable 0.10 mm
TIE4B
valve stem
and guide Factory
0.055 to 0.085 mm
(Exhaust) V3307-CR-TE4B specifica-
0.0022 to 0.0033 in.
V3307-CR- tion
limit 0.0039 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 5.968 to 5.980 mm
specifica-
V2607-CR- 0.2350 to 0.2354 in.
Valve stem tion
TIE4B
O.D. (Intake)
V3307-CR-TE4B Factory
6.960 to 6.975 mm
0.2741 to 0.2746 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 5.953 to 5.965 mm
specifica-
Valve stem V2607-CR- 0.2344 to 0.2348 in.
tion
O.D. TIE4B
(Exhaust) V3307-CR-TE4B Factory
6.960 to 6.975 mm
0.2741 to 0.2746 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 6.010 to 6.025 mm
specifica-
Valve guide V2607-CR- 0.2367 to 0.2372 in.
tion
I.D. (Intake TIE4B
and exhaust) V3307-CR-TE4B Factory
7.030 to 7.045 mm
0.2768 to 0.2773 in.
TIE4B tion
9Y1210674ENS0065US0
1-S78
Replacement of Valve Guide
(When removing)
1. Press out the used valve guide with the valve guide replacing
tool.
(When installing)
1. Clean the new valve guide and valve guide bore, and apply
engine oil to them.
2. Press fit the new valve guide with the valve guide replacing tool.
3. Ream accurately the I.D. of the valve guide to the specified
dimension.
V2607-CR-E4B
Factory
V2607-CR-TE4B 6.010 to 6.025 mm
specifica-
Valve guide V2607-CR- 0.2367 to 0.2372 in.
tion
I.D. (Intake TIE4B
and exhaust) V3307-CR-TE4B Factory
7.030 to 7.045 mm
0.2768 to 0.2773 in.
TIE4B tion
IMPORTANT
• Do not hit the valve guide with a hammer during
replacement.
(A) When Removing (B) When Installing
9Y1210674ENS0066US0
Correction of Valve and Valve Seat
NOTE
• Before you correct the valve and seat, check the valve stem
and measure the I.D. of the valve guide section. Repair
them if necessary.
• After you correct the valve seat, be sure to check the valve
recessing.
1) Correction of valve
1. Correct the valve with a valve refacer.
0.79 rad
Valve face angle Factory specification
45 °
2) Correction of valve seat

1. Slightly correct the seat surface with a 1.0 rad (60 °) or 0.79 rad
(45 °) valve seat cutter.
2. Correct the seat surface with a 0.52 rad (30 °) or 0.26 rad (15 °)
valve seat cutter.
3.3 to 3.6 mm
Valve seat width Factory specification
0.13 to 0.14 in.
3. After you correct the seat, check that the valve seating is flat.
Apply a thin layer of compound between the valve face and
valve seat, and lap them with a valve lapping tool.
4. Check the valve seating with Prussian Blue. The valve seating
surface must show good contact on all sides.
0.79 rad
Valve seat angle Factory specification
45 °
(1) Valve Seat Width (A) Check the Contact

(2) Identical Dimensions (B) Correct Seat Width
(C) Check the Contact
(a) 0.26 rad (15 °) or 0.52 rad (30 °)
(b) 0.79 rad (45 °) or 1.0 rad (60 °)
(c) 0.52 rad (30 °) or 0.26 rad (15 °)
9Y1210674ENS0067US0
1-S79
Free Length and Tilt of Valve Spring
1. Measure the free length (B) of valve spring with a vernier
calipers. If the measurement is less than the allowable limit,
replace it.
2. Put the valve spring on a surface plate, and put a square on the
side of the valve spring. Turn the valve spring to measure the
maximum tilt (A). If the measurement is more than the allowable
limit, replace it.
3. Check the full surface of the valve spring for scratches. If there
is a problem, replace it.
1.0 mm
Tilt (A) Allowable limit
0.039 in.
Factory
V2607-CR-E4B 35.4 to 35.9 mm
specifica-
V2607-CR-TE4B 1.40 to 1.41 in.
tion
V2607-CR-
Free length limit 1.37 in.
(B) Factory
35.1 to 35.6 mm
V3307-CR-TE4B specifica-
1.39 to 1.40 in.
V3307-CR- tion
limit 1.36 in.
(A) Tilt (B) Free Length

9Y1210674ENS0068US0
Setting Load of Valve Spring
1. Put the valve spring on a tester and compress the valve spring
to the specified setting length.
2. Read the compression load on the gauge.
3. If the measurement is less than the allowable limit, replace the
valve spring.
Factory 60.8 N / 29.7 mm
V2607-CR-E4B specifica- 6.20 kgf / 29.7 mm
V2607-CR-TE4B tion 13.7 lbf / 1.17 in.
V2607-CR- 45.9 N / 29.7 mm
TIE4B Allowable
4.68 kgf / 29.7 mm
limit
Setting load / 10.3 lbf / 1.17 in.
setting length Factory 63.5 N / 31.5 mm
specifica- 6.48 kgf / 31.5 mm
V3307-CR-TE4B tion 14.3 lbf / 1.24 in.
V3307-CR-
TIE4B 45.9 N / 31.5 mm
Allowable
4.68 kgf / 31.5 mm
limit
10.3 lbf / 1.24 in.
9Y1210674ENS0069US0
1-S80
Oil Clearance between Rocker Arm and Rocker Arm Shaft
1. Measure the rocker arm I.D. with an internal micrometer.
2. Measure the rocker arm shaft O.D. with an external micrometer.
3. Calculate the oil clearance.
4. If the oil clearance is more than the allowable limit, replace the
rocker arm and measure the oil clearance again. If the oil
clearance stays more than the allowable limit, replace the
rocker arm shaft also.
0.016 to 0.054 mm
Oil clearance between Factory specification
0.00063 to 0.0021 in.
rocker arm and rocker
arm shaft 0.15 mm
Allowable limit
0.0059 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 13.973 to 13.984 mm
specifica-
V2607-CR- 0.55012 to 0.55055 in.
Rocker arm tion
TIE4B
shaft O.D.
14.973 to 14.984 mm
0.58949 to 0.58992 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 14.000 to 14.027 mm
specifica-
V2607-CR- 0.55119 to 0.55224 in.
Rocker arm tion
TIE4B
I.D.
15.000 to 15.027 mm
0.59056 to 0.59161 in.
TIE4B tion
9Y1210674ENS0070US0
1-S81
Oil Clearance between Valve Bridge Arm Shaft and Valve
Bridge Arm
1. Measure the valve bridge arm (1) I.D. with an internal
micrometer.
2. Measure the valve bridge shaft (2) O.D with an external
micrometer.
4. If the oil clearance is more than allowable limit, replace the valve
bridge arm (1) and measure the oil clearance again. If the oil
clearance stays more than the allowable limit, replace the valve
bridge shaft (2) also.
Factory
V2607-CR-E4B 0.018 to 0.057 mm
specifica-
V2607-CR-TE4B 0.00071 to 0.0022 in.
tion
Oil clearance V2607-CR-
between TIE4B Allowable 0.015 mm
valve bridge limit 0.0059 in.
arm and Factory
valve bridge 0.018 to 0.057 mm
shaft 0.00071 to 0.0022 in.
V3307-CR- tion
limit 0.0059 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 8.023 to 8.032 mm
specifica-
V2607-CR- 0.3159 to 0.3162 in.
Valve bridge tion
TIE4B
shaft O.D.
9.023 to 9.032 mm
0.3553 to 0.3555 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 8.050 to 8.080 mm
specifica-
V2607-CR- 0.3170 to 0.3181 in.
Valve bridge tion
TIE4B
arm I.D.
9.050 to 9.080 mm
0.3563 to 0.3574 in.
TIE4B tion
(1) Valve Bridge Arm (2) Valve Bridge Shaft

9Y1210674ENS0071US0
1-S82
Replacement of Valve Bridge Shaft (for V2607-CR-E4B /
V2607-CR-TE4B / V2607-CR-TIE4B) (If necessary)
1. Remove the used valve bridge shaft (1).
2. Clean the valve bridge shaft mounting hole.
3. Apply the liquid seal (Three Bond 1386B or equivalent) to the tip
of the valve bridge shaft when installing shaft at the position
shown in figure (a).
4. Using valve bridge shaft replacing tool (3), press in the new
shaft. (Refer to "5. SPECIAL TOOLS" at "GENERAL" section.)
(1) Valve Bridge Shaft A: Intake Side
(2) Coolant Passage B: Exhaust Side
(3) Valve Bridge Shaft Replacing Tool C: 31.30 to 31.70 mm
(1.233 to 1.248 in.)
(a) Shaft Hole (Through To The
Coolant Passage)
(b) Shaft Hole (Not Through To The
Coolant Passage)
9Y1210674ENS0135US0
1-S83
Replacement of Valve Bridge Shaft (for V3307-CR-TE4B /
V3307-CR-TIE4B) (If necessary)
1. Remove the used valve bridge shaft (2).
2. Clean the valve bridge shaft mounting hole.
3. Using valve bridge shaft replacing tool (3), press in the new
shaft. (Refer to "5. SPECIAL TOOLS" at "GENERAL" section.)
(1) Valve Bridge Arm A: 31.1 to 31.7 mm (1.23 to 1.24 in.)
(2) Valve Bridge Shaft
(3) Valve Bridge Shaft Replacing Tool
9Y1210674ENS0136US0
Push Rod Alignment

1. Put the push rod on V blocks.
2. Measure the push rod alignment.
push rod.
0.25 mm
Push rod alignment Allowable limit
0.0099 in.
(1) Push Rod

9Y1210674ENS0072US0
Oil Clearance between Tappet and Tappet Guide Bore

1. Measure the tappet O.D. with an external micrometer.
2. Measure the tappet guide bore I.D. with a small hole gauge.
4. If the oil clearance is more than the allowable limit or the tappet
has a damage, replace the tappet.
0.020 to 0.050 mm
Oil Clearance between Factory specification
0.00079 to 0.0019 in.
tappet and tappet guide
bore 0.07 mm
Allowable limit
0.003 in.
9.965 to 9.980 mm
Tappet O.D. Factory specification
0.3924 to 0.3929 in.
10.000 to 10.015 mm
Tappet guide bore I.D. Factory specification
0.39370 to 0.39429 in.
9Y1210674ENS0137US0
1-S84
(2) Timing Gears

Timing Gear Backlash (for V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B)
1. Set a dial indicator (lever type) with its point on the gear tooth.
2. Hold the mating gear and move the gear to measure the
backlash.
3. If the backlash is more than the allowable limit, measure the oil
clearance in the journal part of each shaft.
4. If the oil clearance is correct, replace the gear.
0.0400 to 0.118 mm
Backlash between crank 0.00158 to 0.00464 in.
gear and cam gear 0.22 mm
Allowable limit
0.0087 in.
0.0400 to 0.159 mm
Backlash between cam 0.00158 to 0.00625 in.
gear and idle gear 0.22 mm
Allowable limit
0.0087 in.
0.0400 to 0.168 mm
Backlash between idle Factory specification
0.00158 to 0.00661 in.
gear and supply pump
gear 0.22 mm
Allowable limit
0.0087 in.

9Y1210674ENS0073US0
Timing Gear Backlash (for V3307-CR-TE4B / V3307-CR-TIE4B)
1. Set a dial indicator (lever type) with its point on the gear tooth.
2. Hold the mating gear and move the gear to measure the
backlash.
3. If the backlash is more than the allowable limit, measure the oil
clearance in the journal part of each shaft.
4. If the oil clearance is correct, replace the gear.
0.0410 to 0.139 mm
Backlash between crank 0.00162 to 0.00547 in.
gear and cam gear 0.22 mm
Allowable limit
0.0087 in.
0.0410 to 0.145 mm
Backlash between cam 0.00162 to 0.00570 in.
gear and idle gear 0.22 mm
Allowable limit
0.0087 in.
0.0410 to 0.139 mm
Backlash between idle Factory specification
0.00162 to 0.00547 in.
gear and supply pump
gear 0.22 mm
Allowable limit
0.0087 in.

9Y1210674ENS0074US0
1-S85
Side Clearance of Idle Gear
1. Set a dial indicator with its point on the idle gear (1).
2. Move the idle gear (1) to the front and rear to measure the side
clearance.
idle gear collar.
Factory
V2607-CR-E4B 0.050 to 0.20 mm
specifica-
V2607-CR-TE4B 0.0020 to 0.0078 in.
tion
V2607-CR-
Side limit 0.035 in.
clearance of
idle gear Factory
0.15 to 0.25 mm
0.0059 to 0.0098 in.
V3307-CR- tion
limit 0.035 in.
(1) Idle Gear

9Y1210674ENS0075US0
Oil Clearance between Idle Gear Shaft and Idle Gear Bushing
1. Measure the idle gear shaft O.D. with an external micrometer.
2. Measure the idle gear bushing I.D. with an internal micrometer.
bushing.
Factory
V2607-CR-E4B 0.025 to 0.096 mm
specifica-
V2607-CR-TE4B 0.00099 to 0.0037 in.
tion
V2607-CR-
Oil clearance Allowable 0.10 mm
TIE4B
between idle limit 0.0039 in.
gear shaft
and idle gear Factory
0.0250 to 0.106 mm
bushing V3307-CR-TE4B specifica-
0.0020 to 0.0035 in.
V3307-CR- tion
limit 0.0043 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 34.959 to 34.975 mm
specifica-
V2607-CR- 1.3764 to 1.3769 in.
Idle gear tion
TIE4B
shaft O.D.
46.959 to 46.975 mm
1.8488 to 1.8494 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 35.000 to 35.055 mm
specifica-
V2607-CR- 1.3780 to 1.3801 in.
Idle gear tion
TIE4B
bushing I.D.
47.000 to 47.065 mm
1.8504 to 1.8529 in.
TIE4B tion
9Y1210674ENS0076US0
1-S86
Replacement of Idle Gear Bushing
(When removing)
1. Press out the used idle gear bushing with the replacing tool.
(When installing)
1. Clean a new idle gear bushing and idle gear bore, and apply
engine oil to them.
2. Press fit the new bushing with the replacing tool. Make sure that
the bushing end aligns the end of the idle gear.
(A) When Removing (B) When Installing
9Y1210674ENS0077US0
Side Clearance of Camshaft

1. Set a dial indicator with its point on the camshaft.
2. Move the cam gear (1) to the front and rear to measure the side
clearance.
camshaft stopper.
Side clearance of 0.10 mm
Allowable limit
camshaft 0.0039 in.
(1) Cam Gear

9Y1210674ENS0078US0
Camshaft Alignment
1. Hold the 2 end journals of camshaft (1) with V blocks on the
surface plate.
2. Set a dial indicator with its point on the middle journal.
3. Turn the camshaft (1) slowly and read the variation on the
indicator. (Half of the measurement)
camshaft (1).
0.01 mm
Camshaft alignment Allowable limit
0.0004 in.
(1) Camshaft
9Y1210674ENS0079US0
1-S87
Cam Height
1. Measure the height of the cam (2) at its highest point with an
external micrometer.
camshaft (1).
Factory
32.70 mm
specifica-
1.287 in.
V2607-CR-E4B tion
Allowable 32.20 mm
limit 1.268 in.
Factory
32.60 mm
Intake cam 1.283 in.
V2607-CR- tion
height
limit 1.264 in.
Factory
37.50 mm
1.476 in.
V3307-CR- tion
limit 1.457 in.
Factory
33.20 mm
specifica-
1.307 in.
V2607-CR-E4B tion
Allowable 32.70 mm
limit 1.287 in.
Factory
33.00 mm
Exhaust cam 1.299 in.
V2607-CR- tion
height
limit 1.280 in.
Factory
37.90 mm
1.492 in.
V3307-CR- tion
limit 1.472 in.
(1) Camshaft (2) Cam

9Y1210674ENS0080US0
1-S88
Oil Clearance between Camshaft Journal and Cylinder Block
Bore
1. Measure the camshaft journal O.D. with an external micrometer.
2. Measure the cylinder block bore I.D. for the camshaft with an
internal micrometer or a cylinder gauge.
camshaft.
0.050 to 0.091 mm
0.0020 to 0.0035 in.
camshaft journal and
cylinder block bore 0.15 mm
Allowable limit
0.0059 in.
34.934 to 34.950 mm
Camshaft journal 1 O.D. Factory specification
1.3754 to 1.3759 in.
35.000 to 35.025 mm
Cylinder block bore 1 I.D. Factory specification
1.3780 to 1.3789 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 41.934 to 41.950 mm
specifica-
V2607-CR- 1.6510 to 1.6515 in.
Camshaft tion
TIE4B
journal 2 O.D.
43.934 to 43.950 mm
1.7297 to 1.7303 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 42.000 to 42.025 mm
specifica-
Cylinder V2607-CR- 1.6536 to 1.6545 in.
tion
block bore 2 TIE4B
I.D. V3307-CR-TE4B Factory
44.000 to 44.025 mm
1.7323 to 1.7332 in.
TIE4B tion
(1) Camshaft Journal 1 (2) Camshaft Journal 2

9Y1210674ENS0081US0
Replacement of Camshaft Cover (for V3307-CR-TE4B) (If
necessary)
1. Remove the used camshaft cover and clean the hole.
2. Install the new camshaft cover (1) until bumping using camshaft
cover replacing tool. (Refer to "5. SPECIAL TOOLS" at
"GENERAL" section.)
(1) Camshaft Cover
9Y1210674ENS0138US0
1-S89
(3) Piston and Connecting Rod

Piston Pin Bore I.D.
1. Measure the piston pin bore I.D. in the horizontal and vertical
directions with a cylinder gauge.
piston.
Factory
V2607-CR-E4B 26.000 to 26.013 mm
specifica-
V2607-CR-TE4B 1.0237 to 1.0241 in.
tion
V2607-CR-
Piston pin limit 1.026 in.
bore I.D. Factory
28.000 to 28.013 mm
1.1024 to 1.1028 in.
V3307-CR- tion
limit 1.104 in.
9Y1210674ENS0082US0
Oil Clearance between Piston Pin and Small End Bushing
1. Measure the piston pin O.D. where it contacts the bushing with
an external micrometer.
2. Measure the piston pin bushing I.D. at the connecting rod small
end with an internal micrometer.
bushing and measure the oil clearance again. If the oil
clearance stays more than the allowable limit, replace the piston
pin.
Factory
V2607-CR-E4B 0.014 to 0.034 mm
specifica-
V2607-CR-TE4B 0.00056 to 0.0013 in.
tion
V2607-CR-
Oil clearance Allowable 0.15 mm
TIE4B
piston pin and
small end Factory
0.020 to 0.040 mm
bushing V3307-CR-TE4B specifica-
0.00079 to 0.0015 in.
V3307-CR- tion
limit 0.0059 in.
V2607-CR-E4B
Factory
V2607-CR-TE4B 26.006 to 26.011 mm
specifica-
V2607-CR- 1.0239 to 1.0240 in.
Piston pin tion
TIE4B
O.D.
28.006 to 28.011 mm
1.1026 to 1.1027 in.
TIE4B tion
V2607-CR-E4B
Factory
V2607-CR-TE4B 26.025 to 26.040 mm
specifica-
V2607-CR- 1.0246 to 1.0251 in.
Small end tion
TIE4B
bushing I.D.
28.031 to 28.046 mm
1.1036 to 1.1041 in.
TIE4B tion
9Y1210674ENS0083US0
1-S90
Replacement of Small End Bushing (for V2607-CR-E4B /
(When removing)
1. Press out the used bushing.
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil
to them.
2. Set the guide (4) to the bore of the connecting rod (2).
3. Insert a new first bushing (3) onto the small end bushing
replacing tool. (Refer to "5. SPECIAL TOOLS" at "GENERAL"
section.)
4. Press-fit it with a press so that the seam (6) of bushing position
as shown in the figure.
5. Turn the connecting rod inside out, and press-fit the second
bushing similarly.
(1) Small End Bushing Replacing Tool (A) When Installing First Bushing
(2) Connecting Rod (B) When Installing Second Bushing
(3) First Bushing (C) 0.26 rad (15 °)
(4) Guide
(5) Second Bushing
(6) Seam
(7) Oil Hole
(8) Mark
9Y1210674ENS0084US0
Replacement of Small End Bushing (for V3307-CR-TE4B /

V3307-CR-TIE4B)
(When removing)
1. Press out the used bushing using a small end bushing replacing
tool. (Refer to "5. SPECIAL TOOLS" at "GENERAL" section.)
(When installing)
1. Clean a new small end bushing and bore, and apply engine oil
to them.
2. Insert a new bushing onto the tool and press-fit it with a press
so that the seam (4) of bushing position as shown in the figure,
until it is flash with the connecting rod.
(1) Bushing (A) When Removing
(2) Small End Bushing Replacing Tool (B) When Installing
(3) Connecting Rod (C) 0.26 rad (15 °)
(4) Seam
9Y1210674ENS0085US0
1-S91
Connecting Rod Alignment
NOTE
• Make sure that the oil clearance of the small end bushing is
less than the allowable limit.
1. Remove the piston pin from the piston.
2. Install the piston pin into the connecting rod.
3. Install the connecting rod on the alignment tool of the
connecting rod.
4. Put a gauge on the piston pin, and move it against the face
plate.
5. If the gauge does not touch fully against the face plate, measure
the space between the gauge pin and face plate.
connecting rod.
Connecting rod 0.05 mm
Allowable limit
alignment 0.002 in.
9Y1210674ENS0086US0
Piston Ring Gap
1. Put the piston ring into the lower part of the liner (the least worn
out part) with the piston.
2. Measure the ring gap with a feeler gauge.
3. If the ring gap is more than the allowable limit, replace the ring.
V2607-CR- Factory
0.20 to 0.35 mm
E4B specifica-
0.0079 to 0.013 in.
V2607-CR- tion
TE4B
V2607-CR- Allowable 1.25 mm
TIE4B limit 0.0492 in.
Top ring
Factory
V3307-CR- 0.25 to 0.40 mm
specifica-
TE4B 0.0099 to 0.015 in.
tion
V3307-CR-
Piston ring TIE4B Allowable 1.25 mm
gap limit 0.0492 in.
0.30 to 0.45 mm
Second 0.012 to 0.017 in.
ring 1.25 mm
Allowable limit
0.0492 in.
0.25 to 0.45 mm
0.0099 to 0.017 in.
Oil ring
1.25 mm
Allowable limit
0.0492 in.
9Y1210674ENS0087US0
1-S92
Clearance between Piston Ring and Ring Groove
1. Clean the rings and the ring grooves, and install each ring in its
groove.
2. Measure the clearance between the ring and the groove with a
feeler gauge or depth gauge.
3. If the clearance is more than the allowable limit, replace the
piston ring.
4. If the clearance stays more than the allowable limit with new
ring, replace the piston also.
0.050 to 0.090 mm
Top ring
0.0020 to 0.0035 in.
Second 0.090 to 0.12 mm
ring 0.0036 to 0.0047 in.
Clearance 0.020 to 0.060 mm
between Oil ring
0.00079 to 0.0023 in.
piston ring
and ring 0.15 mm
Top ring
groove 0.0059 in.
Second 0.20 mm
Allowable limit
ring 0.0079 in.
0.15 mm
Oil ring
0.0059 in.
9Y1210674ENS0088US0
1-S93
(4) Crankshaft
Side Clearance of Crankshaft
1. Set a dial indicator with its point on the end of the crankshaft (1).
2. Move the crankshaft (1) to the front and rear to measure the side
clearance.
thrust bearings.
4. If the same dimension bearing is not applicable because of the
crankshaft journal wear, replace it with an oversize one. Refer
to the table and figure.
0.15 to 0.35 mm
Side clearance of 0.0059 to 0.013 in.
crankshaft 0.50 mm
Allowable limit
0.020 in.
(Reference)
• Oversize dimensions of crankshaft journal
0.2 mm 0.4 mm
Oversize
0.008 in. 0.02 in.
37.50 to 37.70 mm 37.60 to 37.80 mm
Dimension A
1.477 to 1.484 in. 1.481 to 1.488 in.
26.20 to 26.25 mm 26.40 to 26.45 mm
Dimension B
1.032 to 1.035 in. 1.040 to 1.041 in.
2.8 to 3.2 mm radius 2.8 to 3.2 mm radius
Dimension C
0.11 to 0.12 in. radius 0.11 to 0.12 in. radius
The crankshaft journal must be fine-finished to higher than Rmax = 0.8S
0.2 mm 0.4 mm
Oversize
0.008 in. 0.02 in.
41.10 to 42.10 mm 41.20 to 42.20 mm
Dimension A
1.619 to 1.657 in. 1.622 to 1.661 in.
28.20 to 28.25 mm 28.40 to 28.45 mm
Dimension B
1.111 to 1.112 in. 1.119 to 1.120 in.
Dimension C
(1) Crankshaft (A) Side Clearance of Crankshaft

9Y1210674ENS0089US0
Crankshaft Alignment
1. Hold the 2 end journals of crankshaft with V blocks on the
surface plate.
2. Set a dial indicator with its point on the middle journal.
3. Turn the crankshaft slowly and read the variation on the
indicator. (Half of the measurement)
crankshaft.
0.02 mm
Crankshaft alignment Allowable limit
0.0008 in.
9Y1210674ENS0090US0
1-S94
Oil Clearance between Crank Pin and Crank Pin Bearing
1. Clean the crank pin and crank pin bearing (4).
2. Put a strip of Plastigauge on the center of the crank pin.
3. Install the connecting rod cap (1).
4. Tighten the connecting rod screws (2) to the specified torque.
5. Remove the connecting rod cap again.
6. Measure the width that it becomes flat with the scale to get the
oil clearance.
crank pin bearing (4).
crank pin wear, replace it with an undersize one. Refer to the
table and figure.
NOTE
• Do not put the Plastigauge into the crank pin oil hole.
• When you tighten the connecting rod screws (2), do not
move the crankshaft.
49.980 to 49.991 mm
Crank pin O.D. Factory specification
1.9678 to 1.9681 in.
0.017 to 0.048 mm
0.00067 to 0.0018 in.
crank pin and crank pin
bearing 0.20 mm
Allowable limit
0.0079 in.
IMPORTANT
• To replace it with a specific STD service part, make sure the
crank pin bearing (4) has the same ID color (3) as the
connecting rod.
Connecting rod Crank pin bearing
ID Color Part
Large-end in. dia. Class Center wall thick
code
1.496 to 1.501 mm
53.010 to 53.020 mm 1G772-
Blue L 0.05890 to
2.0870 to 2.0874 in. 22310
0.05909 in.
1.491 to 1.496 mm
Without 53.000 to 53.010 mm 1G772-
S 0.05870 to
color 2.0867 to 2.0870 in. 22330
0.05889 in.
(Reference)
• Undersize dimensions of crank pin
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
Dimension A
1.0 to 1.5 mm relief 1.0 to 1.5 mm relief
*Dimension B
0.040 to 0.059 in. relief 0.040 to 0.059 in. relief
49.780 to 49.791 mm dia. 49.580 to 49.591 mm dia.
Dimension C
1.9599 to 1.9602 in. dia. 1.9520 to 1.9524 in. dia.
The crank pin must be fine-finished to higher than Rmax = 0.8S
*Holes to be de-burred and edges rounded with 1.0 to 1.5 mm
(0.040 to 0.059 in.) relief.
(1) Connecting Rod Cap (4) Crank Pin Bearing

(2) Connecting Rod Screw (5) Center Wall Thick
(3) ID Color
9Y1210674ENS0092US0
1-S95
Oil Clearance between Crankshaft Journal and Crankshaft
Bearing
1. Clean the crankshaft journal (2) and crankshaft bearing.
2. Put a strip of plastigauge on the center of the journal.
IMPORTANT
• Do not put the Plastigauge into the oil hole of the journal.
3. Install the crankcase 2 (1).
4. Tighten the crankcase 2 mounting screws to the specified
torque.
5. Remove the crankcase 2 (1) again.
6. Measure the width that it becomes flat with the scale to get the
oil clearance.
7. If the clearance more than the allowable limit, replace the
crankshaft bearing.
crankshaft journal wear, replace it with an undersize one. Refer
to the table and figure.
V2607-CR-E4B
Factory
V2607-CR-TE4B 72.977 to 72.990 mm
specifica-
V2607-CR- 2.8732 to 2.8736 in.
Crankshaft tion
TIE4B
journal O.D.
79.977 to 79.990 mm
3.1487 to 3.1492 in.
TIE4B tion
Factory
V2607-CR-E4B 0.030 to 0.051 mm
specifica-
V2607-CR-TE4B 0.0012 to 0.0020 in.
tion
Oil clearance V2607-CR-
between TIE4B Allowable 0.20 mm
crankshaft limit 0.0079 in.
journal and Factory
crankshaft 0.030 to 0.073 mm
bearing 0.0012 to 0.0028 in.
V3307-CR- tion
limit 0.0079 in.
(1) Crankcase 2 (3) Crankcase 1

(2) Crankshaft Journal
(To be continued)
1-S96
(Continued)
(Reference)
• Undersize dimensions of crankshaft journal
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
Dimension A
*Dimension B
72.777 to 72.790 mm dia. 72.577 to 72.590 mm dia.
Dimension C
2.8653 to 2.8657 in. dia. 2.8574 to 2.8578 in. dia.
(0.040 to 0.059 in.) relief.
0.2 mm 0.4 mm
Undersize
0.008 in. 0.02 in.
Dimension A
*Dimension B
79.777 to 79.790 mm dia. 79.577 to 79.590 mm dia.
Dimension C
3.1409 to 3.1413 in. dia. 3.1330 to 3.1334 in. dia.
(0.040 to 0.059 in.) relief.
9Y1210674ENS0093US0
1-S97
Replacement of Crankshaft Sleeve
1. Remove the used crankshaft sleeve (2).
2. Set the sleeve guide (3) to the crankshaft (1).
3. Increase the temperature of a new sleeve to between 150 and
200 °C (302 and 392 °F).
4. Set the sleeve to the crankshaft as shown in figure.
5. Press fit the sleeve using the crankshaft sleeve replacing tool
(4). (Refer to "5. SPECIAL TOOLS" at "GENERAL" section.)
NOTE
• Make sure that the large chamfer of the sleeve points to
outward.
• Keep the space ((a) or (c)) between the edge of the
crankshaft gear (1) and the crankshaft sleeve (2).
• Be sure to place the seal (5) when reassembling.
(1) Crankshaft Gear (a) 0.850 to 1.15 mm
(2) Crankshaft Sleeve (0.0335 to 0.0452 in.)
(3) Sleeve Guide (b) 5.5 mm (0.22 in.)
(4) Crankshaft Sleeve Replacing Tool (c) More than 6.5 mm (0.26 in.)
(5) Seal
A: V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B
B: V3307-CR-TE4B /
V3307-CR-TIE4B
9Y1210674ENS0094US0
1-S98
Replacement of Flywheel Housing Oil Seal
1. Remove the used oil seal (2).
2. Clean the new flywheel housing oil seal (2) and apply engine oil
to it.
3. Install the new oil seal (2) to the specific position using the
flywheel housing oil seal replacing tool (1). (Refer to "5.
SPECIAL TOOLS" at "GENERAL" section.)
(1) Flywheel Housing Oil Seal (a) 0 to 0.50 mm (0 to 0.019 in.)
Replacing Tool (b) 1.0 mm (0.039 in.)
(2) Oil Seal
(3) Flywheel Housing A: V2607-CR-E4B / V2607-CR-TE4B /
V2607-CR-TIE4B
B: V3307-CR-TE4B /
V3307-CR-TIE4B
9Y1210674ENS0142US0
Replacement of Front Cover Oil Seal

1. Remove the used front cover oil seal (2).
2. Clean a new front cover oil seal (2) and apply engine oil to it.
3. Install the new oil seal (2) using the front cover oil seal replacing
tool (1). (Refer to "5. SPECIAL TOOLS" at "GENERAL"
section.)
(1) Front Cover Oil Seal Replacing Tool A: 2.0 mm (0.079 in.)
(2) Oil Seal
(3) Front Cover
9Y1210674ENS0143US0
1-S99
Replacement of Camshaft Position Sensor Bushing
(When removing)
1. Press out the used bushing using a camshaft position sensor
bushing replacing tool. (Refer to "5. SPECIAL TOOLS" at
"GENERAL" section.)
(When installing)
1. Clean a new camshaft position sensor bushing and bore.
2. Apply Loctite 962T or Three Bond 1386B to new camshaft
position sensor bushing.
3. Insert a new bushing onto the tool.
4. Press-fit the new bushing with the replacing tool. Make sure that
the bushing end aligns the end of the crankcase.
NOTE
• Keep the space (b) between the edge of the crankcase (1)
and the camshaft position sensor bushing (2).
(1) Crankcase (a) Flywheel Side
(2) Camshaft Position Sensor Bushing (b) 0.1 to 0.6 mm (0.004 to 0.02 in.)
9Y1210674ENS0144US0
(5) Cylinder
Cylinder Wear
1. Measure the I.D. of the cylinder at the 6 positions (see figure)
with a cylinder gauge and find the maximum and minimum inner
diameters.
2. Find the difference between the maximum and the minimum
inner diameters.
3. If the maximum I.D. or the difference is more than the allowable
limit, bore and hone it to the oversize dimension. (Refer to
"Cylinder Correction (Oversize)".)
4. Check the cylinder wall for scratches. If you find deep scratches,
bore the cylinder. (Refer to "Cylinder Correction (Oversize)".)
Factory
V2607-CR-E4B 87.000 to 87.022 mm
specifica-
V2607-CR-TE4B 3.4252 to 3.4260 in.
tion
V2607-CR-
Cylinder Bore limit 3.431 in.
I.D. Factory
94.000 to 94.022 mm
3.7008 to 3.7016 in.
V3307-CR- tion
limit 3.707 in.
(A) Top (a) Right-angled to Piston Pin

(B) Middle (b) Piston Pin Direction
(C) Bottom (Skirt)
9Y1210674ENS0095US0
1-S100
Cylinder Correction (Oversize)
1. If the cylinder wear is more than the allowable limit, bore and
hone it to the specified dimension.
87.250 to 87.272 mm
Oversize cylinder I.D. Factory specification
3.4351 to 3.4359 in.
87.40 mm
Maximum wear Allowable limit
3.441 in.
Finishing Hone to 2.2 to 3.0 μmRz (0.000087 to 0.00011 in.Rz)
2. Replace the piston and piston rings with oversize ones

(0.25 mm, 0.0098 in.).
94.500 to 94.522 mm
Oversize cylinder I.D. Factory specification
3.7205 to 3.7213 in.
94.65 mm
Maximum wear Allowable limit
3.726 in.
Finishing Hone to 2.2 to 3.0 μmRz (0.000087 to 0.00011 in.Rz)
2. Replace the piston and piston rings with oversize ones (0.5 mm,
0.02 in.).
NOTE
• If the maximum I.D. or the difference for the oversize
cylinder is more than the allowable limit, replace the
cylinder block with a new one.
(1) Cylinder I.D. (Before Correction) (2) Cylinder I.D. (Oversize)
9Y1210674ENS0096US0
(6) Oil Pump

Clearance between Inner Rotor and Outer Rotor
1. Measure the clearance between the lobes of the inner rotor and
the outer rotor with a feeler gauge.
2. If the clearance more than the allowable limit, replace the oil
pump rotor assembly.
0.030 to 0.090 mm
Clearance between inner 0.0012 to 0.0035 in.
rotor and outer rotor 0.30 mm
Allowable limit
0.012 in.
9Y1210674ENS0097US0
Clearance between Outer Rotor and Pump Body
1. Measure the clearance between the outer rotor and the pump
body with a feeler gauge.
2. If the clearance more than the allowable limit, replace the oil
pump rotor assembly.
3. If the clearance stays more than the allowable limit after
replacing the oil pump rotor assembly, replace the gear case.
0.100 to 0.184 mm
Clearance between outer 0.00394 to 0.00724 in.
rotor and pump body 0.30 mm
Allowable limit
0.012 in.
9Y1210674ENS0098US0
1-S101
Clearance between Rotor and Cover
1. Put a strip of Plastigauge on the rotor face with grease.
2. Install the cover and tighten the screws with the specified
torque.
3. Remove the cover carefully.
4. Measure the width that Plastigauge becomes flat with the scale
to get the oil clearance.
5. If the clearance is more than the allowable limit, replace oil
pump rotor assembly and the cover.
0.025 to 0.075 mm
Clearance between rotor 0.00099 to 0.0029 in.
and cover 0.225 mm
Allowable limit
0.00886 in.
7.9 to 9.3 N·m

Tightening torque Oil pump cover screw 0.80 to 0.95 kgf·m
5.8 to 6.8 lbf·ft
9Y1210674ENS0099US0
(7) Relief Valve

Free Length of Relief Valve Spring
1. Measure the free length "A" with vernier calipers. If the
measurement is less than the allowable limit, replace it.
2. Check the entire surface of the spring for scratches. Replace it,
if any.
60.0 to 60.5 mm
2.37 to 2.38 in.
Free length "A"
55.0 mm
Allowable limit
2.17 in.
69 to 78 N·m
Tightening torque Relief valve retaining screw 7.0 to 8.0 kgf·m
51 to 57 lbf·ft
(1) Front Cover (4) Packing

(2) Relief Valve (5) Relief Valve Retaining Screw
(3) Spring A: Free Length
9Y1210674ENS0145US0
(8) Starter
Overrunning Clutch
1. Check the pinion for wear or damage.
2. If there is any problem, replace the overrunning clutch
assembly.
3. Check that the pinion turns freely and smoothly in the direction
that it overruns. (Check the overrunning function.)
4. If there is any problem, replace the overrunning clutch
assembly.
9Y1210674ENS0100US0
1-S102
Commutator and Mica
1. Check the contact of the commutator for wear.
2. Grind the commutator with emery paper (#300) if it is lightly
worn.
3. Measure the commutator O.D. with an outside micrometer at
several points.
4. If the minimum O.D. is less than the allowable limit, replace the
armature assembly.
5. If the difference of the O.D.'s exceeds the allowable limit, correct
the commutator on a lathe to the factory specification.
6. Measure the mica undercut.
7. If the undercut is less than the allowable limit, correct it with a
saw blade. Chamfer the segment edges.
32.0 mm
1.26 in.
Commutator O.D.
31.4 mm
Allowable limit
1.24 in.
0.50 mm
0.020 in.
Mica under cut
0.20 mm
Allowable limit
0.0079 in.
(1) Segment (a) Good

(2) Depth of Mica (b) Bad
(3) Mica
9Y1210674ENS0101US0
Brush Wear
1. Measure the brush length (A) with a vernier caliper.
2. If the length is less than the allowable limit, replace the yoke
assembly and brush holder assembly.
3. After you replace the brush, put an emery paper (#300 or
above) on the commutator and correct the contact position.
18.0 mm
0.709 in.
Brush length (A)
11.0 mm
Allowable limit
0.433 in.
(A) Brush Length

9Y1210674ENS0102US0
Brush Holder
1. Check the continuity across the brush holder and the holder
support with a circuit tester.
2. If electricity flows, replace the brush holder assembly.
Resistance between
brush holder and holder Factory specification Infinity
support
9Y1210674ENS0103US0
1-S103
Armature Coil
1. Check the continuity across the commutator and armature coil
core with the resistance range of circuit tester.
2. Check the continuity across the segments of the commutator
with the resistance range of circuit tester.
3. If electricity is out of factory specification, replace the armature
assembly.
Resistance between
commutator and Factory specification Infinity
armature coil core
Resistance between
commutator and Factory specification 0Ω
segment
9Y1210674ENS0104US0
Field Coil
1. Check the continuity across the lead (1) and brush (2) with a
circuit tester.
2. Check the continuity across the brush (2) and yoke (3) with a
circuit tester.
3. If electricity is out of factory specification, replace the yoke
assembly.
Resistance between lead
0Ω
and brush
Resistance between
Infinity
brush and yoke
(1) Lead (3) Yoke

(2) Brush
9Y1210674ENS0105US0
(9) Alternator
Bearing
1. Check that the bearing can turn smoothly.
2. If not, replace it.
9Y1210674ENS0106US0
1-S104
Stator
1. Measure the resistance across each lead of the stator coil with
the resistance range of circuit tester.
2. If the measurement is not in the factory specification, replace
the stator assembly.
3. Check the continuity across each stator coil lead and core with
the resistance range of circuit tester.
4. If it does not show infinity, replace the stator assembly.
Resistance Factory specification Less than 1.0 Ω
9Y1210674ENS0107US0
Rotor
1. Measure the resistance across the slip rings.
2. Check the continuity across the slip ring and core with the
resistance range of circuit tester.
3. If electricity is out of factory specification, replace the rotor.
Resistance between slip
2.8 to 3.3 Ω
rings
Resistance between slip
Infinity
ring and rotor core
9Y1210674ENS0108US0
Slip Ring
1. Check the slip ring for dirt or scratch.
2. If dirt is detected, clean the slip ring using a cloth soaked in
alcohol.
3. If there is slight score, correct with an emery paper (#500 to
600).
4. Measure the O.D. of the slip ring with a vernier calipers.
rotor assembly.
22.7 mm
0.894 in.
Slip ring O.D.
22.1 mm
Allowable limit
0.870 in.
9Y1210674ENS0109US0
Brush Wear
1. Measure the brush length (A) with vernier calipers.
2. If the measurement is less than the allowable limit, replace it.
3. Make sure that the brush moves smoothly.
4. If the brush is damaged, replace it.
18.5 mm
0.728 in.
Brush length (A)
5.0 mm
Allowable limit
0.20 in.
(A) Brush Length

9Y1210674ENS0110US0
1-S105
DIAGNOSIS MANUAL
COMMON RAIL SYSTEM
V2607-CR-E4B,V2607-CR-TE4B,
V3307-CR-TE4B,

Record of Revisions
For pdf, use search function {Search word} to find the all revised locations.
Last digit
Issue Reference
of the Main Revised Point and Corrective Measures {Search word}
month Page
Code No.
1 2015.03 Added the information of V2607-CR-TIE4 / V3307-CR-TIE4 (DOC only)
2 2016.11 Change the flow of checking the operation of the ECU.
• Change to use Diagmaster launcher 1-S10

I INFORMATION

INFORMATION
CONTENTS
1. SAFETY FIRST .............................................................................................................................. I-1

07-CR-E4B, 07-CR-TE4B, 07-CR-TIE4B (DOC only), DM INFORMATION
1. SAFETY FIRST
SAFETY FIRST
• This symbol, the industry's "Safety Alert Symbol", is used throughout this manual and on labels on the
machine itself to warn of the possibility of personal injury. Read these instructions carefully.
• It is essential that you read the instructions and safety regulations before you attempt to repair or use
this unit.
DANGER
• Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
• Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
• Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
IMPORTANT
• Indicates that equipment or property damage could result if instructions are not followed.
NOTE
• Gives helpful information.
9Y1200174INI0001US0
BEFORE SERVICING AND REPAIRING
• Read all instructions and safety instructions in this
manual and on your machine safety decals.
• Clean the work area and machine.
• Park the machine on a firm and level ground.
• Allow the engine to cool before proceeding.
• Stop the engine, and remove the key.
• Disconnect the battery negative cable.
• Hang a "DO NOT OPERATE"tag in operator station.
9Y1200174INI0002US0
SAFETY STARTING
• Do not start the engine by shorting across starter
terminals or bypassing the safety start switch.
• Unauthorized modifications to the engine may impair
the function and / or safety and affect engine life.
9Y1200174INI0003US0
I-1
SAFETY WORKING
• Do not work on the machine while under the
influence of alcohol, medication, or other substances
or while fatigued.
• Wear close fitting clothing and safety equipment
appropriate to the job.
• Use tools appropriate to the work. Makeshift tools,
parts, and procedures are not recommended.
• When servicing is performed together by two or more
persons, take care to perform all work safely.
• Do not touch the rotating or hot parts while the
engine is running.
• Never remove the radiator cap while the engine is
running, or immediately after stopping. Otherwise,
hot water will spout out from radiator. Only remove
radiator cap when cool enough to touch with bare
hands. Slowly loosen the cap to first stop to relieve
pressure before removing completely.
• Escaping fluid (fuel or hydraulic oil) under pressure
can penetrate the skin causing serious injury.
Relieve pressure before disconnecting hydraulic or
fuel lines. Tighten all connections before applying
pressure.
• Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable
or uncomfortable loud noises.
• Do not open high-pressure fuel system.
High-pressure fluid remaining in fuel lines can cause
serious injury. Do not disconnect or attempt to repair
fuel lines, sensors, or any other components
between the high-pressure fuel pump and injectors
on engines with high pressure common rail fuel
system.
• High voltage exceeding 100 V is generated in the
ECU and injector.
Pay sufficient caution to electric shock when
performing work activities.
9Y1200174INI0004US0
AVOID FIRES
• Fuel is extremely flammable and explosive under
certain conditions. Do not smoke or allow flames or
sparks in your working area.
• To avoid sparks from an accidental short circuit,
always disconnect the battery negative cable first
and connect it last.
• Battery gas can explode. Keep sparks and open
flame away from the top of battery, especially when
charging the battery.
• Make sure that no fuel has been spilled on the
engine.
9Y1200174INI0005US0
I-2
VENTILATE WORK AREA
• If the engine must be running to do some work, make
sure the area is well ventilated. Never run the engine
in a closed area. The exhaust gas contains
poisonous carbon monoxide.
9Y1200174INI0006US0
PREVENT ACID BURNS

• Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, clothing and cause
blindness if splashed into eyes. Keep electrolyte
away from eyes, hands and clothing. If you spill
electrolyte on yourself, flush with water, and get
medical attention immediately.
9Y1200174INI0007US0
DISPOSE OF FLUIDS PROPERLY

• Do not pour fluids into the ground, down a drain, or
into a stream, pond, or lake. Observe relevant
environmental protection regulations when
disposing of oil, fuel, coolant, electrolyte and other
harmful waste.
9Y1200174INI0008US0
PREPARE FOR EMERGENCIES

• Keep a first aid kit and fire extinguisher handy at all
times.
• Keep emergency numbers for doctors, ambulance
service, hospital and fire department near your
telephone.
9Y1200174INI0009US0
I-3
1 COMMON RAIL SYSTEM

MECHANISM
CONTENTS
1. BASIC SYSTEM INFORMATION ............................................................................................... 1-M1

[1] SYSTEM CONFIGURATION................................................................................................ 1-M1
[2] FUEL SYSTEM..................................................................................................................... 1-M2
[3] INTAKE AND EXHAUST SYSTEM ...................................................................................... 1-M3
[4] WIRING DIAGRAM .............................................................................................................. 1-M4
(1) Engine Intermediate Harness (Engine Side Harness).................................................... 1-M4
(2) Injector Intermediate Harness (Engine Side Harness) ................................................... 1-M6
(3) ECU Intermediate Harness (OEM Side Harness) .......................................................... 1-M7
(4) System Wiring Diagram................................................................................................ 1-M12
[5] AVAILABLE DATA MONITOR SIGNALS (LEVEL 1) ......................................................... 1-M14
(1) Monitor Items................................................................................................................ 1-M14
(2) Normal Value................................................................................................................ 1-M17
[6] ECU TERMINAL LAYOUT ................................................................................................. 1-M20
(1) ECU Terminal Layout 1 (Engine Side) ......................................................................... 1-M20
(2) ECU Terminal Layout 2 (Machine Side) ....................................................................... 1-M23

07-CR-E4B, 07-CR-TE4B, 07-CR-TIE4B (DOC only), DM COMMON RAIL SYSTEM
1. BASIC SYSTEM INFORMATION

[1] SYSTEM CONFIGURATION
(1) Key Switch ON Signal (10) Overheat Lamp Signal (25) Intake Air Temperature (33) **Temperature Sensor
(2) Starter Switch Signal (11) Glow (Air Heater) Lamp Signal Sensor (DPF Inlet Exhaust
(3) Emergency Stop Switch (12) Starter Relay (26) Glow Plug Temperature) (T1)
(4) Oil Pressure Switch (13) Glow Relay (27) Coolant Temperature Sensor (34) **Temperature Sensor (DOC
(5) CAN Communication for (14) Supply Pump (28) Crankshaft Position Sensor Inlet Exhaust Temperature)
OEM Machine (15) Fuel Temperature Sensor (29) Diesel Particulate Filter (T0)
(*Accelerator Position Signal, (16) SCV (Suction Control Valve) (Hereinafter Referred To As (35) Air Flow Sensor
*Neutral Switch, *Machine (17) Rail Pressure Sensor The "DPF") Muffler
Travel Speed Signal) (18) Rail (30) Camshaft Position Sensor (A) CAN2 Connector
(6) CAN Communication for (19) Pressure Limiter (31) **Temperature Sensor (DPF (For OEM Machine)
Service (20) Injector Outlet Exhaust Temperature) (B) CAN1 Connector
(7) Engine Warning Light Signal (21) EGR DC Motor (T2) (For Service)
(8) Stop Lamp Signal (22) EGR Lift Sensor (32) **Differential Pressure Sensor (C) Engine ECU
(9) Oil Pressure Warning Lamp (23) **Intake Throttle Valve (DPF Differential Pressure) (a) To Fuel Tank
Signal (24) Intake Air Pressure Sensor (∆P)
(To be continued)
1-M1
(Continued)
NOTE
• The parts marked with ** are only for -E4B, -TE4B. (TIE4B do not equip the parts).
9Y1200199CRM0042US0
[2] FUEL SYSTEM
(1) Injector (5) SCV (Suction Control Valve) (9) Fuel Feed Pump A: ECU for Engine
(2) Rail (6) Fuel Cooler (10) Water Separator B: ECU for Machine
(3) Supply Pump (7) Check Valve (11) Fuel Tank C: Sensors
(4) Pressure Limiter (8) Fuel Filter D: Injected Fuel Flow
E: Returned Fuel Flow
F: Feed Fuel Flow
NOTE
9Y1200199CRM0023US0
1-M2
[3] INTAKE AND EXHAUST SYSTEM
(1) Mass Air Flow Sensor (5) *Exhaust Gas Temperature (10) EGR Lift Sensor A: Intake Air Flow
(2) *Exhaust Gas Temperature Sensor2 (T2) (DPF Outlet (11) *Intake Throttle Valve B: Exhaust Gas Flow
Sensor0 (T0) (DOC Inlet Exhaust Gas Temperature) (12) Glow Heater
Exhaust Gas Temperature) (6) Diesel Particulate Filter (13) Boost Pressure Sensor (a) To Muffler
(3) *Exhaust Gas Temperature (Hereinafter Referred To As (14) Intake Air Temperature
Sensor1 (T1) (DPF Inlet The "DPF") Muffler Sensor
Exhaust Gas Temperature) (7) Camshaft Position Sensor (15) Coolant Temperature Sensor
(4) *Differential Pressure Sensor (8) Injector (16) Crankshaft Position Sensor
(DPF Differential Pressure) (9) EGR DC Motor
(∆P)
NOTE
• The parts marked with * are only for -E4B, -TE4B. (TIE4B do not equip the parts).
9Y1200199CRM0024US0
1-M3
[4] WIRING DIAGRAM

(1) Engine Intermediate Harness (Engine Side Harness)
(1) − CAN and EGR

(2) CN202 Intake Air Temperature Sensor
(3) CN203 Coolant Temperature Sensor
(5) CN204 Rail Pressure Sensor
(6) CN205 Crankshaft Position Sensor
(8) CN206 Resistance Connector (1.1 kΩ)
(9) CN207 Oil Pressure Switch
(10) CN208 Boost Pressure Sensor
(11) CN209 / 210 Supply Pump
(12) − Camshaft Position Sensor
(13) CN212 Intake Throttle Valve (V2607-CR-E4 / V2607-CR-TE4 / V3307-CR-TE4)
NOTE
9Y1200199CRM0043US0
1-M4
(1) − CAN and EGR

(3) CN223 EGR Value
(4) CN226 Resistance Connector (120 Ω)
(5) CN224/225 Can Tool
NOTE
9Y1200199CRM0026US0
1-M5
(2) Injector Intermediate Harness (Engine Side Harness)
(1) CN306 Injector Intermediate Connector

(2) CN305 Injector Joint Connector 1
NOTE
9Y1200199CRM0044US0
1-M6
(3) ECU Intermediate Harness (OEM Side Harness)
(1) CN501 ECU (1)

(2) CN502 ECU (2)
(4) − Power Unit
(5) − Diesel Particulate Filter (hereinafter referred to as the "DPF")
(6) − Engine
(7) − Injector
NOTE
9Y1200199CRM0045US0
1-M7
(1) − Power Unit

(2) CN401 Accel Sensor
(3) CN402 Alternator
(4) CN403 Starter Relay
(5) CN404 Starter
(6) CN405 Connector
(7) CN406 Connector
(8) CN413 Main Relay
(9) − Glow Plug
(10) CN416 Glow Relay
(13) − Fuel Feed Pump
(14) − Battery Unit
(15) − Battery
(16) − Key Switch
(17) − Speed Sensor
(18) − CAN for Vehicle
(19) CN407 / 408 CAN Tool
NOTE
9Y1200199CRM0046US0
1-M8
(1) − Diesel Particulate Filter (DPF)

(5) CN104 DPF Differential Pressure Sensor (∆P) (V2607-CR-E4B / V2607-CR-TE4B / V3307-CR-TE4B)
(6) CN105 Air Flow Sensor
NOTE
9Y1200199CRM0047US0
1-M9
(1) − Engine
NOTE
9Y1200199CRM0048US0
1-M10
(1) − Injector
NOTE
9Y1200199CRM0049US0
1-M11
(4) System Wiring Diagram

V2607-CR-E4B, V2607-CR-TE4B, V3307-CR-TE4B
(1) Main Relay (10) Battery (21) Vehicle Speed Sensor (29) Stop Switch
(2) Fuel Feed Pump (11) Glow Relay (22) DPF Differential Pressure (30) Parked Regeneration Switch
(3) CAN1 Connector (12) Glow Plug Sensor (∆P) (31) Parking Switch
(For Service) (13) Injector 1 (23) SCV (Suction Control Valve) (32) Regeneration Inhibit Switch
(4) CAN2 Connector (14) Injector 2 (24) Fuel Temperature Sensor (33) Neutral Switch
(For OEM Machine) (15) Injector 3 (25) Coolant Temperature Sensor (34) Oil Switch
(5) EGR Valve (16) Injector 4 (26) Rail Pressure Sensor (35) DPF Temperature Sensor (T0)
(6) Starter (17) Crankshaft Position Sensor (27) Boost Sensor (36) DPF Temperature Sensor (T1)
(7) Air Flow Sensor (18) Camshaft Position Sensor (28) Intake Air Temperature (37) DPF Temperature Sensor (T2)
(8) Intake Throttle Valve (19) Accel Sensor 1 Sensor
(9) Starter Relay (20) Accel Sensor 2 DPF: Diesel Particulate Filter
NOTE
9Y1200199CRM0050US0
1-M12
V2607-CR-TIE4B, V3307-CR-TIE4B
(1) Main Relay (8) Starter Relay (17) Camshaft Position Sensor (24) Rail Pressure Sensor
(2) Fuel Feed Pump (9) Battery (18) Accel Sensor 1 (25) Boost Sensor
(3) CAN1 Connector (10) Glow Relay (19) Accel Sensor 2 (26) Intake Air Temperature
(For Service) (11) Glow Plug (20) Vehicle Speed Sensor Sensor
(4) CAN2 Connector (12) Injector 1 (21) SCV (Suction Control Valve) (27) Stop Switch
(For OEM Machine) (13) Injector 2 (22) Fuel Temperature Sensor (28) Neutral Switch
(5) EGR Valve (14) Injector 3 (23) Coolant Temperature Sensor (29) Oil Switch
(6) Starter (15) Injector 4
(7) Air Flow Sensor (16) Crankshaft Position Sensor
NOTE
9Y1200199CRM0051US0
1-M13
[5] AVAILABLE DATA MONITOR SIGNALS (LEVEL 1)

(1) Monitor Items
Classification Signal Name Unit Terminal Name Terminal No.
Engine speed active flag – – –
Pulse / Cam speed active flag – – –
Rotary -1
signal Engine speed min (rpm) NE + / − E52 / E72
Machine speed * km/h SPD V14
Accelerator pedal position % – –
Accelerator pedal position sensor 1
V APS1 V47
output voltage *
Accelerator pedal position sensor 2
V APS2 V67
output voltage *
Boost pressure kPa – –
Boost pressure sensor output
V PIM E67
voltage
Fuel temperature °C – –
Fuel temperature sensor output
V THF E48
voltage
Input Analog Coolant temperature °C – –
signal
Coolant temperature sensor output
V THW E66
voltage
Intake air temperature °C – –
Intake air temperature sensor output
V THA E47
voltage
Atmospheric pressure kPa – –
Atmospheric pressure sensor output
V PATM –
voltage
V18,
V38,
Battery voltage V +BP
V58,
V78
Key switch – IG-SW V13, V33
Digital
Starter switch – STA-SW V12
signal
Neutral switch * – N-SW V30
NOTE
• The signals marked with * are inputs from ECU for machine through CAN. Terminal names and terminal
numbers have become invalid.
9Y1200199CRM0034US0
1-M14

3
Final fuel injection quantity mm /st – –
Target rail pressure MPa – –
Actual rail pressure MPa MPa – –
Rail pressure sensor output voltage V PFUEL 1/2 E68 / E49
Target suction control valve (SCV)
mA – –
current
Actual suction control valve (SCV)
mA SCV+ / − E09, E29 / E10, E30
current
Pump learning condition – – –
Pump difference learning correction
mA – –
value
Pressure feedback integral guard
– – –
Basic flag
control Engine stop flag – – –
signal Low temperature start mode flag – – –
Registration history (#1 cylinder) – – –
Output Registration history (#2 cylinder) – – –
Number of registrations
– – –
(#1 cylinder)
– – –
(#2 cylinder)
– – –
(#3 cylinder)
– – –
(#4 cylinder)
Exhaust gas recirculation (EGR)
% – –
valve target position
% – –
Actuator valve actual position
– – (CAN)
position sensor output
Glow (air heater) relay – GRLY V24
9Y1200199CRM0035US0
1-M15

Differential pressure 1 output
V DPS E45
voltage
Exhaust gas temperature 0 output
V IDOC E44
voltage
V ODOC E63
voltage
V ODPF E43
voltage
Intake air temperature built-in MAF
V IATS V49
output voltage
Intake throttle valve lift output
V ITS V48
voltage
Differential pressure 1 kPa – –
Exhaust gas temperature 0 °C – –
Mass air flow for intake throttle kg/h – –
Intake air temperature built-in MAF °C – –
Target intake throttle valve opening % – –
Intake throttle final duty control
% – –
quantity
DPF
Output
data Intake throttle valve lift % – –
PM sedimentation quantity 1 mg – –
PM sedimentation quantity 2 mg – –
Final fuel injection quantity
L – –
multiplication quantity
Target mass air flow kg/h – –
Pump learning end time h – –
Hour meter h – –
DPF auto regeneration last active
sec – –
time
Regeneration running time min – –
Source address of TSC1 – – –
Parking SW – – –
Neutral SW – – –
DPF auto regeneration inhibit SW – – –
DPF manual regeneration force SW – – –
Oil pressure SW – – –
-1
Target speed of isochronous control min (rpm) – –
DPF regeneration control level – – –
DPF regeneration control status – – –
9Y1200199CRM0036US0
1-M16
(2) Normal Value

During
During
Classifica- Engine During No-load
Signal Name Unit Idling Accelera-
tion Stops Start-Up Maximum
tion
Speed
0 → 800 Approx. Approx.
Approx.
min-1 (Ordinary 800 2700
Engine speed 0 800 →
(rpm) tempera- (After (After
2700
Pulse / ture) warm-up) warm-up)
Rotary Engine speed active
signal – OFF ON ON ON ON
flag
Cam speed active flag – OFF ON ON ON ON
Machine speed km/h When the machine stopped: 0
Final accelerator pedal
% 0 0 0 0 → 100 100
position opening
Accelerator pedal
position sensor 1 V
output voltage
Sensor unused by CAN input
Accelerator pedal
position sensor 2 V
output voltage
Approx. Approx. Approx.
Boost pressure kPa – –
100 100 100
Boost pressure sensor Approx. Approx. Approx.
V – –
output voltage 1.0 1.0 1.0
In- Fuel temperature °C Representative value:
put Approx. 20 °C (68 °F) → Approx. 2.4 V
Fuel temperature Representative value:
Analog V
sensor output voltage Approx. 40 °C (104 °F) → Approx. 1.5 V
signal
Coolant temperature °C Representative value:
Approx. 20 °C (68 °F) → Approx. 2.4 V
Coolant temperature Representative value:
V
sensor voltage output Approx. 80 °C (176°F) → Approx. 0.5 V
Intake air temperature °C Representative value:
Intake air temperature Representative value:
V
sensor output voltage Approx. 40 °C (104 °F) → Approx. 1.5 V
Atmospheric pressure kPa Representative value:
Atmospheric pressure Approx. 100 kPa → 3.7 V (Depending on the atmospheric
V pressure)
sensor output voltage
When stopped: Approx. 12.5 V
When operating: Approx. 14 V
Battery voltage V
(Depends on the battery charging condition, whether or not
there is a load voltage, rotation speed)
Key Switch – ON ON ON ON ON
Digital
Start switch – OFF ON OFF OFF OFF
signal
Neutral switch – During neutral: ON
9Y1200199CRM0037US0
1-M17
During
During
Engine During No-load
Classification Signal Name Unit Idling Accelera-
Stops Start-Up Maximum
tion
Speed
0 → 80 Approx.
0 Approx. 12 Approx. 30
Final fuel injection mm3 (Ordinary 12→75
(Indication (After (After
quantity /st tempera- (After
value - 50) warm-up) warm-up)
ture) warm-up)
Depends on the rotation speed, load (After warm-up)
When idling: Approx. 40 to 50 MPa
(410 to 500 kgf/cm2, 5800 to 7200 psi)
Target rail pressure MPa During no-load maximum speed: 95.0 to 115 MPa
(969 to 1170 kgf/cm2, 13800 to 116600 psi)
During acceleration : 95.0 to 130 MPa
(969 to 1320 kgf/cm2, 13800 to 18800 psi)
Actual rail pressure Approx. the same as the target value
MPa –
Mpa (Follow to the target value)
When stopped: Approx. 1.0 V
Rail pressure sensor
V When idling: 1.65 to 1.80 V
output voltage
Basic During no-load maximum speed: 2.50 to 2.85 V
Out- During acceleration: 2.5 to 3.3 V
control
put
signal Target suction control 1700 to Approx. Approx. Approx.
mA –
valve (SCV) current 2000 1800 1400 1600
Actual suction control Approx. the same as the target value
mA
valve (SCV) current (Follow to the target value)
Normally 2 or 3*1
Pump learning Indicates the following depending on the learning status: 255
–
condition (Default value), 1 (Provisional learning completion), 0 (Actual
learning), 2 (Actual learning completion), 3 (Relearning)
Pump deviation
learning correction mA ±200 mA (Guideline *2)
value
Pressure feedback
– Normally OFF
integral guard flag
Engine stop flag – ON OFF OFF OFF OFF
Low temperature start
– OFF ON OFF OFF OFF
mode flag
NOTE
• *1: Very occasionally, it does not shift from 3 to 2. If there is an engine malfunction on the status above,
perform the forced-relearning.
• *2: As the following value of A varies depending on pump, the table above is for guideline. If the value of
A has a wider gap than the initial learning value, there may be out of the range of the above table.
A net normal value is the value that provided by the forced-learning several times: Compared with A
12 V spec: A - 100 ≤ normal value ≤ A + 50
The current shall be used as a reference (guideline) only as this value varies depending on the pump
used.
1-M18
During
During
Classifica- Engine During No-load
Signal Name Unit Idling Accelera-
tion Stops Start-Up Maximum
tion
Speed
Exhaust gas
recirculation (EGR) % Depends on the rotation speed, load and temperature
valve target position
Exhaust gas
Approx. the same as the target EGR position
Actua- recirculation (EGR) %
(Follow to the target value)
tor valve actual position
Exhaust gas
16 to 106 (CAN communication data)
recirculation (EGR) –
(Valve lift : 0 to 10 mm)
position sensor output
Glow (air heater) relay – Only during cold start-up (before-and-after): ON
Differential pressure 1 kPa
Input range : –1.7 to 34.5 kPa
Differential pressure 1 Output range : 0.5 to 4.5 V
V
sensor output voltage
Exhaust gas
°C Representative value:
temperature 0
Exhaust gas Representative value :
temperature 0 sensor V Approx. 250 °C (482 °F) → Approx. 2.3 V
output voltage
Exhaust gas
Out- °C Representative value :
temperature 1
put Approx. 100 °C (212 °F) → Approx. 4.4 V
output voltage
Exhaust gas
DPF °C Representative value :
temperature 2
data Approx. 100 °C (212 °F) → Approx. 4.4 V
output voltage
Intake air temperature
°C Representative value :
built-in MAF
Approx. 20 °C (68 °F) →Approx. 3.1 V
Intake air temperature Representative value :
built-in MAF sensor V Approx. 80 °C (176 °F) → Approx. 0.9 V
output voltage
Mass air flow for intake
kg/h 12.96 to 698.4 (1.239 to 4.598 V)
throttle
100 100
Intake throttle valve lift % 100 to 0
(Full open) (Full open)
Intake throttle valve lift Approx. Approx.
V 0.5 to 4.375 V
output voltage 0.5 V 0.5 V
9Y1200199CRM0038US0
1-M19
[6] ECU TERMINAL LAYOUT

(1) ECU Terminal Layout 1 (Engine Side)
No. Terminal Name Signal Name

E01 ITV+ INTAKE THROTTLE VALVE MOTOR (+)
E02 – –
E03 – –
E04 – –
E05 – –
E06 – –
E07 – –
E08 – –
E09 SCV+ SCV (SUCTION CONTROL VALVE) (+)
E10 SCV− SCV (SUCTION CONTROL VALVE) (−)
E11 – –
E12 – –
E13 A-VCC1 SENSOR (POWER SUPPLY)
E14 COM1 INJECTION COMMON 1
E15 TWV1 INJECTION DRIVE1 (No.1 CYLINDER)
E17 – –
E21 ITV− INTAKE THROTTLE VALVE MOTOR (−)
E22 – –
E23 – –
E24 – –
E25 – –
E26 – –
E27 – –
E28 – –
E29 SCV+ SCV (SUCTION CONTROL VALVE) (+)
E30 SCV− SCV (SUCTION CONTROL VALVE) (−)
1-M20

E31 – –
E32 – –
E33 A-VCC2 SENSOR (POWER SUPPLY)
E37 – –
E41 – –
E42 – –
E43 ODPF OUTLET DPF (DPF Exhaust Gas Temperature SENSOR T2)
E44 IDOC INLET DOC (DPF Exhaust Gas Temperature SENSOR T0)
E45 DPS DIFFERENTIAL PRESSURE SENSOR
E46 – –
E47 THA INTAKE AIR TEMPERATURE SENSOR
E48 THF FUEL TEMPERATURE SENSOR
E49 PFUEL2 RAIL PRESSURE SENSOR 2
E50 – –
E51 – –
E52 NE+ CRANKSHAFT POSITION SENSOR (+)
E53 G-VCC CAMSHAFT POSITION SENSOR (POWER SUPPLY)
E54 G-GND CAMSHAFT POSITION SENSOR (GROUND)
E55 INJ-SLD SHIELD GROUND
E56 THA RTN INTAKE AIR TEMPERATURE SENSOR RTN
E57 A-GND3 DPF Exhaust Gas Temperature SENSOR T0, T1, T2 GROUND
E58 THF RTN FUEL TEMPERATURE SENSOR RTN
E59 – –
E60 – –
1-M21

E61 – –
E62 – –
E63 ODOC OUTLET DOC (DPF EXHAUST GAS TEMPERATURE SENSOR T1)
E64 – –
E65 – –
E66 THW COOLANT TEMPERATURE SENSOR
E67 PIM BOOST PRESSURE SENSOR
E68 PFUEL1 RAIL PRESSURE SENSOR 1
E69 AFS MASS AIR FLOW SENSOR
E70 – –
E71 – –
E72 NE- CRANKSHAFT POSITION SENSOR (−)
E73 G+ CAMSHAFT POSITION SENSOR (+)
E74 – –
E75 NE-SLD CRANKSHAFT POSITION SENSOR SHIELD GROUND
E76 THW RTN COOLANT TEMPERATURE SENSOR RTN
E77 PIM RTN BOOST PRESSURE SENSOR RTN
E78 PFUEL RTN RAIL PRESSURE SENSOR RTN
E79 – –
E80 – –
9Y1200199CRM0039US0
(1) ECU Wiring Harness (4) ECU Wiring Harness

Connector 1 (Engine Side) Connector 2 (Machine Side)
(2) ECU Connector 1 (5) E01 Pin Position
(Engine Side) (6) V01 Pin Position
(3) ECU Connector 2
(Machine Side)
9Y1200199CRM0040US0
1-M22
(2) ECU Terminal Layout 2 (Machine Side)

V01 +BF BATTERY+ (MAIN RELAY)
V02 – –
V03 MREL MAIN RELAY
V04 – –
V05 STA-RLY STARTER RELAY
V06 OIL-LAMP OUTPUT FOR OIL PRESSURE DECREASE LAMP SIGNAL
V07 GL-LAMP OUTPUT FOR GLOW (AIR HEATER) LAMP SIGNAL
V08 STOP-LAMP OUTPUT FOR ENGINE STOP LAMP SIGNAL
V09 ENG-WL OUTPUT FOR ENGINE WARNING LIGHT SIGNAL
V10 – –
V11 – –
V12 STA-SW STARTER SWITCH
V13 IG-SW KEY SWITCH ON
V14 SPD MACHINE TRAVEL SPEED SIGNAL
V15 – –
V16 CAN1-L CAN1-L (FOR SERVICE)
V17 CAN2-L CAN2-L (FOR MACHINE)
V18 +BP BATTERY+ (MAIN RELAY)
V19 BATT BATTERY+
V20 CASE-GND CASE GROUND
V21 +BF BATTERY+ (MAIN RELAY)
V22 – –
V23 MREL MAIN RELAY
V24 GRLY GLOW (AIR HEATER) RELAY
V25 – –
V26 AR-LAMP ACTIVE REGENERATION LAMP
V27 OH-LAMP OUTOUT FOR OVERHEAT LAMP SIGNAL
V28 PRR-LAMP PARKED REGENERATION REQUEST LAMP
V29 OIL-SW OIL PRESSURE DECREASE SWITCH
V30 N-SW NEUTRAL SWITCH
1-M23

V31 – –
V32 STOP-SW EMERGENCY STOP SWITCH
V33 IG-SW KEY SWITCH ON
V34 – –
V35 – –
V36 CAN1-H CAN1-H (FOR SERVICE)
V37 CAN2-H CAN2-H (FOR MACHINE)
V39 P-GND POWER GROUND
V40 S-GND SIGNAL GROUND
V41 – –
V42 – –
V43 – –
V44 – –
V45 A-GND10 MASS AIR FOLW SENSOR GROUND
V46 APS1-GND ACCELERATOR POSITION SENSOR1 (GROUND)
V47 APS1 ACCELERATOR POSITION SENSOR1
V48 ITS INTAKE THROTTLE POSITION SENSOR
V49 IATS INTAKE AIR TEMPERATURE SENSOR (IN MASS AIR FLOW SENSOR)
V50 A-VCC10 ACCELERATOR POSITION SENSOR2 (POWER SUPPLY)
V51 A-VCC11 ACCELERATOR POSITION SENSOR1 (POWER SUPPLY)
V52 – –
V53 – –
V54 – –
V55 – –
V56 – –
V57 – –
V60 S-GND SIGNAL GROUND
1-M24

V61 – –
V62 – –
V63 – –
V64 – –
DIFFERENTIAL PRESSURE SENSOR GROUND /
V65 A-GND11
INTAKE THROTTLE POSITION SENSOR GROUND
V66 APS2-GND ACCELERATOR POSITION SENSOR2 (GROUND)
V67 APS2 ACCELERATOR POSITION SENSOR2
V68 – –
V69 – –
V70 – –
V71 A-VCC12 DIFFERENTIAL PRESSURE SENSOR (POWER SUPPLY)
V72 – –
V73 – –
V74 R1-SW REGENERATION INHIBIT SWITCH
V75 P-SW PARKING SWITCH
V76 – –
V77 – –
9Y1200199CRM0041US0
(1) ECU Wiring Harness (4) ECU Wiring Harness

Connector 1 (Engine Side) Connector 2 (Machine Side)
(2) ECU Connector 1 (5) E01 Pin Position
(Engine Side) (6) V01 Pin Position
(3) ECU Connector 2
(Machine Side)
9Y1200199CRM0040US0
1-M25
SERVICING
CONTENTS
1. GENERAL....................................................................................................................................1-S1
[1] OVERALL DIAGNOSTIC PROCEDURE...............................................................................1-S1
[2] QUESTIONING .....................................................................................................................1-S2
[3] LIST OF MALFUNCTION SYMPTOM ...................................................................................1-S5
[4] ACTIONS FOR NON-REOCCURRING MALFUNCTIONS ...................................................1-S6
2. DIAGNOSTIC TOOL CONNECTION PROCEDURE ..................................................................1-S8
[1] DIAGNOSTIC CONNECTOR POSITIONS ...........................................................................1-S8
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE ............................................................1-S8
[3] CHECKING THE COMMUNICATION OPERATION OF THE INTERFACE (DST-i) .............1-S9
[4] CHECKING THE OPERATION OF THE ECU ....................................................................1-S10
(1) Starting Diagmaster.......................................................................................................1-S10
(2) DST-i Communication Settings .....................................................................................1-S12
3. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE LEARNING .............................................1-S16
4. DIAGNOSIS BY MALFUNCTION SYMPTOM...........................................................................1-S18
[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM ...........................................................1-S18
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM.....................................................................1-S22
(1) Engine Warning Light Comes On ..................................................................................1-S22
(2) Engine Does Not Start...................................................................................................1-S22
(3) Takes A Long Time Before Engine Starts .....................................................................1-S26
(4) Idle Failure.....................................................................................................................1-S30
(5) Engine Noise .................................................................................................................1-S33
(6) High fuel consumption ...................................................................................................1-S35
(7) Poor Acceleration (Insufficient Output)..........................................................................1-S40
(8) Abnormal Black Smoke Emitted ....................................................................................1-S45
(9) Abnormal White Smoke Emitted....................................................................................1-S49
(10)Engine Stalls On Deceleration ......................................................................................1-S54
5. DIAGNOSTIC PROCEDURE BY DTC ......................................................................................1-S58
[1] DTC LIST.............................................................................................................................1-S58
[2] DIAGNOSTIC PROCEDURE BY DTC ..............................................................................1-S121
(1) NE - G Phase Shift (DTC P0016 / 636-7)....................................................................1-S124
(2) Intake Air Temperature Built-in MAF Sensor: Abnormality (DTC P0072 / 171-4,
DTC P0073 / 171-3) ....................................................................................................1-S125
(3) Pressure Limiter Emergency Open (DTC P0087 / 633-7) ...........................................1-S128
(4) High Rail Pressure (DTC P0088 / 157-0) ....................................................................1-S133
(5) SCV Stuck (DTC P0089 / 1347-7)...............................................................................1-S138
(6) Fuel Leak (in High Pressured Fuel System) (DTC P0093 / 1239-1) ...........................1-S143
(7) Intake Air Volume: Low (DTC P0101 / 132-1) .............................................................1-S148
(8) MAF Sensor Abnormality (DTC P0102 / 132-4, P0103 / 132-3)..................................1-S149
(9) Intake Air Temperature: High (Inter Cooler Model Only) (DTC P0111 / 172-0)...........1-S151
(10)Intake Air Temperature Error (DTC P0112 / 172-4, P0113 / 172-3) ...........................1-S152
(11)Coolant Temperature Sensor Abnormality (DTC P0117 / 110-4, P0118 / 110-3) .......1-S155
(12)Fuel High Temperature (DTC P0181 / 174-0) .............................................................1-S158
(13)Fuel Temperature Sensor Abnormality (DTC P0182 / 174-4, P0183 / 174-3) ............1-S159
(14)Rail Pressure Sensor Abnormality (DTC P0192 / 157-4, P0193 / 157-3) ...................1-S162
(15)Injector Charge Voltage: High (DTC P0200 / 523535-0).............................................1-S166
(16)Open Circuit of Harness/Coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 / 654-3,
P0204 / 652-3).............................................................................................................1-S168
(17)Engine Overheat (DTC P0217 / 110-0) .......................................................................1-S171
(18)Engine Overrun (DTC P0219 / 190-0).........................................................................1-S173

(19)Boost Pressure Sensor Abnormality (DTC P0237 / 102-4, P0238 / 102-3) ................1-S174
(20)Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335 / 636-8, P0336
/ 636-2) ........................................................................................................................1-S178
(21)Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340 / 723-8, P0341 /
723-2) ..........................................................................................................................1-S183
(22)Air Heater Relay Driving Circuit Abnormality (DTC P0380 / 523544-3 / 523544-4) ...1-S187
(23)EGR Actuator Abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4,
P0409 / 523572-4) .......................................................................................................1-S191
(24)Oil Pressure Error (P0524 / 100-1)..............................................................................1-S194
(25)Exhaust Gas Temperature Sensor 1 (T1) Abnormality (DTC P0543 / 3242-4,
P0544 / 3242-3) ...........................................................................................................1-S196
(26)Exhaust Gas Temperature Sensor 0 (T0) Abnormality (DTC P0546 / 4765-4,
P0547 / 4765-3) ...........................................................................................................1-S199
(27)Battery Voltage Abnormality (DTC P0562 / 168-4, P0563 / 168-3) .............................1-S202
(28)QR Data Abnormality (DTC P0602/523538-2, P0602/523538-7) ...............................1-S205
(29)ECU Flash-ROM and CPU Abnormality (DTC P0605 / 628-2, P0606 / 1077-2,
P0606/ 523527-2) ........................................................................................................1-S206
(30)Injector Charge Voltage Abnormality (DTC P0611 / 523525-1) ..................................1-S208
(31)SCV Drive System Abnormality (DTC P0628 / 1347-4, P0629 / 1347-3)....................1-S210
(32)Sensor Supply Voltage 1 Abnormality (DTC P0642 / 3509-4, P0643 / 3509-3) ..........1-S214
(33)Sensor Supply Voltage 2 Abnormality (DTC P0652 / 3510-4, P0653 / 3510-3) ..........1-S216
(34)Main Relay is Locked in Closed Position (DTC P0687 / 1485-2) ................................1-S218
(35)Pump Seizing (DTC P1274 / 523539-2, P1275 / 523540-2) .......................................1-S221
(36)EEPROM Check Sum Error (DTC P1990 / 523700-13, P1991 / 523701-13, P1992
/ 523702-13) ................................................................................................................1-S226
(37)Intake Throttle Feedback Error (DTC P2108 / 523580-2) ...........................................1-S228
(38)Accelerator Position Sensor 1 Abnormality (DTC P2122 / 91-4, P2123 / 91-3) ..........1-S230
(39)Accelerator Position Sensor 2 Abnormality (DTC P2127 / 29-4, P2128 / 29-3) ..........1-S234
(40)Accelerator Position Sensor Error (CAN) (DTC P2131 / 523543-2)............................1-S238
(41)Accelerator Position Sensor Correlation Error (DTC P2135 / 91-2) ............................1-S240
(42)Common 1 System Injector Drive Circuit Open (DTC P2146 / 523523-2) ..................1-S241
(43)Common 1 TWV Actuation System Short (DTC P2147 / 523523-4, P2148 /
523523-3) ....................................................................................................................1-S244
(44)Common 2 System Injector Drive Circuit Open (DTC P2149 / 523524-2) ..................1-S248
(45)Common 2 TWV Actuation System Short (DTC P2150 / 523524-4, P2151 /
523524-3) ....................................................................................................................1-S251
(46)Barometric Pressure Sensor Error (DTC P2228 / 108-4, P2229 / 108-3) ...................1-S255
(47)EGR (DC Motor) Abnormality (DTC P2413 / 523575-7, P2414 / 523576-2, P2415
/ 523577-2) ..................................................................................................................1-S257
(48)Exhaust Gas Temperature Sensor 2 (T2) Abnormality (DTC P242C / 3246-4,
P242D / 3246-3) ..........................................................................................................1-S260
(49)Differential Pressure Sensor 1 Abnormality (DTC P2454 / 3251-4, P2455 / 3251-3) ...1-S263
(50)Intake Throttle Lift Sensor Abnormality (DTC P2621 / 523583-4, P2622 /
523582-3) ....................................................................................................................1-S267
(51)Emission Deterioration (DTC P3001 / 3252-0) ............................................................1-S269
(52)Exhaust Gas Temperature Sensor 0: Emergency High (DTC P3002 / 4765-0) ..........1-S271
(55)Excessive PM3 (DTC P3006 / 3701-15) .....................................................................1-S277
(56)Excessive PM4 (DTC P3007 / 3701-16) .....................................................................1-S278
(57)Excessive PM5 (DTC P3008 / 3701-0) .......................................................................1-S279
(58)Boost Pressure Low (DTC P3011 / 132-15) ................................................................1-S280
(59)Low Coolant Temperature in Parked Regeneration (DTC P3012 / 523589-17)..........1-S282
(60)Parked Regeneration Time Out (DTC P3013 / 523590-16) ........................................1-S283
(61)All Exhaust Gas Temperature Sensor Failure (DTC P3018 / 523599-0) ....................1-S285
(62)Initial Pump-calibration Incomplete (DTC P3019 / 523600-0) .....................................1-S286
(63)High Exhaust Gas Temperature After Emergency High Temperature DTC (DTC
P3023 / 523601-0) .......................................................................................................1-S287
(64)High Frequency of Regeneration (DTC P3024 / 523602-0) ........................................1-S288

(65)Over Heat Pre-caution (DTC P3025 / 523603-15) ......................................................1-S289
(66)CAN2 Bus Off (DTC U0075 / 523547-2) .....................................................................1-S290
(67)No Communication with EGR (DTC U0076 / 523578-2) .............................................1-S292
(68)CAN1 Bus Off (DTC U0077 / 523604-2) .....................................................................1-S294
(69)CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 / 523592-2,
U0084 / 523593-2, U0085 / 523594-2, U0086 / 523595-2, U0087 / 523596-2,
U0089 / 523598-2).......................................................................................................1-S295
6. INSPECTION PROCEDURE FOR EACH SYSTEM ...............................................................1-S299
[1] AIR INTAKE SYSTEM INSPECTION PROCEDURE ........................................................1-S299
[2] FUEL SYSTEM INSPECTION PROCEDURE...................................................................1-S300
[3] ELECTRIC SYSTEM INSPECTION PROCEDURE ..........................................................1-S305
(1) Basics Of Checking Electrical / Electronic Circuit Systems.........................................1-S305
(2) Connector Connection Fault Verification Method ........................................................1-S308
(3) Checking The Power And Ground System (Main Relay, ECU Circuit)........................1-S309

1. GENERAL
[1] OVERALL DIAGNOSTIC PROCEDURE
9Y1200199CRS0608US0
1-S1
[2] QUESTIONING
• Use the trouble check sheet to ensure that the customer's explanation is fully understood.
• Accurately judge information concerning the malfunction.
Grasp the situation firmly, using five 5W1H (Who, What, When, Where, Why, How) as a basis.
Ex: Low ambient temperature, starting, normal conditions, proximity to engine, metallic noise, etc.
(Reference)
Do not ask random questions. Ask questions that will aid in narrowing down the possible malfunctioning system
while making educated guesses based on the malfunction symptoms.
9Y1200199CRS0609US0
Questioning Points
What? Malfunction symptom
When? Date, time, frequency of occurrence.
Where? Field conditions
What were conditions like at the time of Driving conditions, operating conditions,
malfunction? weather.
What happened? Type of malfunction.
9Y1200199CRS0610US0
Trouble Check Sheet for KUBOTA Common Rail System
When the machine is received from the customer, it is
necessary to verify the "malfunction symptoms" and the "generated
malfunction data" with the customer. This is performed based on the
trouble check sheet.
(1) Trouble Check Sheet
Because:
• The malfunction symptom may not be reproduced at the
workshop.
• The customer's complaint does not always match the
malfunction.
• If the person performing repairs is not working from the correct
malfunction symptoms, man-hours will be wasted.
The question chart can aid the service person in diagnosing,

repairing and verifying repair work.
9Y1200199CRS0611US0
1-S2
Trouble Check Sheet

Machine details
Customer name
Customer
address
Machine serial
Machine model
number
Engine serial
Purchase date
number
Hourmeter
Repair date hours
indicator
Warranty
Warranty Judgment Yes No
Injector Supply Pump
Defective parts Common rail Fuel Filter
Others ( )
Replace parts details
Quantity Units Part number
Supply Pump
Serial number
Quantity Units Part number
Cylinder 1 ( ) Cylinder 2 ( )
Serial number
Injector Cylinder 3 ( ) Cylinder 4 ( )
Injector 1 Injector 2
Defective injector
Injector 3 Injector 4
Injector Supply Pump
Actual part replacement Common rail Fuel Filter
ECU Others ( )
Customer complaint
a. No initial combustion b. No complete combustion
1. Engine no start
c. No cranking
a. Engine crank slowly
2. Difficult to start
b. Others ( )
a. Incorrect first idle b. Noise
c. Hunting idle from ( ) to ( ) min-1 (rpm)
d. High idling ( ) min-1 (rpm)
3. Poor idling
e. Low idling ( ) min-1 (rpm)
f. Rough
g. Others ( )
a. Hesitation b. Surging
4. Poor driveability c. Knocking d. Lack of power
e. Others ( )
a. Black b. White
5. Abnormal smoke
c. Others ( )
a. Large quantity b. Blurred
6. Fuel leakage Injector Supply Pump
Leaking from:
Others ( )
7. Engine not stop
8. Engine stall
9. Others
9Y1200199CRS0612US0
1-S3
Condition when problem occurs ( Duplicated answers can be possible )

a. Fine b. Cloudy
c. Rainy d. Snow
1. Weather
e. Flood
f. Others ( )
2. Outdoor temperature Approx. °C ( °F)
3. Altitude Approx. m
a. Cold Write the position of the indicator on coolant
temperature gauge.
b. Warming up
c. After warming up
4. Engine coolant d. Any temperature
e. Others ( )
a. Starting b. Just after starting

c. Idling d. Racing
5. Engine operation e. Acceleration f. Deceleration
g. While at work
h. Others ( )
a. Constant b. Once only
6. Problem frequency
c. Sometime ( Time per day/month )
7. Engine warning light Turn on a light Turn off a light
Fill the parts in if you use optional parts or non-genuine parts for electrical, intake/exhaust and fuel system.
8. Optional parts
( )
Dealer check
1. Duplicate the problem a. Yes (Duplicate) b. No (Not occur)
a. Abnormal (What is code )
2. Diagnosis trouble code
b. Normal (No code)
a. Normal b. Cracked
3. Appearance c. Discolored
d. Others ( )
a. Normal
4. Fuel condition
b. Abnormal ( )
9Y1200199CRS0613US0
1-S4
[3] LIST OF MALFUNCTION SYMPTOM

Malfunctions and corresponding symptoms resulting from the CRS may also be generated from other sources,
such as the engine (mechanical parts), the fuel system, etc. When performing CRS troubleshooting, the aim is not to
quickly determine that the CRS is the cause of a malfunction. Rather, the cause should be exhaustively considered
while verifying the causes listed below.
Malfunction
Area of Fault Cause Action
symptom
Fuel system Poor fuel Switch to the correct fuel (No.2-D diesel fuel).
Engine oil deterioration. Change engine oil.
Replace with the appropriate engine oil (API
Engine overheat Inappropriate engine oil.
Lubrication system Service Classification CF grade or higher).
Faulty oil pump. Replace oil pump.
Insufficient engine oil level Add engine oil.
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Air mixed with the fuel system. Perform fuel system air bleeding.
Fuel system Faulty fuel filter. Replace fuel filter.
Insufficient Poor or inappropriate fuel. Switch to the correct fuel (No.2-D diesel fuel).
output
Worn cylinder liner and the piston ring
Engine of the piston. (Low compression Overhaul engine.
pressure)
Other Overheat Refer to "Engine Overheat" items.
Intake system Clogged air cleaner element. Clean or replace air cleaner element.
Insufficient fuel. Add fuel and perform fuel system air bleeding.
Fuel system clogged. Clean the fuel system.
Large amount of intermixing water to
the water separator, element clogging Clean or replace.
and deformation.
Fuel system
Air being introduced through fuel
Tighten connections.
system connection points.
Clogged fuel filter Replace fuel filter.
Fuel feed pump operation fault. Replace fuel feed pump.
Injection pipe connection loose. Tighten connecting nut.
Faulty starting Battery fault Inspect battery.

Faulty starter wiring. Replace starter wiring.
Tighten battery terminal connections, or replace
Loose battery cable.
Electrical system cables.
Faulty starter operation. Replace starter assembly.
Starting assist device (glow heater)
Replace starting assist device (glow heater).
fault.
Lubrication system Excessive engine oil viscosity. Replace with oil of appropriate viscosity.
Burnt pistons. Replace piston, piston ring and cylinder block.
Engine Burnt main bearing. Replace main bearing and crankshaft.
Low compression pressure. Overhaul engine.
Other Ring gear damage. Flywheel / starter replacement.
Poor valve clearance Adjust valve clearance.
Poor valve seat contact. Break in valve and valve seat, or replace.
Idle fault Engine Low coolant temperature. Perform warm-up operation.
Large difference in cylinder-to cylinder
Overhaul engine.
compression pressure.
9Y1200199CRS0614US0
1-S5
[4] ACTIONS FOR NON-REOCCURRING MALFUNCTIONS

• In cases where the malfunction does not reoccur, perform the actions below to determine the cause of the
malfunction.
• In cases where the malfunction does not reoccur at the dealer, sales company or workshop, perform the work that
actually caused the malfunction.
• Check the fuel pipe system [including the fuel feed pump (electromagnetic pump) and tank], intake system and
exhaust system.
• If the malfunction does not reoccur, there may be an ECU malfunction. For diagnostic purposes only, temporarily
replace the ECU with a unit that functions normally to perform the check procedure. At the same time, be sure to
perform difference learning for the supply pump and input QR Code for injectors. If there would be no change,
ECU should not be replaced.
9Y1200199CRS0615US0
Malfunction symptom
Idle speed
Action abnormal
Engine will not
Dead battery engine stall
start
sluggish poor
acceleration
Verify that there is no Diagnostic Trouble Code (DTC) stored in the memory. –  
Using the trouble check sheet as a base, perform a reoccurrence test in
"Reoccurrence" mode. Use this data (engine ECU (PCM) voltage value, etc.)   
to determine the cause of the malfunction.
Assume that an electrical system wiring harness or connector is the cause of
the malfunction and vibrate these components by hand to verify whether or
not a malfunction occurs and a DTC is generated.
–  
Assume that an electrical system female connector terminal is the cause of

the malfunction and verify that the connection points are not defective.
Recommended Tools: KOWA Precision Handling
Feeling Tool Set (KLM-10- 20) Depending on the terminal, a matching size
may not be available.
–  
Insert the male terminal that matches the shape of the female terminal and
check for looseness.
1-S6
Malfunction symptom
Idle speed
Action abnormal
Engine will not
Dead battery engine stall
start
sluggish poor
acceleration
Heat the accelerator sensor and other electrical components with a hair dryer.
Verify whether or not the voltage value (resistance value) changes.
NOTE
• Do not exceed 60 °C (140 °F) (still touchable by hand) when heating.
• Do not remove the component case and add heat directly to
electronic parts.
– – 
Verify whether or not malfunction symptoms occur under heavy engine loads
 – 
(headlights, A/C, wiper, etc. switches ON).
If any commercial electrical products have been installed, remove them and
  
verify whether or not the malfunction symptoms occur.
If it is thought that the malfunction occurs in rainy or high temperature weather, spray the machine
with water and verify whether or not the malfunction occurs.
NOTE
• Do not spray water directly onto the engine. Spray water mist on the entire surface of
the radiator to indirectly change the temperature and humidity of the engine
compartment.
• Do not spray water directly on electrical parts.
 
9Y1200199CRS0616US0
1-S7
2. DIAGNOSTIC TOOL CONNECTION PROCEDURE

[1] DIAGNOSTIC CONNECTOR POSITIONS
1. Refer to the operator's manual for this machine to check the
position for connecting the diagnosis tool.
(1) Terminal IG-SW (V13, V33) (a) CAN1 Connector
(2) Terminal CAN1-H (V36)
(3) Terminal S-GND (V60)
(4) Terminal CAN1-L (V16)
9Y1200199CRS0617US0
[2] DIAGNOSTIC TOOL CONNECTION PROCEDURE

IMPORTANT
• At first time usage, it is necessary to do "Communication Setting" with administrator user account.
• Prepare a PC on which the diagnostic software has already been installed.
• When connecting the diagnosis cable, ensure that the key switch on the machine side is OFF.
9Y1200199CRS0618US0
1. Start up a PC on which the diagnostic software has been
installed with administrator user account.
2. Connect the machine-side CAN1 connector (a) to the interface
connector (To Machine) (2) with the cable (To Machine) (1).
3. Connect the cable (USB) (4) to the USB connector (To PC) (3)
and then connect the USB cable to the USB port on PC.
4. Start the diagnostic software.
5. Select "Communication Setting" from "System Setting" in the
menu and execute. (Only when performing the initial settings.)
NOTE
• The USB port used while the "Communication Setting"
process, should always be used.
(1) Cable (To Machine) (5) DC Jack (Reserved)*
(2) Interface Connector (To Machine)
(3) USB Connector (To PC)*
(4) Cable (USB) (a) CAN1 Connector
* Rubber cap is attached to USB connector and DC jack each
9Y1200199CRS0619US0
1-S8
[3] CHECKING THE COMMUNICATION OPERATION OF THE

INTERFACE (DST-i)
The communication operation can be checked with the
illuminating condition of the five indicators on the DST-i unit.
If a communication error occurs, check the illuminating
condition of each indicator and repair or replace the malfunction
(including cable open circuits).
(1) Power Indicator (4) PC Communication (USB) Indicator
(2) Machine Communication Indicator (5) Error Detection Indicator
(3) PC Communication (Bluetooth)
Indicator
No. Type of LED Color LED Status Details

(1) Power Indicator Light OFF Power OFF
Green Power is supplied from machine cable or USB
Light ON
cable
(2) Machine Communication Indicator Light OFF Stand-by for communication
Green Light Flashing (synchronized
Communication in progress
with communication)
(3) PC Communication (Bluetooth) Indicator Bluetooth communication status
Blue Reserved
(Bluetooth is option)
(4) PC Communication (USB) Indicator USB cable has not connected to PC or USB
Light OFF
driver has not installed to PC
Light ON Stand-by for communication
Green
Light Flashing Stand-by for establishment of communication
Light Flashing (synchronized
Communication in progress
with communication)
(5) Error Detection Indicator Light OFF Normal conditions
Red
Light Flashing Error occurs
9Y1200199CRS0620US0
DST-i operation Status and Display Specification
 Light Operation During Normal Conditions
LED Status
DST-i Status
Power Machine USB Error
Power OFF    
Power ON    
USB stand-by status    
USB cable has not connected to PC or USB driver has not installed to PC    
Machine stand-by for communication    
Machine / USB communication in progress    
 Light Operation During Abnormal Operation

LED Status
DST-i Status
Power Machine USB Error
   
System Error
   
: Light OFF : Light ON : Light Flashing : Light Flashing (Synchronized

with communication)
9Y1200199CRS0621US0
1-S9
[4] CHECKING THE OPERATION OF THE ECU

(1) Starting Diagmaster
1. Double-click the "Diagmaster Launcher" icon on your computer desktop.
2. Select "Diagmaster" and then click the button.
3. Enter your "User ID" and "Password", and then click the button.
1-S10
4. The Diagmaster version screen appears.
5. The Diagmaster initial screen appears.
9Y1200199CRS1215US0
1-S11
(2) DST-i Communication Settings

1. From the "Menu", select "System Setting", and then "Communication Setting"
2. Click the interface select button.
1-S12
3. Select "DST-i", and then click the mouse button.
4. Click the button.
NOTE
• If you failed in the setting, confirm the connection and start again from procedure 1. to 4..
9Y1200199CRS0623US0
1-S13
5. From "Menu", select "Start Diagnosis", and then "New Diagnosis".
6. Click the button.
1-S14
7. The transmitting to ECU progress indicator appears.
8. The "Project" screen appears.
NOTE
• If you failed in the setting, confirm the content of procedure 6. and start again from procedure 5. to 8..
9Y1200199CRS0624US0
1-S15
3. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE

LEARNING
The four items below are used (including the supply pump difference learning).
1 Injector non-injection instruction
2 EGR actuation test From the active test screen
3 Air heater relay actuation test
4 Supply pump difference learning (clear the learning value) From the utility screen
9Y1200199CRS0625US0
(Operating conditions → specified tool conditions)
1. The conditions below are required for 1. Injector non-injection instruction and 4. Supply pump difference learning:
• Machine is stopped (KWPSPD = 0)
• Neutral switch is ON (XNEU = 1 or ON)
9Y1200199CRS0626US0
[Operation details]
1. Injector non-injection instruction
• Stop the injection for each cylinder injector in accordance with the requests from the tool.
Factory Engine vibration and noise are increased when the injection for the corresponding cylinder is stopped. The same results
specification must be attained from all the cylinders.
NOTE
• Do not judge with the corresponding cylinder only: also compare with the symptoms in the other
cylinders.
2. EGR actuation test
• Operate as shown in the diagram below and in accordance with the requests from the tool.
Low side: When target EGR valve openings of 0 % and 15 % are given alternately, there must not be disparity in the actual
Factory EGR valve opening.
specification High side: When target EGR valve openings of 35 % and 60 % are given alternately, there must not be disparity in the
actual EGR valve opening.
NOTE
• In some cases the actual opening may be different from the target opening.
The reason for this is because the learning value is always reflected for 0 lift, after being used for a long
time 0 points are shifted.
As such, the factory spec. is a relative evaluation and not an absolute evaluation.
(1) Opening (2) Operation check on the fully (3) Operation check on the fully (4) Fully open → impact
closed valve side open valve side dampening when fully closed
1-S16
3. Air heater relay actuation test
• Operate as shown in the diagram below and in accordance with the requests from the tool.
Factory
Operates repeatedly between ON and OFF in accordance with the specified cycle.
specification
4. Supply pump difference learning (clear the learning value)

IMPORTANT
• Must be performed after replacing the supply pump or ECU.
• Clear the learning completion flag in accordance with the requests from the tool. (Initialize)
Factory A difference learning completion message comes from the tool.
specification In addition, when the "Pump difference learning status" is checked with the monitor function, the status is 2 or 3.
NOTE
• When the diagnosis related pressure is detected, or when the actual rail pressure can not follow the target
pressure properly, perform pump difference learning and see what happens. (As there are some cases
that can not complete the relearning (status 2) from status 3.)
• This major symptom is extreme air in fuel line or filter clogged etc., and it normally occurred when
operating with the extreme vacuum pressure. Perform pump difference learning particularly when the
replacement of the filter (too much dirt) has not performed or the engine stalls by air in fuel line etc.
(The conditions of pump difference learning)
• Condition of the pump difference learning is ; After the engine has warmed up (after the thermostat is opened)
and the machine is stopped + the neutral switch is ON (neutral status) + the engine is idling (accelerator open
position 0 %).
9Y1200199CRS0627US0
1-S17
4. DIAGNOSIS BY MALFUNCTION SYMPTOM

[1] LIST OF MALFUNCTION CAUSES BY SYMPTOM
• Verify the malfunction symptom, and perform diagnosis according to the appropriate number.
• Many diagnostic procedures include check and verification of malfunction symptom while it occurs. Be sure to
perform work while verifying the malfunction symptom.
No. Malfunction Symptom Detail
1 Engine Warning Light Comes On. –
Engine does not crank (starter motor does not
rotate).
2 Engine Does Not Start. Engine stops when the key switch returns to the ON
position from the ST position (engine does not rotate
under its own power).
Takes a long time before engine starts.
3 Takes A Long Time Before Engine Starts.
May accompany idle failure.
Idle speed is lower than the standard value or
4 Idle Failure unstable.
Engine may stall.
Abnormal noises come from inside the engine.
5 Engine Noise
Engine sound is loud.
6 High Fuel Consumption Fuel consumption has increased significantly.
Acceleration is slower than before when depressing
the accelerator pedal.
7 Poor Acceleration (Insufficient Output)
Power feels insufficient compared with previously.
Large amount of rotation drop.
The amount of black smoke in the exhaust gas has
8 Black Smoke Emitted.
increased abnormally compared with previously.
The amount of white smoke in the exhaust gas has
9 White Smoke Emitted.
increased abnormally compared with previously.
Engine speed drops when releasing the accelerator
pedal.
Engine stalls on deceleration with the accelerator
10 Engine Stalls On Deceleration. pedal fully closed.
Engine stalls immediately after the machine stops
when decelerating with the accelerator pedal fully
closed.
9Y1200199CRS0628US0
1-S18
Malfunction Cause
Control System Engine
Coolant temperature sensor

Accelerator position sensor
Crankshaft position sesor
Camshaft position sensor

Damaged sensor pulsar gear
Damaged sensor pulsar gear
Low compression pressure
Insufficient engine oil level

Low engine oil viscosity
Air gap size is too large
Air gap size is too large
Valve clearance fault

Engine internal fault
False signal output
False signal output
Valve timing fault

No signal output
No signal output
No signal output
No signal output
Misadjustment
Malfunction Cause
Engine Warning   
1         
Light Comes On *1 *1 *2
Engine Does Not
2         
Start
Takes A Long
3 Time Before         
Engine Starts
4 Idle Failure         
5 Engine Noise       
High Fuel
6        
Consumption
Poor
Acceleration
7            
(Insufficient
Output)
Black Smoke
8       
Emitted
White Smoke
9      
Emitted
Engine Stalls On
10     
Deceleration
*1: When the engine rotation change is large, it lights.
*2: It lights for a timing positional wrong gear.
9Y1200199CRS0629US0
1-S19
Malfunction Cause
Control System Engine Electrical System Intake System
Glow (intake air heater) system

Intake system components
Fuel temperature sensor
Boost pressure sensor
Rail pressure sensor
Battery
Charging system malfunction
Turbocharge malfunction
Starter relay malfunction
Main relay malfunction
Intake air heater fault

Air cleaner clogging
Does not discharge
False signal output
False signal output
False signal output
SCV malfunction
No signal output
No signal output
No signal output
Does not charge

EGR valve fault
Faulty relay
Leak
Malfunction Cause
Engine Warning 
1         
Light Comes On *1
Engine Does Not
2          
Start
Takes A Long
3 Time Before       
Engine Starts
4 Idle Failure   
5 Engine Noise     
High Fuel
6      
Consumption
Poor
Acceleration
7        
(Insufficient
Output)
Black Smoke
8       
Emitted
White Smoke
9         
Emitted
Engine Stalls On
10  
Deceleration
*1: When pressure doesn't hang to the boost pressure sensor, it is likely to light.
9Y1200199CRS0630US0
1-S20
Malfunction Cause
Fuel System Cooling System Others
SCV malfunction
Power transmission malfunction (including clutch slipping) *1

Injectors
(radiator, hoses, thermostat, cooling fan, etc.)
Damaged fan belt or misadjusted belt tension
Improper concentration of antifreeze
Large dragging (including brake) *1
Defective CAN communication

Supply pump learning failure
Blockage, leake, malfunction
Faulty fuel pressure limiter

Supply pump malfunction
Cooling system failure

Clogged fuel filter
Loose fit parts

Fuel quality
Blockage
Leak
Malfunction Cause
Engine Warning
1      
Light Comes On
Engine Does Not
2        
Start
Takes A Long
3 Time Before        
Engine Starts
4 Idle Failure         
5 Engine Noise       
High Fuel
6          
Consumption
Poor
Acceleration
7           
(Insufficient
Output)
Black Smoke
8      
Emitted
White Smoke
9        
Emitted
Engine Stalls On
10      
Deceleration
*1: It emphatically searches for the machine side.
9Y1200199CRS0631US0
1-S21
[2] DIAGNOSIS BY MALFUNCTION SYMPTOM

(1) Engine Warning Light Comes On
1. Turn the key switch ON and check that the fuel feed pump is operating. If it is not operating, check in accordance
with "6.[2] FUEL SYSTEM INSPECTION PROCEDURE - 5. Check the Fuel Feed Pump".(Refer to page 1-S303)
2. Connect diagnosis tool and read DTC. Refer to pertinent DTC diagnosis guidelines and implement diagnosis.
9Y1200199CRS0632US0
(2) Engine Does Not Start

Possible causes:
1. Fuel feed pump operation fault.
2. Starting assist device (intake air heater)
• Applicable only when the temperature is low: −10 °C (14 °F) or less
• Refer to the workshop manual for the machine and check the air heater, relay and related wiring harness.
*Refer to the previous "List of malfunction causes by symptom" for the subsequent details.
3. Engine fault
• Low compression pressure.
• Engine internal fault
• Valve timing fault
4. Control system
• Damage to the pulsar gear of the crankshaft position sensor
• Air gap of the crankshaft position sensor is large
• Damage to the pulsar gear of the camshaft position sensor
• SCV operation fault
• Main relay malfunction
5. Engine electrical system
• Battery fault
• Charging system malfunction
• Starter relay malfunction
6. Intake system
• Glow (intake air heater) relay fault
• Intake air heater fault
7. Fuel system
• Fuel quality
• Fuel filter clogging
• Fuel pressure limiter fault
• Fuel line clogging, leak
8. CRS (including the wiring harness)
• Power supply system
• Output system (supply pump, injector and common rail)
• Input system (sensors and switches)
• ECU
9. Others
• Large amount of drag (including the brakes, etc.)
9Y1200199CRS0633US0
1. Check the Fuel Feed Pump Operation
1. Turn the key switch ON and check that the fuel feed pump is
operating.
Factory
Operates when the key switch is turned ON.
specification
OK Go to "2. Check the DTC".

NG Check in accordance with "6.[2] FUEL SYSTEM INSPECTION
PROCEDURE - 5. Check the Fuel Feed Pump". (Refer to page 1-S303)
(1) Fuel Feed Pump

9Y1200199CRS0634US0
1-S22
2. Check the DTC
1. Turn the key switch ON and check the DTC.
Factory
No DTC is output.
specification
Communication error
OK Go to "3. Check the Starting Assist Device".
NG Go to "6. Check the ECU Power Supply and Grounding".
DTC presently existing

NG Check in accordance with the troubleshooting procedures for each DTC.
Past DTC only

NG Reproduce defect by referring to the freeze frame data, etc.
(a) CAN1 Connector

9Y1200199CRS0635US0
3. Check the Starting Assist Device
1. Refer to the workshop manual for the machine and check the air
heater, relay and related wiring harness.
2. In case the engine can not start when it is new or after the
maintenance, make sure to connect the injector harness
connector of the head cover position.
3. If the starter relay is used, neutral condition is required
depending on the model. Use the monitor function to check
whether the neutral switch (signal) is ON.
4. Perform an active test for models that have relay control in the
ECU on the engine side.
Factory Operates repeatedly between ON and OFF in accordance
specification with the specified cycle.
OK Go to "4. Check the Intake System".

NG Checking and repair of starting assist device (intake air heater).
(a) CAN1 Connector

9Y1200199CRS0636US0
4. Check the Intake System
1. Check in accordance with "6.[1] AIR INTAKE SYSTEM
INSPECTION PROCEDURE". (Refer to page 1-S299)
OK Go to "5. Check the Fuel System".
NG Repair in accordance with "6.[1] AIR INTAKE SYSTEM INSPECTION
PROCEDURE". (Refer to page 1-S299)
9Y1200199CRS0637US0
1-S23
5. Check the Fuel System
1. Check in accordance with "6.[2] FUEL SYSTEM INSPECTION
OK Go to "6. Check the ECU Power Supply and Grounding".
NG Repair in accordance with "6.[2] FUEL SYSTEM INSPECTION
(1) Rail (2) Supply Pump

9Y1200199CRS0638US0
6. Check the ECU Power Supply and Grounding

1. Turn the key switch ON and measure the voltage between the
ECU +BP terminals (V18 / V38 / V58 / V78) and ground (body /
battery terminal) and ECU S-GND terminal (V40 / V60) and
ground (body / battery terminal).
Factory +BP terminal - ground: 10 V or higher
specification S-GND terminal - ground: 0.5 V or lower
OK Go to "7. Check the Crankshaft Position Sensor and Camshaft Position

Sensor Signal".
NG Diagnose by referring to "6.[3]. ELECTRIC SYSTEM INSPECTION
PROCEDURE - (3) Checking The Power And Ground System (Main
Relay ECU Circuit)". (Refer to page 1-S309)
9Y1200199CRS0639US0
7. Check the Crankshaft Position Sensor and Camshaft
Position Sensor Signals
1. Set the key switch to START position and crank the engine.
Check the "Engine speed active flag" and "Cam speed active
flag" using the diagnosis tool data monitor function.
Factory
Both sides ON and constant
specification
OK Normal.
NG Go to "8. Supply Pump Difference Learning and Checking the Monitor".
Both flags Cause of the engine starting failure has been determined.
are Determine the malfunction area by referring to sections in
unsatisfact P0335, P0336 (Refer to page 1-S178) and P0340, P0341
ory. (Refer to page 1-S183) in "5.[2] DIAGNOSIS BY DTC".
Only one Care should be taken as this does not cause engine starting
side of the failure. Since the sensor signal is abnormal, determine the
flag is malfunction area by referring to sections in P0335, P0336
unsatisfact (Refer to page 1-S178) and P0340, P0341 (Refer to page
ory. 1-S183) in "5.[2] DIAGNOSIS BY DTC" as was the case in the
above.
(a) CAN1 Connector

9Y1200199CRS0640US0
1-S24
8. Supply Pump Difference Learning and Checking the Monitor
1. Perform difference learning for the supply pump in accordance
with "3. ACTIVE TEST AND SUPPLY PUMP DIFFERENCE
LEARNING". (Refer to page 1-S16)
2. In accordance with the previous "List of malfunction causes by
symptom", use the diagnosis tool for a monitor check of the
mode flags during start-up, such as the coolant temperature, rail
pressure, SCV current value and battery voltage. (Refer to page
1-S18)
OK Go to "9. Check the Engine".
NG Repair the malfunction.
(a) CAN1 Connector

9Y1200199CRS0641US0
9. Check the Engine
1. Check the compression pressure, valve timing and the inside of
the engine.
OK Normal.
(1) Compression Tester

9Y1200199CRS0642US0
1-S25
(3) Takes A Long Time Before Engine Starts

Possible causes:
2. Engine fault
3. Control system
• Damage to the pulsar gear of the camshaft position sensor
4. Engine electrical system
• Battery fault
5. Intake system
• Intake air heater fault
6. Fuel system
• Fuel quality
7. CRS (Including the wiring harness)
• Output system (Supply pump, injector and common rail)
• Input system (Sensors and switches)
• ECU
8. Others
• Large amount of drag (Including the brakes, etc.)
9Y1200199CRS0643US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification

Past DTC only

(a) CAN1 Connector

9Y1200199CRS0645US0
1-S26
2. In case the engine can not start when it is new or after the
maintenance, make sure to connect the injector harness
connector of the head cover position.
3. If the starter relay is used, neutral condition is required
depending on the model. Use the monitor function to check
whether the neutral switch (signal) is ON.

(a) CAN1 Connector

9Y1200199CRS0636US0
9Y1200199CRS0637US0

OK Go to "6. Check the Crankshaft Position Sensor".

9Y1200199CRS0648US0
6. Check the Crankshaft Position Sensor

1. Refer to DTC P0335 and P0336, and implement checking of the
crankshaft position sensor.
OK Go to "7. Check the Camshaft Position Sensor".
NG Repair and replacement of the crankshaft position sensor-related parts.

(NE Sensor)
9Y1200199CRS0649US0
1-S27
7. Check the Camshaft Position Sensor
camshaft position sensor.
OK Go to "8. Check the Rail Pressure Sensor and Supply Pump".
NG Repair and replacement of camshaft position sensor-related parts.

(G Sensor)
9Y1200199CRS0650US0
8. Check the Data Related to Pressure Control

1. Measure the "Target rail pressure" and "Actual rail pressure"
when accelerator is operated as indicated below using the
diagnosis tool data monitor function.
The "Actual rail pressure" always follow to the "Target rail
pressure".
1. When idling:
40 to 50 MPa (410 to 500 kgf/cm2, 5800 to 7200 psi)
2. Accelerator opening
0 → 100 % (During acceleration):
Factory
Maximum value 95.0 to 130 MPa (969 to 1320 kgf/cm2,
specification
13800 to 18800 psi)
3. No-load maximum speed:
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
4. The numerical value is stable under normal operating and
the target value corresponds with actual pressure value.
OK Go to "9. Check the Injector (Including the Pipes, etc.)"

NG (Check the trouble related to pressure)
Refer to the pressure system items (P0087, P0088, P0089 and P0093
(Refer to page 1-S128)) and SCV abnormality items (P0628 and P0629
(Refer to 1-S210)) in "5.[2] DIAGNOSTIC PROCEDURE BY DTC",
perform diagnosis for the ECU, wiring harness and sensor, and repair or
replace the required parts.
NOTE
• Some diagnosis items above may be mentioned twice.
(a) CAN1 Connector

9Y1200199CRS0651US0
9. Check the Injector (Including the Pipes, etc.)
1. Perform the diagnosis tool active test (stopping the injector
injection by cylinder) and check the injector performance.
Engine vibration and noise are increased and the rotation
Factory rate is reduced when the injection for the corresponding
specification cylinder is stopped.
The same results must be attained from all the cylinders.

NG Check and repair faulty parts including the high pressure line of the
defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0652US0
1-S28
10. Check the Engine
the engine.
OK Normal.

9Y1200199CRS0653US0
1-S29
(4) Idle Failure

Possible causes:
2. Engine fault
3. Control system
4. Fuel system
• Supply pump learning has not been performed
• Fuel quality
• ECU
6. Others
9Y1200199CRS0654US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification

OK Go to "3. Check the Injector (Including the Pipes, etc.)".
Past DTC only

(a) CAN1 Connector

9Y1200199CRS0656US0
1-S30
Factory rate is reduced when the injection for the corresponding

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0657US0
9Y1200199CRS0637US0

OK Go to "6. Check the Accelerator Position Sensor.

9Y1200199CRS0659US0
6. Check the Accelerator Position Sensor
CAUTION
• When checking, pay attention to the angle of mounting
instead of the output signal quality.
1. Inspect in accordance with the operator's manual.
NG Replacement of accelerator position sensor.
9Y1200199CRS0660US0

(NE Sensor)
9Y1200199CRS0661US0
1-S31

(G Sensor)
9Y1200199CRS0662US0

pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
OK Go to "10. Check the Engine"

NG (Check the trouble related to pressure
NOTE
(a) CAN1 Connector

9Y1200199CRS0663US0
the engine.
OK Normal.

9Y1200199CRS0653US0
1-S32
(5) Engine Noise

Possible causes:
1. Engine fault
• Valve clearance fault
2. Control system
3. Intake system
• Leak from the intake system parts
4. Fuel system
• Fuel quality
5. Cooling system
• Fan belt damage or tension misadjustment
6. CRS (including related fuel line)
• Input system (sensors)
• ECU
7. Others
• Loose parts (including part interference sound)
9Y1200199CRS0665US0
1. Check the DTC
Factory
No DTC is output.
specification
OK Go to "2. Check the Crankshaft Position Sensor"

(a) CAN1 Connector

9Y1200199CRS0666US0


(NE Sensor)
9Y1200199CRS0667US0


(G Sensor)
9Y1200199CRS0668US0
1-S33
1. Engine vibration and noise are increased and the rotation
Factory speed is reduced when the injection for the corresponding
2. The same results must be attained from all the cylinders.
OK Go to "5. Check the Engine and Machine Body".

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0669US0
5. Check the Engine and Machine Body
1. Check the compression pressure, valve clearance, valve timing
and the inside of the engine.
OK Normal.
2. Check for loose parts in the engine and on the machine body
(including part interference sound).
3. Check for a large amount of drag (including the brakes, etc.).
OK Normal.

9Y1200199CRS0670US0
1-S34
(6) High fuel consumption

Possible causes:
Reduced engine performance is detected and the fuel consumption is higher for this reason.
1. The engine performance is reduced and the fuel consumption is higher for this reason
Reduced engine performance is not detected but the fuel consumption is higher.
1. Usage habits of the user or use of non-standard parts
• Not the standard specification
– Tires, wheels
– Intake / exhaust system parts
• Used for a long time under poor fuel consumption conditions
– Engine used for a long time under a high load
– Long idling time
• Frequently used under driving conditions with a large injection quantity
– Low mileage for each drive (frequently used before the engine has warmed up)
• Faulty maintenance
– Engine oil (dirt)
– Air filter, fuel filter (dirt, clogging)
– Radiator clogging
2. Powertrain malfunctions not involving the engine
• Large driving resistance
– Large resistance for actuation
– Tire air pressure
– Brake drag
• Clutch slipping
4. Engine fault
• Engine oil viscosity fault
5. Control system
6. Intake system
• Air cleaner clogging
• Turbocharger operation fault
7. Fuel system
• Fuel quality
8. CRS (including related parts)
• Output system (supply pump and injector)
• Input system (sensors) *A cause for larger injection quantity
9Y1200199CRS0671US0
1-S35
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification
OK Go to "3. Comparison of Fuel Economy".

(a) CAN1 Connector

9Y1200199CRS0673US0
3. Comparison of Fuel Economy

1. Compare with a normal device working under the same
operating conditions and measure the amount of consumed fuel
(amount left in the tank).
OK Use a specific example to explain and make the user understand that
under some operating conditions the fuel consumption will increase and
that the machine is not malfunctioning.
NG Go to "4. Check the Engine and Machine Condition".
9Y1200199CRS0674US0
4. Check the Engine and Machine Condition
1. Check for the usage habits of the user or use of non-standard
parts.
• Use of non-standard parts such as tires, wheels and intake /
exhaust system parts
• Used under poor fuel consumption conditions
– Engine used for a long time under a high load
– Long idling time
• Faulty maintenance
– Engine oil level and dirt
– Air filter, fuel filter dirt and clogging
– Radiator clogging
OK Go to "Check for malfunctions in the powertrain".
NG Give guidance to the user.
2. Check for malfunctions in the powertrain.
• Check the driving resistance
– Is a large resistance required for actuation?
– Is the tire air pressure correct?
– Is there brake drag?
NG Adjust or repair the malfunction.
9Y1200199CRS0675US0
1-S36
(Reference)
Pay attention particularly to the following two points:
• Service fuel (for summer / winter seasons, and cold region)
• Fuel leak from the fuel line
NG Repair or replace the malfunctioning component.

9Y1200199CRS0676US0
(Reference)
Pay attention particularly to the following point:
• Intake air leak
OK Go to "7. Check the Coolant Temperature Increase Rate".
9Y1200199CRS0677US0
7. Check the Coolant Temperature Increase Rate

1. Check the speed of the coolant temperature increase on the
coolant temperature gauge in the instrument panel (compared
with a normal device).
NG Check and repair the cooling system.
9Y1200199CRS0678US0


(NE Sensor)
9Y1200199CRS0679US0

OK Go to "10. Check the Rail Pressure Sensor And Supply Pump".

(G Sensor)
9Y1200199CRS0680US0
1-S37
pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)

NOTE
(a) CAN1 Connector

9Y1200199CRS0681US0

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0682US0
1-S38
1. Check the compression pressure, valve clearance, valve timing,
the inside of the engine and engine oil viscosity.
2. Check the timing gear.
3. Check the turbocharger.
OK Normal.
NG Repair or replace the related parts.
(1) Compression Tester (2) Turbocharger

9Y1200199CRS0683US0
1-S39
(7) Poor Acceleration (Insufficient Output)

Possible causes:
2. Large driving resistance due to problems in the machine itself that do not involve the engine
• Large resistance for actuation
• Tire air pressure
• Power transmission fault
• Brake drag
3. Engine fault
4. Control system
• Accelerator position sensor misadjustment
5. Intake system
6. Fuel system
• Fuel quality
7. CRS (including related parts)
• Input system (sensors) *A cause for larger injection quantity
• ECU
8. Others
• Defective CAN communication
9Y1200199CRS0684US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
1-S40
2. Check the DTC
Factory
No DTC is output.
specification

Past DTC only

(a) CAN1 Connector

9Y1200199CRS0686US0
CAUTION
OK Go to "4. Check the Idle Condition".
9Y1200199CRS0687US0
4. Check the Idle Condition
1. Check if idling is normal.
Factory
Stable at specified speed.
specification
OK Go to "5. Malfunction Verification - 1".

NG Refer to "(4) Idle Failure", and implement checking and repair.(Refer to
page 1-S30)
9Y1200199CRS0688US0
5. Malfunction Verification - 1
1. Reproduce running conditions (engine speed, machine speed,
gear shift, etc.) as pointed out by the driver. Compare with
another machine of the same model and check whether poor
acceleration and power shortage can be sensed.
Factory
No malfunction should be detected.
specification
OK Explain to the driver that the machine is in a normal condition.

(Reference)
• Give appropriate advice to the driver about matters concerning
anything noticed that is related to his driving manner (such as
selection of shift, etc.).
NG Go to "6. Malfunction Verification - 2".
9Y1200199CRS0689US0
1-S41
6. Malfunction Verification - 2
1. Check for a large driving resistance due to problems in the
machine itself that do not involve the engine.
• Large resistance for actuation
• Tire air pressure
• Brake drag
NG Repair or adjust the malfunction.
9Y1200199CRS0690US0
9Y1200199CRS0691US0


9Y1200199CRS0692US0


(NE Sensor)
9Y1200199CRS0693US0


(G Sensor)
9Y1200199CRS0694US0
1-S42
pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)

NOTE
(a) CAN1 Connector

9Y1200199CRS0695US0
OK Go to "13. Check the Engine"

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0696US0
1-S43
OK Normal.

9Y1200199CRS0697US0
1-S44
(8) Abnormal Black Smoke Emitted

Possible causes:
2. Engine fault
3. Control system
• EGR valve fault
4. Intake system
5. Fuel system
• Fuel quality
• ECU
9Y1200199CRS0698US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification

Past DTC only

(a) CAN1 Connector

9Y1200199CRS0700US0
1-S45
9Y1200199CRS0701US0


9Y1200199CRS0702US0
CAUTION
9Y1200199CRS0703US0

(NE Sensor)
9Y1200199CRS0649US0

OK Go to "8. Check the EGR Valve".

(G Sensor)
9Y1200199CRS0705US0
1-S46
8. Check the EGR Valve
Refer to "5.[2] DIAGNOSTIC PROCEDURE BY DTC" for the
detailed EGR-related check. A simplified version is shown below.
(Refer to page 1-S121)
CAUTION
• Check that the EGR valve does not open before the engine
has warmed up [coolant temperature: 65 °C (149 °F)].
1. Use the monitor function to check whether the actual opening
meets the target opening.
Refer to "1.[5].(2) Normal Value". (Refer to page 1-M17)
Factory In addition, for the check procedures refer to
specification "5.[2] DIAGNOSTIC PROCEDURE BY DTC". (Refer to page
1-S121)
2. Perform an active test (EGR actuation test).
(Low side)
When target EGR valve openings of 0 % and 15 % are given
alternately, there must not be disparity in the actual EGR
Factory valve opening.
specification (High side)
When target EGR valve openings of 35 % and 60 % are
given alternately, there must not be disparity in the actual
EGR valve opening.

NG Replace the EGR valve.
(a) CAN1 Connector

9Y1200199CRS0706US0
pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)

NOTE
(a) CAN1 Connector

9Y1200199CRS0707US0
1-S47

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0708US0
OK Normal.

9Y1200199CRS0709US0
1-S48
(9) Abnormal White Smoke Emitted

Possible causes:
2. Starting assist device fault (air heater and glow (air heater) relay do not operate)
3. Engine fault
4. Control system
• EGR valve fault
5. Intake system
6. Fuel system
• Fuel quality
• ECU
9Y1200199CRS0710US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification

Past DTC only

(a) CAN1 Connector

9Y1200199CRS0645US0
1-S49
OK Go to "4. Check the Idle Condition".

(a) CAN1 Connector

9Y1200199CRS0713US0
Factory
specification

NG Refer to "(4) Idle Failure", and implement checking and repair.(Refer to
page 1-S30)
9Y1200199CRS0714US0

9Y1200199CRS0715US0


9Y1200199CRS0716US0


(NE Sensor)
9Y1200199CRS0661US0
1-S50
OK Go to "9. Check the EGR Valve".

(G Sensor)
9Y1200199CRS0718US0
9. Check the EGR Valve

Refer to "5.[2] DIAGNOSTIC PROCEDURE BY DTC" for the
detailed EGR-related check. A simplified version is shown below.
CAUTION
• Check that the EGR valve does not open before the engine
has warmed up [coolant temperature: 65 °C (149 °F)].
1. Use the monitor function to check whether the actual opening
meets the target opening.
Refer to "1.[5].(2) Normal Value". (Refer to page 1-M17)
Factory In addition, for the check procedures refer to
specification "5.[2] DIAGNOSTIC PROCEDURE BY DTC". (Refer to page
1-S121)
2. Perform an active test (EGR actuation test).
(Low side)
When target EGR valve openings of 0 % and 15 % are given
alternately, there must not be disparity in the actual EGR
Factory valve opening.
specification (High side)
When target EGR valve openings of 35 % and 60 % are
given alternately, there must not be disparity in the actual
EGR valve opening.

NG Replace the EGR valve.
(a) CAN1 Connector

9Y1200199CRS0719US0
1-S51
pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)

NOTE
(a) CAN1 Connector

9Y1200199CRS0681US0

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0682US0
1-S52
OK Normal.
defective cylinder.

9Y1200199CRS0722US0
1-S53
(10) Engine Stalls On Deceleration

Possible causes:
2. Engine fault
3. Control system
4. Intake system
5. Fuel system
• Fuel quality
• ECU
9Y1200199CRS0723US0
operating.
Factory
specification

(1) Fuel Feed Pump

9Y1200199CRS0634US0
2. Check the DTC
Factory
No DTC is output.
specification

OK Go to "3. Check the idle condition".
Past DTC only

OK Go to "3. Check the idle condition".
(a) CAN1 Connector

9Y1200199CRS0725US0
1-S54
Factory
specification

NG Refer to "(4) Idle Failure", and implement checking and repair. (Refer to
page 1-S30)
9Y1200199CRS0726US0

9Y1200199CRS0637US0


9Y1200199CRS0659US0
CAUTION
9Y1200199CRS0660US0

(NE Sensor)
9Y1200199CRS0661US0
1-S55

(G Sensor)
9Y1200199CRS0662US0

pressure".
1. When idling:
Factory
specification
13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)

NOTE
(a) CAN1 Connector

9Y1200199CRS0707US0

defective cylinder.
(a) CAN1 Connector

9Y1200199CRS0708US0
1-S56
OK Normal.

9Y1200199CRS0734US0
1-S57
5. DIAGNOSTIC PROCEDURE BY DTC

[1] DTC LIST
Name NE-G phase shift
ISO 14229
P0016
P-Code
SPN 636
J1939-73
FMI 7
SPN Name Engine Position Sensor
SAE J1939 Table C1
DTC Name NE-G phase shift
Management Unit
NEGUM
for Detected Part
• Large phase shift between NE (crankshaft position sensor) pulse and G (camshaft
Detection item
position sensor) pulse
• Engine is operating above low idle speed
• Battery voltage is normal
DTC Set • Sensor supply voltage VCC# is normal
Preconditions • NE signal is normal
• G signal is normal
• Coolant temperature is 10 °C (50 °F) or higher
(Approximate)
DTC set parameter
• Phase difference between NE pulse and G pulse is within ±0.26 rad (±15 °)
Time to action or • 10 times or more
number of error
detection
Limp Home Action • Output limitation: Approximately 75 % of normal condition
by engine ECU
(system action)
Behaviour During (Invalid G signal)
Malfunction • Engine hesitates at start-up
Engine Warning • ON
Light
Recovery from • Diagnostic counter =zero
error
Delay time for • Delay time varies with engine speed in proportional relation.
recovery • If it is set 30 sec at 800 min-1 (rpm), it is shorten to 15 sec at 1600 min-1 (rpm) operation.
• Engine hesitates at start-up
Remark • NE: Crankshaft position sensor
• G: Camshaft position sensor
9Y1200199CRS0735US0
1-S58
Name Intake air temperature built-in MAF sensor abnormality

ISO 14229
P0072 P0073
P-Code
SPN 171 171
J1939-73
FMI 4 3
SPN Name Ambient Air Temperature Ambient Air Temperature
SAE J1939 Table C1
Intake air temperature built-in MAF sensor: Intake air temperature built-in MAF sensor:
DTC Name
Low High
Management Unit
THAIL THAIH
for Detected Part
• Ground short circuit of sensor / harness • Open circuit or +B short circuit of sensor
Detection item
/ harness.
DTC Set • Battery voltage is normal • Battery voltage is normal
Preconditions
• Intake air temperature built-in MAF • Intake air temperature built-in MAF
DTC set parameter
sensor voltage: 0.1 V or less sensor voltage: 4.9 V or more
Time to action or • 2.8 sec. or more • 2.8 sec. or more
number of error
detection
Limp Home Action • 25 °C (77 °F) [default value] • 25 °C (77 °F) [default value]
by engine ECU
(system action)
Behaviour During • None • None
Malfunction
Engine Warning • ON • ON
Light
Recovery from • Diagnostic counter = zero • Diagnostic counter = zero
error
Delay time for • Immediately • Immediately
recovery
Remark
9Y1200199CRS0736US0
1-S59
Name Pressure limiter emergency open

ISO 14229
P0087
P-Code
SPN 633
J1939-73
FMI 7
SPN Name Engine Fuel Actuator 1 Control Command
SAE J1939 Table C1
DTC Name Pressure limiter emergency open
Management Unit
PLACT
for Detected Part
Detection item • Pressure limiter emergency open
DTC Set • Rail pressure sensor is normal
Preconditions • Sensor supply voltage VCC# is normal
• Combination of below A and B
A: Fuel leak (P0093) is detected
B: Condition (1) or (2) is fulfilled;
DTC set parameter (1) Rail pressure exceeds 191 MPa (1950 kgf/cm2, 27700 psi)
(2) Within 1 sec, after the rail pressure goes below 191 MPa (1950 kgf/cm2, 27700 psi)
[Before the pressure decrease, the rail pressure is above 191 MPa (1950 kgf/cm2,
27700 psi)]
Time to action or • 1 time or more
number of error
detection
• Output limitation: Approximately 50 % of normal condition
Limp Home Action
• Speed limitation (Accelerator limitation: 50 %)
by engine ECU
• EGR stop
(system action)
• Intake throttle 100 % open (except DOC model)
Behaviour During • Insufficient output
Malfunction • Worsening exhaust gas performance
Light
Recovery from • Key switch turn OFF
error
Delay time for –
recovery
• To minimize PM emission to Diesel Particulate Filter (hereinafter referred to as the
Remark "DPF")
• Engine speed may go down due to lack of fuel pressure, regardless limp home de-rating
9Y1200199CRS0737US0
1-S60
Name High rail pressure

ISO 14229
P0088
P-Code
SPN 157
J1939-73
FMI 0
SPN Name Engine Injector Metering Rail 1 Pressure
SAE J1939 Table C1
DTC Name High rail pressure
Management Unit
PCEX
for Detected Part
Detection item • Actual pressure exceeds the command pressure
DTC Set • Rail pressure sensor is normal
Preconditions • Sensor supply voltage VCC# is normal
DTC set parameter • Actual pressure ≥ 197 MPa (2010 kgf/cm2, 28600 psi)
Time to action or • 1 sec. or more
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
Light
Recovery from • Diagnostic counter = zero
error
Delay time for • 30 sec.
recovery
Remark • To minimize PM emission
9Y1200199CRS0738US0
1-S61
Name SCV stuck

ISO 14229
P0089
P-Code
SPN 1347
J1939-73
FMI 7
SPN Name Engine Fuel Feed Pump Pressurizing Assembly #1
SAE J1939 Table C1
DTC Name SCV stuck
Management Unit
SCVS
for Detected Part
• SCV stuck at open position (Actual rail pressure continuously exceeds the command rail
Detection item
pressure)
• Supply pump is normal and pump calibration has been executed
• Engine is operating (Q: 4 mm3/st or higher)
DTC Set • Injector is normal
Preconditions • Battery voltage is normal
• Sensor supply voltage VCC# is normal
• Rail pressure sensor is normal
• Discharge request of supply pump goes below 0 mm3/st and the actual rail pressure is
DTC set parameter 10 MPa (100 kgf/cm2, 1400 psi) higher than command pressure
• Above state continues for 26 seconds or more
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
• Insufficient output
Behaviour During
• Worsening exhaust gas performance
Malfunction
• Engine stops in some case
Light
error
Delay time for –
recovery
• To minimize PM emission
Remark
9Y1200199CRS0739US0
1-S62
Name Fuel leak (in high pressured fuel system)

ISO 14229
P0093
P-Code
SPN 1239
J1939-73
FMI 1
SPN Name Engine Fuel Leakage 1
SAE J1939 Table C1
DTC Name Fuel leak (in high pressured fuel system)
Management Unit
FLEAK
for Detected Part
• Fuel leak from high pressured fuel system
Detection item (Fuel consumption is calculated from the difference of fuel pressure of before and after
the injection, and the error will be detected when excess fuel consumption is found)
DTC Set
• Supply pump (SCV) is normal
Preconditions
• Injector and injector drive circuit are normal
• NE signal is active [Engine is operating (700 min-1 (rpm) or higher)]
• No DTC of P0087, P0088, P0089
(a): the flow volume which is calculated from the difference of rail pressure (decrease)
(b): total volume of injection and leakage
Fuel leak is judged with following conditions:
• In case, engine speed is more than 1200 min-1 (rpm):
DTC set parameter When the difference of (a) and (b) is 120 mm3/st or above, (a) is higher than (b), and
fuel leak is not from opening pressure limiter
• In case, engine speed is 1200 min-1 (rpm) or less:
When the difference of (a) and (b) is 400 mm3/st or above, (a) is higher than (b), and
fuel leak is not from opening pressure limiter
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
Behaviour During
Malfunction
Light
error
Delay time for –
recovery
Remark
9Y1200199CRS0740US0
1-S63
Name Intake air volume: Low

ISO 14229
P0101
P-Code
SPN 132
J1939-73
FMI 1
SPN Name Engine Inlet Air Mass Flow Rate
SAE J1939 Table C1
DTC Name Intake air volume: Low
Management Unit
GA
for Detected Part
Detection item • Engine inlet air mass flow rate lacking (Disconnect turbo blower intake hose)
• Engine is operating [1000 min-1 (rpm) or higher]
• Coolant temperature is 15 °C (59 °F) or higher (Coolant temperature sensor is normal)
DTC Set • MAF sensor is normal
Preconditions • EGR valve is normal
• Intake throttle valve is normal
DTC set parameter • Engine Inlet Air Mass Flow Rate: less than half of target value
Time to action or • 10.0 sec. or more
number of error
detection
by engine ECU • EGR stop
(system action) • Intake throttle 100 % open (except DOC model)
Malfunction
Light
error
Delay time for –
recovery
Remark
9Y1200199CRS0741US0
1-S64
Name MAF sensor abnormality

ISO 14229
P0102 P0103
P-Code
SPN 132 132
J1939-73
FMI 4 3
SPN Name Engine Inlet Air Mass Flow Rate Engine Inlet Air Mass Flow Rate
SAE J1939 Table C1
DTC Name MAF sensor: Low MAF sensor: High
Management Unit
MAFL MAFH
for Detected Part
• Open circuit or ground short circuit of • +B short circuit of sensor / harness
Detection item
sensor / harness.
• Battery voltage is normal • Battery voltage is normal
• Starter Switch signal (ECU: V12 • 700 min-1 (rpm) ≤ engine speed ≤
DTC Set terminal) is not activated 2800 min-1 (rpm)
Preconditions • Sensor supply voltage is normal • Target intake mass air flow is 460 or less
and it continues for 3 secs
• Sensor supply voltage is normal
• Mass air flow sensor voltage: 0.1 V or • Mass air flow sensor voltage: 4.9 V or
DTC set parameter
less more in certain operation condition
number of error
detection
• Sensor output: 0.7 times of target value • Sensor output: 0.7 times of target value
at normal condition [default value] at normal condition [default value]
Limp Home Action • Output limitation: Approximately 75 % of • Output limitation: Approximately 75 % of
by engine ECU normal condition normal condition
(system action) • EGR stop • EGR stop
• Intake throttle 100 % open • Intake throttle 100 % open
(except DOC model) (except DOC model)
Behaviour During • Insufficient output • Insufficient output
Malfunction • Worsening exhaust gas performance • Worsening exhaust gas performance
Light
Recovery from • Key switch turn OFF • Key switch turn OFF
error
Delay time for – –
recovery
• Engine is not stopped forcibly by ECU. • Engine is not stopped forcibly by ECU.
However KUBOTA strongly However KUBOTA strongly
Remark
recommends operator to stop engine as recommends operator to stop engine as
soon as possible. soon as possible.
9Y1200199CRS0742US0
1-S65
Name Intake air temperature: high (Inter cooler model only)

ISO 14229
P0111
P-Code
SPN 172
J1939-73
FMI 0
SPN Name Air Inlet Temperature
SAE J1939 Table C1
Intake air temperature: high
DTC Name
Inter cooler model only
Management Unit
THAABH
for Detected Part
Detection item • Intake air temperature too high
DTC Set • Battery voltage is normal
Preconditions • Key switch is ON
DTC set parameter • Intake air temperature higher than ambient temperature +60 °C (+140 °F)
number of error
detection
by engine ECU
(system action)
Behaviour During • None
Malfunction
Light
error
Delay time for –
recovery
Remark • Inter cooler model only
9Y1200199CRS0743US0
1-S66
Name Intake air temperature error

ISO 14229
P0112 P0113
P-Code
SPN 172 172
J1939-73
FMI 4 3
SPN Name Engine Air Inlet Temperature Engine Air Inlet Temperature
SAE J1939 Table C1
DTC Name Intake air temperature error: Low Intake air temperature error: High
Management Unit
THAL THAH
for Detected Part
Detection item
/ harness
Preconditions
• Voltage of intake air temperature sensor • Voltage of intake air temperature sensor
DTC set parameter
is 0.05 V or less is 4.9 V or above
number of error
detection
• During start-up = −20 °C (−4 °F) • During start-up = −20 °C (−4 °F)
Limp Home Action
[default value] [default value]
by engine ECU
• Under other conditions = 40 °C (104 °F) • Under other conditions = 40 °C (104 °F)
(system action)
Behaviour During • Amount of white smoke increases at low • Amount of white smoke increases at low
Malfunction temperatures temperatures
Light
error
Delay time for • 30 sec. • 30 sec.
recovery
• White smoke increases at low • White smoke increases at low
Remark
temperature temperature
9Y1200199CRS0744US0
1-S67
Name Coolant temperature sensor abnormality

ISO 14229
P0117 P0118
P-Code
SPN 110 110
J1939-73
FMI 4 3
SPN Name Engine Coolant Temperature Engine Coolant Temperature
SAE J1939 Table C1
DTC Name Coolant temperature sensor: Low Coolant temperature sensor: High
Management Unit
THWL THWH
for Detected Part
Detection item
/ harness
Preconditions
• Voltage of coolant temperature sensor is • Voltage of coolant temperature sensor is
DTC set parameter
0.1 V or less 4.9 V or above
number of error
detection
Limp Home Action [default value] [default value]
by engine ECU • Output limitation: Approximately 75 % of • Output limitation: Approximately 75 % of
(system action) normal condition normal condition
• EGR stop • EGR stop
• Amount of white smoke increases at low • Amount of white smoke increases at low
Behaviour During temperatures temperatures
Malfunction • Insufficient output • Insufficient output
• Worsening exhaust gas performance • Worsening exhaust gas performance
Light
error
recovery
• White smoke increases at low • White smoke increases at low
Remark
9Y1200199CRS0745US0
1-S68
Name Fuel high temperature

ISO 14229
P0181
P-Code
SPN 174
J1939-73
FMI 0
SPN Name Fuel Temperature
SAE J1939 Table C1
DTC Name Fuel high temperature
Management Unit
THFABH
for Detected Part
Detection item • Fuel temperature high
• Passed 300 sec after cranking
DTC Set
• Engine speed is 800 min-1 (rpm) or more
Preconditions
• Fuel temperature sensor is normal
DTC set parameter • Fuel temperature higher than 90 °C (194 °F)
number of error
detection
by engine ECU
(system action)
Behaviour During • None
Malfunction
Light
error
Delay time for • 30 sec.
recovery
Remark
9Y1200199CRS0746US0
1-S69
Name Fuel temperature sensor abnormality

ISO 14229
P0182 P0183
P-Code
SPN 174 174
J1939-73
FMI 4 3
SPN Name Engine Fuel Temperature 1 Engine Fuel Temperature 1
SAE J1939 Table C1
DTC Name Fuel temperature sensor: Low Fuel temperature sensor: High
Management Unit
THFL THFH
for Detected Part
Detection item
/ harness
Preconditions
• Voltage of temperature sensor in supply • Voltage of temperature sensor in supply
DTC set parameter
pump is 0.1 V or less pump is 4.9 V or above
number of error
detection
Limp Home Action
by engine ECU
(system action)
• Output limitation: Approximately 75 % of • Output limitation: Approximately 75 % of
normal condition normal condition
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0747US0
1-S70
Name Rail pressure sensor abnormality

ISO 14229
P0192 P0193
P-Code
SPN 157 157
J1939-73
FMI 4 3
SPN Name Engine Injector Metering Rail 1 Pressure Engine Injector Metering Rail 1 Pressure
SAE J1939 Table C1
DTC Name Rail pressure sensor: Low Rail pressure sensor: High
Management Unit
PCL PCH
for Detected Part
Detection item • Failure of sensor / harness.
• Failure of sensor
Preconditions • Sensor supply voltage VCC# is normal • Sensor supply voltage VCC# is normal
• Voltage of rail pressure sensor is 0.7 V or • Voltage of rail pressure sensor is 4.9 V or
DTC set parameter
less above
Time to action or • Transient • Transient
number of error
detection
• Speed limitation (Accelerator limitation: • Speed limitation (Accelerator limitation:
Limp Home Action
50 %) 50 %)
by engine ECU
(system action)
• Engine forcibly stopped 60 sec. later • Engine forcibly stopped 60 sec. later
• Insufficient output • Insufficient output
Behaviour During
• Worsening running noise • Worsening running noise
Malfunction
• Increase in white smoke • Increase in white smoke
• Engine stops • Engine stops
Light
error
recovery
• To minimize PM emission • To minimize PM emission
Remark • Engine running noise increases. • Engine running noise increases.
• White smoke increases. • White smoke increases.
9Y1200199CRS0748US0
1-S71
Name Injector charge voltage: High

ISO 14229
P0200
P-Code
SPN 523535
J1939-73
FMI 0
SPN Name proprietary
SAE J1939 Table C1
DTC Name Injector charge voltage: High
Management Unit
OCHG
for Detected Part
Detection item • Injector charge voltage: High
Preconditions • CPU is normal
DTC set parameter • Injector charge voltage: High
number of error
detection
Limp Home Action
• EGR stop
by engine ECU
(system action)
• Engine forcibly stopped 60 sec. later
Behaviour During
Malfunction
• Engine stops
Light
error
Delay time for –
recovery
Remark
9Y1200199CRS0749US0
1-S72
Name Open circuit of harness/coil

ISO 14229
P0201 P0202
P-Code
SPN 651 653
J1939-73
FMI 3 3
SPN Name Engine Injector Cylinder #01 Engine Injector Cylinder #03
SAE J1939 Table C1
Open circuit of harness/coil in 1st cylinder Open circuit of harness/coil in 3rd cylinder
DTC Name
injector injector
Management Unit
NCTWV1 NCTWV2
for Detected Part
• Open circuit of harness • Open circuit of harness
Detection item
• Open circuit of injector coil • Open circuit of injector coil
• Engine is operating • Engine is operating
Preconditions • During injection • During injection
• CPU is normal • CPU is normal
• Open circuit of harness or open circuit of • Open circuit of harness or open circuit of
DTC set parameter
injector coil injector coil
Time to action or • 8 times or more • 8 times or more
number of error
detection
Limp Home Action normal condition normal condition
by engine ECU • EGR stop • EGR stop
(system action) • Intake throttle 100 % open • Intake throttle 100 % open
Behaviour During
• Large vibration • Large vibration
Malfunction
Light
error
recovery
• Injectors which have no error are • Injectors which have no error are
Remark
operated. operated.
• Engine vibration increases. • Engine vibration increases.
9Y1200199CRS0750US0
1-S73
Name Open circuit of harness/coil

ISO 14229
P0203 P0204
P-Code
SPN 654 652
J1939-73
FMI 3 3
SPN Name Engine Injector Cylinder #04 Engine Injector Cylinder #02
SAE J1939 Table C1
Open circuit of harness/coil in 4th cylinder Open circuit of harness/coil in 2nd cylinder
DTC Name
injector injector
Management Unit
NCTWV3 NCTWV4
for Detected Part
• Open circuit of harness • Open circuit of harness
Detection item
• Open circuit of injector coil • Open circuit of injector coil
• Engine is operating • Engine is operating
Preconditions • During injection • During injection
• CPU is normal • CPU is normal
• Open circuit of harness or open circuit of • Open circuit of harness or open circuit of
DTC set parameter
injector coil injector coil
number of error
detection
Behaviour During
• Large vibration • Large vibration
Malfunction
Light
error
recovery
• Injectors which have no error are • Injectors which have no error are
Remark
operated. operated.
9Y1200199CRS0751US0
1-S74
Name Engine overheat Engine overrun

ISO 14229
P0217 P0219
P-Code
SPN 110 190
J1939-73
FMI 0 0
SPN Name Engine Coolant Temperature Engine Speed
SAE J1939 Table C1
DTC Name Engine overheat Engine overrun
Management Unit
THWOT NEOR
for Detected Part
Detection item • Overheat of engine coolant temperature • Engine speed exceeds threshold speed
DTC Set • Coolant temperature sensor is normal • Key switch is ON
Preconditions
• Engine coolant temperature ≥ 120 °C • Engine speed ≥ 3500 min-1 (rpm)
DTC set parameter
(248 °F)
Time to action or • 5 sec. or more • 3 revolutions or more
number of error
detection
• Output limitation: Approximately 75 % of • Stop injection (Q = 0 mm3/st)
Limp Home Action normal condition
(system action) • Intake throttle 100 % open
(except DOC model)
Behaviour During • Insufficient output • Overrun
Malfunction • Overheat
Light
error
Delay time for • 30 sec. • Immediately
recovery
Remark
9Y1200199CRS0752US0
1-S75
Name Boost pressure sensor abnormality

ISO 14229
P0237 P0238
P-Code
SPN 102 102
J1939-73
FMI 4 3
SPN Name Engine Intake Manifold #1 Pressure Engine Intake Manifold #1 Pressure
SAE J1939 Table C1
DTC Name Boost pressure sensor: Low Boost pressure sensor: High
Management Unit
PIML PIMH
for Detected Part
Detection item • Failure of sensor / harness
• Voltage of boost pressure sensor is 0.2 V • Voltage of boost pressure sensor is 4.9 V
DTC set parameter
or below or above
number of error
detection
Limp Home Action • 65kPa (0.66 kgf/cm2, 9.4 psi) • 65 kPa (0.66 kgf/cm2, 9.4 psi)
by engine ECU [default value] [default value]
(system action)
Malfunction
Light
error
recovery
• Default value is changed in • Default value is changed in
Remark consideration with high altitude usage consideration with high altitude usage
• Engine power drops. • Engine power drops.
9Y1200199CRS0753US0
1-S76
Name Crankshaft position sensor (NE sensor) abnormality

ISO 14229
P0335 P0336
P-Code
SPN 636 636
J1939-73
FMI 8 2
SPN Name Engine Position Sensor Engine Position Sensor
SAE J1939 Table C1
No input of NE sensor (Crankshaft position NE sensor (Crankshaft position sensor)
DTC Name
sensor) pulse pulse number error
Management Unit
NENOP NEPUM
for Detected Part
• Open circuit or short circuit of sensor / • Open circuit or short circuit of sensor /
Detection item harness harness
• Failure of sensor • Failure of sensor
DTC Set • Sensor supply voltage VCC# is normal • Sensor supply voltage VCC# is normal
Preconditions • Engine is not stalled • Engine speed is 350 min-1 (rpm) or
higher
DTC set parameter • No recognition of Ne sensor pulse • Pulse count per rotation is not 56 teeth
number of error
detection
(system action)
(Running only with G signal) (Running only with G signal)
Behaviour During • Faulty starting • Faulty starting
Malfunction • Vibration is slightly large • Vibration is slightly large
• Insufficinet output • Insufficinet output
Light
error
• Delay time varies with engine speed in • Delay time varies with engine speed in
proportional relation proportional relation
Delay time for
• If it is set 30 sec. at 800 min-1 (rpm), it is • If it is set 30 sec. at 800 min-1 (rpm), it is
recovery
shorten to 15 sec. at 1600 min-1 (rpm) shorten to 15 sec. at 1600 min-1 (rpm)
operation operation
• Faulty starting. • Faulty starting.
Remark
• Engine vibration increases slightly. • Engine vibration increases slightly.
9Y1200199CRS0754US0
1-S77
Name Camshaft position sensor (G sensor) abnormality

ISO 14229
P0340 P0341
P-Code
SPN 723 723
J1939-73
FMI 8 2
SPN Name Engine Speed 2 Engine Speed 2
SAE J1939 Table C1
No input of G sensor (Camshaft position G sensor (Camshaft position sensor) pulse
DTC Name
sensor) pulse number error
Management Unit
GNOP GPUM
for Detected Part
• Open circuit or short circuit of sensor / • Open circuit or short circuit of sensor /
• Failure of sensor • Failure of sensor
Preconditions • Engine is not stalled • Engine speed is 350 min-1 (rpm) or
higher
• No recognition of G sensor pulse • Pulse count per rotation is not
DTC set parameter
5 teeth
number of error
detection
Limp Home Action • None • None
by engine ECU
(system action)
Behaviour During (Invalid G signal) (Invalid G signal)
Malfunction • Engine hesitates at start-up • Engine hesitates at start-up
Light
error
• Delay time varies with engine speed in • Delay time varies with engine speed in
proportional relation proportional relation
Delay time for
• If it is set 30 sec. at 800 min-1 (rpm), it is • If it is set 30 sec. at 800 min-1 (rpm), it is
recovery
shorten to 15 sec. at 1600 min-1 (rpm) shorten to 15 sec. at 1600 min-1 (rpm)
operation operation
Remark • Engine hesitates at start-up • Engine hesitates at start-up
9Y1200199CRS0755US0
1-S78
Name Air heater relay driving circuit abnormality

ISO 14229
P0380 P0380
P-Code
SPN 523544 523544
J1939-73
FMI 3 4
SPN Name proprietary proprietary
SAE J1939 Table C1
+B short of air heater relay driving circuit Ground short of air heater relay driving
DTC Name
circuit
Management Unit
GRELBT GRELGD
for Detected Part
• +B short of air heater relay driving circuit • Ground short or open circuit of air heater
Detection item
relay driving circuit
DTC Set
• During air heater relay drive command is • Other than during air heater relay drive
Preconditions
activated command is activated
• +B short circuit of harness • Open circuit of harness, Ground short
DTC set parameter
circuit
Time to action or • 1 sec. or more • 1 sec. or more
number of error
detection
by engine ECU
(system action)
(At low temperature) (At low temperature)
Behaviour During
• Faulty starting • Faulty starting
Malfunction
• Increase in white smoke • Increase in white smoke
Light
error
recovery
(At low temperature)
Remark • Faulty starting
• White smoke increases.
9Y1200199CRS0756US0
1-S79
Name EGR actuator abnormality

ISO 14229
P0403 P0404 P0409
P-Code
SPN 523574 523574 523572
J1939-73
FMI 3 4 4
SPN Name proprietary proprietary proprietary
SAE J1939 Table
C1
DTC Name EGR actuator open circuit EGR actuator coil short EGR position sensor failure
Management Unit
DCMEGROPC DCMEGROCC LEGRC
for Detected Part
• EGR actuator open • EGR actuator coil short • EGR position sensor
Detection item
circuit failure
• Battery voltage is normal • Battery voltage is normal • Battery voltage is normal
• No DTC of U0077 "CAN1 • No DTC of U0077 "CAN1 • No DTC of U0077 "CAN1
DTC Set
Bus off" Bus off" Bus off"
Preconditions
• EGR control line is • EGR control line is • EGR control line is
normal normal normal
• EGR actuator open error • EGR actuator coil short • EGR position sensor
DTC set parameter signal received via CAN error signal received via error signal received via
CAN CAN
Time to action or • 2.8 sec or more • 2.8 sec. or more • 2.8 sec. or more
number of error
detection
• Output limitation: • Output limitation: • Output limitation:
Limp Home Action
Approximately 75 % of Approximately 75 % of Approximately 75 % of
by engine ECU
normal condition normal condition normal condition
(system action)
• EGR stop • EGR stop • EGR stop
• Insufficient output • Insufficient output • Insufficient output
Behaviour During
• Worsening exhaust gas • Worsening exhaust gas • Worsening exhaust gas
Malfunction
performance performance performance
Engine Warning • ON • ON • ON
Light
Recovery from • Key switch turn OFF • Key switch turn OFF • Key switch turn OFF
error
Delay time for – – –
recovery
Remark
9Y1200199CRS0757US0
1-S80
Name Oil pressure error

ISO 14229
P0524
P-Code
SPN 100
J1939-73
FMI 1
SPN Name Engine Oil Pressure
SAE J1939 Table C1
DTC Name Oil pressure error
Management Unit
POILDN
for Detected Part
Detection item • Oil pressure switch
DTC Set • Key switch turn ON
Preconditions • Starter Switch signal (ECU: V12 terminal) is not activated
• 10 sec or more after engine start [700 min-1 (rpm) or higher]
DTC set parameter • Oil pressure switch ON: continues one sec or more
Time to action or • Transient
number of error
detection
Limp Home Action • None
by engine ECU
(system action)
Behaviour During • Engine stops
Malfunction
Light
error
Delay time for –
recovery
Remark
9Y1200199CRS0758US0
1-S81
Name Exhaust gas temperature sensor 1 (T1) abnormality

ISO 14229
P0543 P0544
P-Code
SPN 3242 3242
J1939-73
FMI 4 3
SPN Name After treatment 1 Diesel Particulate Filter After treatment 1 Diesel Particulate Filter
SAE J1939 Table C1 Intake Gas Temperature Intake Gas Temperature
DTC Name Exhaust gas temperature sensor 1: Low Exhaust gas temperature sensor 1: High
Management Unit
THAEX1L THAEX1H
for Detected Part
Detection item
/ harness.
• Coolant temperature is 65 °C (149 °F) or
more: continues longer than 10 min. after
DTC Set engine starting
Preconditions • 100 °C (212 °F) ≤ T0 ≤ 800 °C (1472 °F):
continues longer than 10 sec. or 100 °C
(212°F) ≤ T2 ≤ 800 °C (1472 °F):
continues longer than 10sec.
• Diesel Particulate Filter (hereinafter • DPF inlet temperature sensor (T1)
referred to as the "DPF") inlet voltage: 4.92 V or more
DTC set parameter
temperature sensor (T1) voltage: 0.08 V
or less
number of error
detection
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0759US0
1-S82

ISO 14229
P0546 P0547
P-Code
SPN 4765 4765
J1939-73
FMI 4 3
SPN Name After treatment 1 Diesel Oxidation Catalyst After treatment 1 Diesel Oxidation Catalyst
SAE J1939 Table C1 Intake Gas Temperature Intake Gas Temperature
Management Unit
THAEX0L THAEX0H
for Detected Part
Detection item
/ harness.
(212°F) ≤ T2 ≤ 800 °C (1472 °F):
continues longer than 10 sec.
• DOC inlet temperature sensor (T0) • DOC inlet temperature sensor (T0)
DTC set parameter
voltage: 0.08 V or less voltage: 4.92 V or more
number of error
detection
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0760US0
1-S83
Name Battery voltage abnormality

ISO 14229
P0562 P0563
P-Code
SPN 168 168
J1939-73
FMI 4 3
SPN Name Battery Potential / Power Input 1 Battery Potential / Power Input 1
SAE J1939 Table C1
DTC Name Battery voltage: Low Battery voltage: High
Management Unit
VBBL VBBH
for Detected Part
• Open circuit, short circuit or damage of • Open circuit, short circuit or damage of
• Failure of battery • Failure of battery
• Key switch is ON • Key switch is ON
DTC Set
• Starter Switch signal (ECU: V12 • Starter Switch signal (ECU: V12
Preconditions
terminal) is not activated terminal) is not activated
• ECU recognition of battery voltage is • ECU recognition of battery voltage is
DTC set parameter below 8 V in 12 V system above 16 V in 12 V system
• Not monitored during cranking
number of error
detection
Light
Recovery from • Diagnostic counter = zero • Key switch turn OFF
error
Delay time for • 30 sec. –
recovery
Remark
9Y1200199CRS0761US0
1-S84
Name QR data abnormality

ISO 14229
P0602 P0602
P-Code
SPN 523538 523538
J1939-73
FMI 2 7
SAE J1939 Table C1
DTC Name QR data error No QR data
Management Unit
QRERR QRNOT
for Detected Part
Detection item • QR data read error from EEPROM • Area of QR data on EEPROM is vacant
DTC Set • Key switch is ON • Key switch is ON
Preconditions
DTC set parameter • QR data read error from EEPROM • Area of QR data on EEPROM is vacant.
number of error
detection
• Nozzle caribration is not executed • Nozzle correction factor = 0
Limp Home Action
• Output limitation: Approximately 75 % of [default value]
by engine ECU
normal condition • Output limitation: Approximately 75 % of
(system action)
normal condition
Malfunction
Light
error
recovery
Remark • To cover each injector dispersion
9Y1200199CRS0762US0
1-S85
Name ECU FLASH ROM and CPU abnormality

ISO 14229
P0605 P0606 P0606
P-Code
SPN 628 1077 523527
J1939-73
FMI 2 2 2
SPN Name Program Memory Engine Fuel Injection Pump Proprietary
SAE J1939 Table Controller
C1
ECU FLASH ROM error ECU CPU (Main IC) error ECU CPU (Monitoring IC)
DTC Name
error
Management Unit
FROM MCPU SCPU
for Detected Part
• FLASH ROM error • Failure of CPU • Failure of monitoring IC
Detection item
of CPU
• Key switch is ON • Key switch is ON • Key switch is ON
• Battery voltage is 10 V or • Battery voltage is 10 V or
DTC Set more more
Preconditions • Starter Switch signal • Starter Switch signal
(ECU: V12 terminal) is (ECU: V12 terminal) is
not activated not activated
• Check-sum error • CPU fatal error • Failure of monitoring IC
DTC set parameter
of CPU
Time to action or • 1 time or more • 1 time or more • 1 time or more
number of error
detection
Limp Home Action • Engine stopped without • Engine Stop • Engine Stop
by engine ECU delay
(system action)
Behaviour During • Engine stops • Engine stops • Engine stops
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0763US0
1-S86
Name Injector charge voltage abnormality

ISO 14229
P0611
P-Code
SPN 523525
J1939-73
FMI 1
SAE J1939 Table C1
DTC Name Injector charge voltage: Low
Management Unit
LCHG
for Detected Part
• Injector charge voltage: Low
Detection item
• Failure of charge circuit of ECU
Preconditions • CPU is normal
DTC set parameter
number of error
detection
• Insufficinet output
Behaviour During
Malfunction
Light
error
Delay time for –
recovery
Remark
9Y1200199CRS0764US0
1-S87
Name SCV drive system abnormality

ISO 14229
P0628 P0629
P-Code
SPN 1347 1347
J1939-73
FMI 4 3
SPN Name Engine Fuel Feed Pump Pressurizing Engine Fuel Feed Pump Pressurizing
SAE J1939 Table C1 Assembly #1 Assembly #1
DTC Name SCV drive system error +B short circuit of SCV
Management Unit
DRSCV BSSCV
for Detected Part
• Open circuit or ground short circuit of • +B short circuit of SCV
Detection item
SCV
DTC Set • Key switch is ON • Key switch is ON
Preconditions • Starter Switch signal (ECU: V12 • Starter Switch signal (ECU: V12
DTC set parameter • Open circuit or ground short of SCV • +B short circuit of SCV
number of error
detection
• Speed limitation (Accelerator limitation: • Speed limitation (Accelerator limitation:
Limp Home Action
50 %) 50 %)
by engine ECU
(system action)
• Engine forcibly stopped 60 sec later • Engine forcibly stopped 60 sec later
Behaviour During • Insufficinet output • Insufficinet output
Light
error
recovery
• Engine speed may go down due to low
fuel pressure regardless limp home
Remark de-rating
• Engine may stop automatically before
stopped forcibly by ECU
9Y1200199CRS0765US0
1-S88
Name Sensor supply voltage 1 abnormality

ISO 14229
P0642 P0643
P-Code
SPN 3509 3509
J1939-73
FMI 4 3
SPN Name Sensor supply voltage 1 Sensor supply voltage 1
SAE J1939 Table C1
DTC Name Sensor supply voltage 1: Low Sensor supply voltage 1: High
Management Unit
VCC1L VCC1H
for Detected Part
• Sensor supply voltage 1 error or • Sensor supply voltage 1 error or
Detection item
recognition error recognition error
DTC Set • Key switch turn ON • Key switch turn ON
DTC set parameter • Voltage to sensor is below 4.375 V • Voltage to sensor is above 5.625 V
number of error
detection
Limp Home Action • Speed limitation (Accelerator limitation: • Speed limitation (Accelerator limitation:
by engine ECU 50 %) 50 %)
• Engine stops in some case • Engine stops in some case
Light
error
recovery
• Emission related • Emission related
Remark • Faulty starting. • Faulty starting.
• Engine stops in some case. • Engine stops in some case.
9Y1200199CRS0766US0
1-S89
Name Sensor supply voltage 2 abnormality

ISO 14229
P0652 P0653
P-Code
SPN 3510 3510
J1939-73
FMI 4 3
SPN Name Sensor supply voltage 2 Sensor supply voltage 2
SAE J1939 Table C1
DTC Name Sensor supply voltage 2: Low Sensor supply voltage 2: High
Management Unit
VCC2L VCC2H
for Detected Part
• Sensor supply voltage 2 error or • Sensor supply voltage 2 error or
Detection item
recognition error recognition error
DTC Set • Key switch turn ON • Key switch turn ON
DTC set parameter • Voltage to sensor is below 4.375 V • Voltage to sensor is above 5.625 V
number of error
detection
(system action)
Behaviour During
Malfunction
Light
error
recovery
• Emission related • Emission related
Remark
9Y1200199CRS0767US0
1-S90
Name Main relay is locked in closed position

ISO 14229
P0687
P-Code
SPN 1485
J1939-73
FMI 2
SPN Name ECM Main Relay
SAE J1939 Table C1
DTC Name Main relay is locked in closed position
Management Unit
MRYCS
for Detected Part
Detection item • Failure of main relay
DTC Set • Key switch is OFF
Preconditions • Engine stops
DTC set parameter • Main relay stays active longer than 1 sec. without command
number of error
detection
Limp Home Action • None
by engine ECU
(system action)
Behaviour During • Dead battery
Malfunction
Engine Warning • OFF
Light
error
Delay time for • 5.3 sec.
recovery
Remark • Battery goes dead
9Y1200199CRS0768US0
1-S91
Name Pump seizing

ISO 14229
P1274
P-Code
SPN 523539
J1939-73
FMI 2
SAE J1939 Table C1
DTC Name Pump seizing 1
Management Unit
PMPPR
for Detected Part
Detection item • High pressure 1 error
Preconditions • Rail pressure sensor is normal
(Approximate parameter)
• Rail pressure of 230 MPa (2350 kgf/cm2, 33400 psi) or more continues 1 second under
the condition of above 800 min-1 (rpm)
DTC set parameter
• Rail pressure of 220 MPa (2250 kgf/cm2, 31900 psi) or more continues 1 second under
the condition of below 800 min-1 (rpm) [Threshold changes depending on the engine
speed. 700 min-1 (rpm) should be used as a reference]
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
Light
error
Delay time for –
recovery
Remark
• To avoid extremely high pressure in injection system
9Y1200199CRS0769US0
1-S92
Name Pump seizing

ISO 14229
P1275
P-Code
SPN 523540
J1939-73
FMI 2
SAE J1939 Table C1
DTC Name Pump seizing 2
Management Unit
PMPEX
for Detected Part
Detection item • High pressure 2 error
Preconditions • Rail pressure sensor is normal
(Approximate parameter)
• Rail pressure of above 197 MPa (2010 kgf/cm2, 28600 psi), and below 230 MPa
(2350 kgf/cm2, 33400 psi) continues total time for 35 seconds under condition of above
800 min-1 (rpm) [Threshold changes depending on the engine speed. 2000 min-1 (rpm)
DTC set parameter
should be used as a reference]
• Or, rail pressure of above 220 MPa (2250 kgf/cm2, 31900 psi) continues total time for
1.7 second under condition of below 800 min-1 (rpm) [Threshold changes depending on
the engine speed. 700 min-1 (rpm) should be used as a reference]
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
Light
error
Delay time for –
recovery
Remark
• To avoid extremely high pressure in injection system
9Y1200199CRS0770US0
1-S93
Name EEPROM check sum error

ISO 14229
P1990 P1991 P1992
P-Code
SPN 523700 523701 523702
J1939-73
FMI 13 13 13
SAE J1939 Table
C1
EEPROM check sum error EEPROM check sum error EEPROM check sum error
DTC Name
(DST1) (DST2)
Management Unit
EEPKB EEPDST1 EEPDST2
for Detected Part
• KBT-EEPROM check • DST1-EEPROM check • DST2-EEPROM check
Detection item
sum error sum error sum error
DTC Set • Battery voltage is normal • Battery voltage is normal • Battery voltage is normal
Preconditions
• EEPROM check sum • EEPROM check sum • EEPROM check sum
DTC set parameter
error error (DST1) error (DST2)
Time to action or • Transient • Transient • Transient
number of error
detection
Limp Home Action • None • None • None
by engine ECU
(system action)
Behaviour During • None • None • None
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0771US0
1-S94
Intake throttle feedback

Name Accelerator position sensor 1 abnormality
error
ISO 14229
P2108 P2122 P2123
P-Code
SPN 523580 91 91
J1939-73
FMI 2 4 3
SPN Name proprietary Accelerator Pedal Position 1 Accelerator Pedal Position 1
SAE J1939 Table
C1
Intake throttle feedback Accelerator position sensor Accelerator position sensor
DTC Name
error 1: Low 1: High
Management Unit
DCMIFB ACCP1L ACCP1H
for Detected Part
• Intake throttle feedback • Ground short circuit or • Battery short circuit out of
Detection item error open circuit of sensor / sensor / harness
harness
DTC Set
• Sensor supply voltage • Sensor supply voltage
Preconditions
VCC2 is normal VCC2 is normal
(Approximate parameter) • Voltage of accelerator • Voltage of accelerator
• Deviation of throttle position sensor 1 is 0.3 V position sensor 1 is 4.8 V
DTC set parameter
position is not corrected or less or less
in 20 times
Time to action or • 5 sec. or more • Transient • Transient
number of error
detection
• Output limitation: • Forced Idle • Forced Idle
Limp Home Action Approximately 75 % of (Accelerator = 0 %) (Accelerator = 0 %)
by engine ECU normal condition
(system action) • Intake throttle 100 %
open
Behaviour During • None • Insufficient output • Insufficient output
Malfunction
Light
Recovery from • Key switch turn OFF • Diagnostic counter = zero • Diagnostic counter = zero
error
Delay time for – • 3 sec. • 3 sec.
recovery
Remark
9Y1200199CRS0772US0
1-S95
Name Accelerator position sensor 2 abnormality

ISO 14229
P2127 P2128
P-Code
SPN 29 29
J1939-73
FMI 4 3
SPN Name Accelerator Pedal Position 2 Accelerator Pedal Position 2
SAE J1939 Table C1
DTC Name Accelerator position sensor 2: Low Accelerator position sensor 2: High
Management Unit
ACCP2L ACCP2H
for Detected Part
• Ground short circuit or open circuit of • Battery short circuit out of sensor /
Detection item
sensor / harness harness
Preconditions • Sensor supply voltage VCC1 is normal • Sensor supply voltage VCC1 is normal
• Voltage of accelerator position sensor 2 • Voltage of accelerator position sensor 2
DTC set parameter
is 0.3 V or less is 4.8 V or less
number of error
detection
Limp Home Action • Forced Idle (Accelerator = 0 %) • Forced Idle (Accelerator = 0 %)
by engine ECU
(system action)
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0773US0
1-S96
Accelerator position sensor corelation

Name Accelerator position sensor error (CAN)
error
ISO 14229
P2131 P2135
P-Code
SPN 523543 91
J1939-73
FMI 2 2
SPN Name proprietary Accel Pedal Sensor 1
SAE J1939 Table C1
DTC Name Accelerator position sensor error (CAN) Accelerator position sensor corelation error
Management Unit
ACCPCAN ACCPP
for Detected Part
• Accelerator position sensor signal error • Deviation from designed correlation in
Detection item (sensor / harness open circuit, ground two sensors
short circuit etc)
DTC Set • Key switch turn ON • Accelerator position sensor1 is normal
Preconditions • Starter Switch signal (ECU: V12 • Accelerator position sensor2 is normal
terminal) is not activated
• Accelerator position sensor error signal • Deviation from designed corelation in
DTC set parameter received by CAN two sensors
• It depends on engine application
number of error
detection
Limp Home Action • Not applicable • Forced Idle
by engine ECU (Accelerator = 0 %)
(system action)
Malfunction
Light
error (CAN signal recovers)
Delay time for • Immediately • 3 sec.
recovery
Remark
9Y1200199CRS0774US0
1-S97
Name Common 1 system injector drive circuit open

ISO 14229
P2146
P-Code
SPN 523523
J1939-73
FMI 2
SAE J1939 Table C1
DTC Name Injector drive circuit open in No.1 and 4 Cylinder simultaneously
Management Unit
NCCOM1
for Detected Part
Detection item • Wiring harness open circuit
• Engine is operating
Preconditions • During injection
• CPU is normal
DTC set parameter • When wiring harness open circuit
number of error
detection
Behaviour During • Large vibration
Light
error
Delay time for –
recovery
• Injectors which have no DTC are operated
Remark
• Engine vibration increases.
• Engine stops in some case.
9Y1200199CRS0775US0
1-S98
Name Common 1 TWV actuation system short

ISO 14229
P2147 P2148
P-Code
SPN 523523 523523
J1939-73
FMI 4 3
SAE J1939 Table C1
1 & 4 cylinder injector short to ground at 1 & 4 cylinder injector short to +B at power
DTC Name power supply side, or all cylinder injector supply side, or all cylinder injector short to
short to ground +B
Management Unit
GSTWV1 BSTWV1
for Detected Part
Detection item • Wiring harness short to ground • Wiring harness short to +B
DTC Set • Engine is operating • Engine is operating
Preconditions • Battery voltage is normal • Battery voltage is normal
• When wiring harness short to ground • When wiring harness short to +B occurs
DTC set parameter
occurs
number of error
detection
• Injectors which have DTC stop injection • Injectors which have error stop injection
Limp Home Action
by engine ECU
(system action)
Behaviour During • Large vibration • Large vibration
Light
error
recovery
• Injectors which have no DTC are • Injectors which have no DTC are
operated operated
Remark • To minimize PM emission • To minimize PM emission
9Y1200199CRS0776US0
1-S99
Name Common 2 system injector drive circuit open

ISO 14229
P2149
P-Code
SPN 523524
J1939-73
FMI 2
SAE J1939 Table C1
DTC Name Injector drive circuit open in No.2 and 3 Cylinder simultaneously
Management Unit
NCCOM2
for Detected Part
Detection item • Wiring harness open circuit
Preconditions • During injection
• CPU is normal
DTC set parameter • When wiring harness open circuit
number of error
detection
Behaviour During • Large vibration
Light
error
Delay time for –
recovery
• Injectors which have no DTC are operated
Remark
• Engine vibration increases.
• Engine stops in some case.
9Y1200199CRS0777US0
1-S100
Name Common 2 TWV actuation system short

ISO 14229
P2150 P2151
P-Code
SPN 523524 523524
J1939-73
FMI 4 3
SAE J1939 Table C1
2 & 3 cylinder injector short to ground at 2 & 3 cylinder injector short to +B at power
DTC Name power supply side, or all cylinder injector supply side, or all cylinder injector short to
short to ground +B
Management Unit
GSTWV2 BSTWV2
for Detected Part
Detection item • Wiring harness short to ground • Wiring harness short to +B
DTC Set • Engine is operating • Engine is operating
Preconditions • Battery voltage is normal • Battery voltage is normal
• When wiring harness short to ground • When wiring harness short to +B occurs
DTC set parameter
occurs
number of error
detection
• Injectors which have error stop injection • Injectors which have error stop injection
• Output limitation: Approximately 75 % of • Output limitation Approximately 75 % of
Limp Home Action
by engine ECU
(system action)
Behaviour During • Large vibration • Large vibration
Light
error
recovery
• Injectors which have no DTC are • Injectors which have no DTC are
operated operated
Remark • To minimize PM emission • To minimize PM emission
9Y1200199CRS0778US0
1-S101
Name Barometric pressure sensor error

ISO 14229
P2228 P2229
P-Code
SPN 108 108
J1939-73
FMI 4 3
SPN Name Barometric Pressure Barometric Pressure
SAE J1939 Table C1
Barometric pressure sensor error (Low Barometric pressure sensor error (High
DTC Name
side) side)
Management Unit
PATML PATMH
for Detected Part
• Sensor / ECU internal circuit short to • Sensor / ECU internal circuit short to +B
Detection item
ground
Preconditions
• Barometric pressure sensor voltage: • Barometric pressure sensor voltage:
DTC set parameter
1.6 V or less 4.4 V or more
number of error
detection
Limp Home Action • 65 kPa (0.66 kgf/cm2, 9.4 psi) • 65 kPa (0.66 kgf/cm2, 9.4 psi)
by engine ECU [default value] [default value]
(system action)
Malfunction
Light
error
recovery
• Default value is changed in • Default value is changed in
Remark consideration with high altitude usage consideration with high altitude usage
• Engine power drops. • Engine power drops.
9Y1200199CRS0779US0
1-S102
Name EGR (DC motor) abnormality

ISO 14229
P2413 P2414 P2415
P-Code
SPN 523575 523576 523577
J1939-73
FMI 7 2 2
SAE J1939 Table
C1
EGR actuator valve stuck EGR (DC motor) overheat EGR (DC motor)
DTC Name
temperature sensor failure
Management Unit
EGRVSC EGRAMBTMPC EGRTHC
for Detected Part
• EGR actuator valve stuck • EGR (DC motor) • EGR (DC motor)
Detection item overheat temperature sensor
failure
• No DTC of U0077 "CAN1 • No DTC of U0077 "CAN1 • No DTC of U0077 "CAN1
DTC Set
Bus off" Bus off" Bus off"
Preconditions
• EGR control line is • EGR control line is • EGR control line is
normal normal normal
• EGR actuator valve stuck • EGR (DC motor) • EGR (DC motor)
error signal received via temperature error signal temperature sensor error
DTC set parameter CAN (thermistor: 125 °C signal received via CAN
(257 °F) or more)
received via CAN
Time to action or • 2.8 sec. or more • 2.8 sec. or more • 2.8 sec. or more
number of error
detection
• Output limitation: • Output limitation: • Output limitation:
Limp Home Action
Approximately 75 % of Approximately 75 % of Approximately 75 % of
by engine ECU
normal condition normal condition normal condition
(system action)
• EGR stop • EGR stop • EGR stop
• Insufficient output • Insufficient output • Insufficient output
Behaviour During
• Worsening exhaust gas • Worsening exhaust gas • Worsening exhaust gas
Malfunction
performance performance performance
Light
error
recovery
Remark
9Y1200199CRS0780US0
1-S103

ISO 14229
P242C P242D
P-Code
SPN 3246 3246
J1939-73
FMI 4 3
SAE J1939 Table C1 Outlet Gas Temperature Outlet Gas Temperature
Management Unit
THAEX2L THAEX2H
for Detected Part
Detection item
/ harness.
(212°F) ≤ T1 ≤ 800 °C (1472 °F):
• DPF outlet temperature sensor (T2) • DPF outlet temperature sensor (T2)
DTC set parameter
voltage: 0.08 V or less voltage: 4.92 V or more
number of error
detection
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0781US0
1-S104
Name Differential pressure sensor 1 abnormality

ISO 14229
P2454 P2455
P-Code
SPN 3251 3251
J1939-73
FMI 4 3
SAE J1939 Table C1 Differential Pressure Differential Pressure
DTC Name Differential pressure sensor 1: Low Differential pressure sensor 1: High
Management Unit
PEX1L PEX1H
for Detected Part
Detection item
/ harness.
• DPF differential pressure sensor voltage: • DPF differential pressure sensor voltage:
DTC set parameter
0.21 V or less 4.7 V or more
number of error
detection
• 0 kPa (0.0 kgf/cm2, 0.0 psi) [default • 0 kPa (0.0 kgf/cm2, 0.0 psi) [default
Limp Home Action
value] value]
by engine ECU
(system action)
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0782US0
1-S105
Name Intake throttle lift sensor abnormality

ISO 14229
P2621 P2622
P-Code
SPN 523582 523582
J1939-73
FMI 4 3
SAE J1939 Table C1
DTC Name Intake throttle lift sensor: Low Intake throttle lift sensor: High
Management Unit
ITHRPREL ITHRPREH
for Detected Part
Detection item • Intake throttle lift sensor low • Intake throttle lift sensor high
• Intake throttle lift sensor voltage: 0.1 V or • Intake throttle lift sensor voltage: 4.89 V
DTC set parameter
less or more
Time to action or • 2.8 sec or more • 2.8 sec. or more
number of error
detection
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0783US0
1-S106
Name Emission deterioration

ISO 14229
P3001
P-Code
SPN 3252
J1939-73
FMI 0
SPN Name After treatment 1 Exhaust Gas
SAE J1939 Table C1 Temperature 2 Preliminary FMI
DTC Name Emission deterioration
Management Unit
DOCDTHEX
for Detected Part
Detection item • DOC is heated up due to unburned fuel
• Other than during regeneration mode
DTC Set
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 5 min after engine
Preconditions
starting
DTC set parameter • T1 − T0 ≥ 250 °C (482 °F)
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
• Intake throttle 100 % open
Malfunction
Light
error
Delay time for –
recovery
Remark • To minimize PM emission to DPF
9Y1200199CRS0784US0
1-S107
Exhaust gas temperature sensor 0: Exhaust gas temperature sensor 1:

Name
Emergency high Emergency high
ISO 14229
P3002 P3003
P-Code
SPN 4765 3242
J1939-73
FMI 0 0
SPN Name After treatment 1 Exhaust Gas After treatment 1 Exhaust Gas
SAE J1939 Table C1 Temperature 1 Preliminary FMI Temperature 2 Preliminary FMI
Emergency Emergency
DTC Name
Exhaust gas temperature sensor 0: High Exhaust gas temperature sensor 1: High
Management Unit
EXTEMPT0 EXTEMPT1
for Detected Part
Detection item • DOC inlet temperature (T0) high • DPF inlet temperature (T1) high
• Exhaust gas temperature sensor T0,T1 • Exhaust gas temperature sensor T0,T1
DTC Set
and T2 are normal and T2 are normal
Preconditions
• DOC inlet temperature (T0): 700 °C • DPF inlet temperature (T1): 715 °C
DTC set parameter
(1292 °F) or more (1319 °F) or more
Time to action or • 2.0 sec. or more • 9.0 min. or more
number of error
detection
• Stop injection (Q = 0 mm3/st) • Stop injection (Q = 0 mm3/st)
Limp Home Action • Engine stop • Engine stop
by engine ECU • Inhibit starter relay activation until • Inhibit starter relay activation until
(system action) exhaust gas temperature reduces down exhaust gas temperature reduces down
to 300 °C (572 °F) to 300 °C (572 °F)
• Engine stops • Engine stops
Behaviour During
• Inhibitef cranking until down to 300 °C • Inhibitef cranking until down to 300 °C
Malfunction
(572 °F) (572 °F)
Light
Recovery from • Under 300 °C (572 °F) & key switch turn • Under 300 °C (572 °F) & key switch turn
error OFF OFF
recovery
• In case engine ECU is not involved to • In case engine ECU is not involved to
drive starter, starter activation should be drive starter, starter activation should be
Remark inhibited by other way until exhaust gas inhibited by other way until exhaust gas
temperature reduces down to 300 °C temperature reduces down to 300 °C
(572 °F) (572 °F)
9Y1200199CRS0785US0
1-S108
Name Exhaust gas temperature sensor 2: Emergency high

ISO 14229
P3004
P-Code
SPN 3246
J1939-73
FMI 0
SPN Name After treatment 1 Exhaust Gas
SAE J1939 Table C1 Temperature 3 Preliminary FMI
Emergency
DTC Name
Exhaust gas temperature sensor 2: High
Management Unit
EXTEMPT2
for Detected Part
Detection item • DPF outlet temperature (T2) high
DTC Set • Exhaust gas temperature sensor T0,T1 and T2 are normal
Preconditions • Battery voltage is normal
DTC set parameter • DPF outlet temperature (T2): 820 °C (1508 °F) or more
Time to action or • 2.0 sec. or more
number of error
detection
• Stop injection (Q = 0 mm3/st)
• Engine stop
Limp Home Action
• EGR stop
by engine ECU
• Intake throttle 0 % open (Close)
(system action)
• Inhibit starter relay activation until exhaust gas temperature reduces down to 300 °C
(572 °F)
Behaviour During • Engine stops
Malfunction • Inhibitef cranking until down to 300 °C (572 °F)
Light
Recovery from • Under 300 °C (572 °F) & key switch turn OFF
error
Delay time for –
recovery
• In case engine ECU is not involved to drive starter, starter activation should be inhibited
Remark
by other way until exhaust gas temperature reduces down to 300 °C (572 °F)
9Y1200199CRS0786US0
1-S109
Name Excessive PM3

ISO 14229
P3006
P-Code
SPN 3701
J1939-73
FMI 15
SPN Name Diesel Particulate Filter Status
SAE J1939 Table C1
DTC Name Excessive PM3
Management Unit
DPFPMEX2
for Detected Part
Detection item • PM accumulation level3
Preconditions
• PM accumulation more than trigger level
DTC set parameter
• Regeneration level = 3
number of error
detection
by engine ECU
(system action)
Malfunction
Light
error
Delay time for • Immediately
recovery
Remark • To minimize PM out put
9Y1200199CRS0787US0
1-S110
Name Excessive PM4 Excessive PM5

ISO 14229
P3007 P3008
P-Code
SPN 3701 3701
J1939-73
FMI 16 0
SPN Name Diesel Particulate Filter Status Diesel Particulate Filter Status
SAE J1939 Table C1
DTC Name Excessive PM4 Excessive PM5
Management Unit
DPFPMEX3 DPFPMEX4
for Detected Part
Detection item • PM accumulation level4 • PM accumulation level5
Preconditions
• PM accumulation more than trigger level • PM accumulation more than trigger level
DTC set parameter
• Regeneration level = 4 • Regeneration level = 5
number of error
detection
(system action)
Malfunction
Light
error
Delay time for • Immediately –
recovery
• To minimize PM out put • To minimize PM out put
• Engine is not stopped forcibly by ECU
Remark However KUBOTA strongly
recommends operator to stop engine as
soon as possible.
9Y1200199CRS0788US0
1-S111
Name Boost pressure low

ISO 14229
P3011
P-Code
SPN 132
J1939-73
FMI 15
SPN Name Engine Inlet Air Mass Flow Rate
SAE J1939 Table C1
DTC Name Boost pressure low
Management Unit
GA2
for Detected Part
Detection item • Disconnect the hose between the turbo blower out and intake flange
• Other than during regeneration mode
• Target intake air flow value is 950 mg/cyl or more
• MAF sensor is normal
DTC Set
• EGR valve is normal
Preconditions
• Boost pressure sensor is normal
• Barometric pressure sensor is normal
• Coolant temperature sensor is normal
DTC set parameter • Boost pressure sensor output is below target level in high air flow operating condition
number of error
detection
Limp Home Action
by engine ECU
• EGR stop
(system action)
Malfunction
Light

error
Delay time for –

recovery
Remark • Engine power is restricted by boost pressure signal accordingly

• To minimize PM emission to DPF
9Y1200199CRS0789US0
1-S112
Low coolant temperature in parked

Name Parked regeneration time out
regeneration
ISO 14229
P3012 P3013
P-Code
SPN 523589 523590
J1939-73
FMI 17 16
SAE J1939 Table C1
Low coolant temperature in parked Parked regeneration time out
DTC Name
regeneration
Management Unit
ST5TIMEUP MNRGNTIMEUP
for Detected Part
• During regeneration mode, engine • Time out error: regeneration incomplete
Detection item warm-up condition is not satisfied due to low temperature of DPF
(coolant temperature is low)
• During parked active regeneration mode • During parked active regeneration mode
DTC Set
Preconditions
more
• Engine coolant temperature stays below • Regeneration process is not completed
DTC set parameter 65 °C (149 °F) for 1500 seconds or more within 2700 sec
under parked regeneration process.
number of error
detection
by engine ECU
(system action)
Malfunction
Light

error (Leaving from parked active (Leaving from parked active
regeneration status) regeneration status)
recovery
Remark
9Y1200199CRS0790US0
1-S113
All exhaust gas temperature sensor

Name Initial pump-calibration incomplete
failure
ISO 14229
P3018 P3019
P-Code
SPN 523599 523600
J1939-73
FMI 0 0
SAE J1939 Table C1
DTC Name All exhaust gas temperature sensor failure Initial pump-calibration incomplete
Management Unit
THAEXALL IPMPSTDYNOT
for Detected Part
• All exhaust gas temperature sensor • Pump-calibration history
Detection item
failure simultaneously
• Engine speed is 1400 min-1 (rpm) or • Battery voltage is normal
more
• Quantity of injection is 30 mm3/st or more
DTC Set • Coolant temperature is 65 °C (149 °F) or
Preconditions more: continues longer than 300 sec.
• Intake air temperature is 0 °C (32 °F) or
more
• Passed 100sec after cranking
• All exhaust gas temperature sensor • Initial pump calibration incomplete
DTC set parameter
failure (sensor low) simultaneously
Time to action or • 100 sec. or more • Transient
number of error
detection
Limp Home Action • Output limitation: Approximately 75 % of • None
by engine ECU normal condition
(system action)
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0791US0
1-S114
High exhaust gas temperature after

Name High frequency of regeneration
emergency high temperature DTC
ISO 14229
P3023 P3024
P-Code
SPN 523601 523602
J1939-73
FMI 0 0
SAE J1939 Table C1
High exhaust gas temperature after High frequency of regeneration
DTC Name
emergency high temperature DTC
Management Unit
STAINHIBIT RGNINTWRN
for Detected Part
• Exhaust gas temperature sensor 0, 1, 2 • Time interval from the end time to the
Detection item
output start time of the regeneration
• All exhaust gas temperature (T0, T1 and • Regeneration time interval within 30 min.
DTC set parameter
T2) reduces down to 300 °C (572°F) occurs three times continuously
number of error
detection
• Engine stop • Output limitation: Approximately 50 % of
Limp Home Action
• Inhibit starter relay activation until all normal condition
by engine ECU
exhaust gas temperature (T0, T1 and • EGR stop
(system action)
T2) reduces down to 300 °C (572 °F)
Behaviour During • None • Worsening exhaust gas performance
Malfunction (NOx)
Light
error
recovery
Remark
9Y1200199CRS0792US0
1-S115
Name Over heat pre-caution CAN2 Bus off

ISO 14229
P3025 U0075
P-Code
SPN 523603 523547
J1939-73
FMI 15 2
SAE J1939 Table C1
DTC Name Over heat pre-caution CAN2 Bus off
Management Unit
THWOT2 CANB2
for Detected Part
• Coolant temperature • CAN2 +B / GND short circuit or high
Detection item
traffic error
DTC Set • Coolant temperature sensor is normal • Battery voltage is normal
• Engine coolant temperature ≥ 110 °C • CAN2 Bus off
DTC set parameter
(230 °F)
Time to action or • Transient • 2 sec. or more
number of error
detection
Limp Home Action • None • Forced Idle (Accelerator = 0 %)
by engine ECU
(system action)
Behaviour During • Worsening exhaust gas performance • Insufficient output
Malfunction (NOx) • Transmitted data is invalid
Light
error
recovery
Remark • Transmitted CAN data are invalid.
9Y1200199CRS0793US0
1-S116
Name No communication with EGR CAN1 Bus off

ISO 14229
U0076 U0077
P-Code
SPN 523578 523604
J1939-73
FMI 2 2
SAE J1939 Table C1
DTC Name No communication with EGR CAN1 Bus off
Management Unit
CANOPENEGR CANB1
for Detected Part
• No communication with EGR • CAN1 +B / GND short circuit or high
Detection item
traffic error
DTC Set
• Starter Switch signal (ECU: V12 • Key switch is ON
Preconditions
terminal) is not activated
DTC set parameter • Interruption of CAN • CAN1 Bus off
Time to action or • 1.3 sec. or more • 2 sec. or more
number of error
detection
Malfunction • Worsening exhaust gas performance • Transmitted data is invalid
Light
error
recovery
Remark • Transmitted CAN data are invalid.
9Y1200199CRS0794US0
1-S117
Name CAN2 frame error

ISO 14229
U0081 U0082 U0083
P-Code
SPN 523548 523591 523592
J1939-73
FMI 2 2 2
SAE J1939 Table
C1
CAN-KBT frame error CAN CCVS (Parking SW CAN CM1 (Regen SW)
DTC Name and Vehicle Speed) frame frame error
error
Management Unit
CANOPENGENU CANOPENCCVS CANOPENCM1
for Detected Part
• CAN-KBT original frame • CAN_CCVS • CAN_CM1
Detection item
open circuit error communication stopping communication stopping
• Key switch turn OFF to • Starter Switch signal • Starter Switch signal
ON (ECU: V12 terminal) is (ECU: V12 terminal) is
DTC Set • Starter Switch signal not activated not activated
Preconditions (ECU: V12 terminal) is
not activated
• No error of "CAN2 Bus
off"
• CAN2 KBT frame open • CAN CCVS frame time • CAN CM1 frame time out
DTC set parameter
circuit error out error error
Time to action or • Transient • 0.5 sec. or more • 2.0 sec. or more
number of error
detection
Limp Home Action • Forced Idle • Parking SW = OFF, • Regeneration inhibit =
by engine ECU (Accelerator = 0 %) Vehicle speed = 0 ON, Parked regeneration
(system action) [default value] SW = OFF [default value]
Behaviour During • Insufficient output • None • None
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0795US0
1-S118

ISO 14229
U0084 U0085 U0086
P-Code
SPN 523593 523594 523595
J1939-73
FMI 2 2 2
SAE J1939 Table
C1
CAN DDC1 (Transmission) CAN ETC2 (Neutral SW) CAN ETC5 (Neutral SW)
DTC Name
frame error frame error frame error
Management Unit
CANOPENDDC CANOPENETC2 CANOPENETC5
for Detected Part
• CAN_DDC1 • CAN_ETC2 • CAN_ETC5
Detection item
communication stopping communication stopping communication stopping
DTC Set • Starter Switch signal • Starter Switch signal • Starter Switch signal
Preconditions (ECU: V12 terminal) is (ECU: V12 terminal) is (ECU: V12 terminal) is
not activated not activated not activated
• CAN DDC1 frame time • CAN ETC2 frame time • CAN ETC5 frame time
DTC set parameter
out error out error out error
Time to action or • 0.5 sec. or more • 0.5 sec. or more • 0.5 sec. or more
number of error
detection
• Accelerator non-linear • Neutral SW = OFF • Neutral SW = OFF
Limp Home Action processing flag = 0 [default value] [default value]
by engine ECU [default value]
(system action) • Accelerator non-linear
processing invalid
Behaviour During • None • None • None
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0796US0
1-S119

ISO 14229
U0087 U0089
P-Code
SPN 523596 523598
J1939-73
FMI 2 2
SAE J1939 Table C1
DTC Name CAN TSC1 frame error CAN EBC1 frame error
Management Unit
CANOPENTSC1TM CANOPENABS
for Detected Part
Detection item • CAN_TSC1 communication stopping • CAN_EBC1 communication stopping
DTC Set
• Starter Switch signal (ECU: V12 • Starter Switch signal (ECU: V12
Preconditions
• No request to "TSC1 buffer" continues 3 • CAN EBC1 frame time out error
DTC set parameter times after over-ride control request
(other than 0x00)
Time to action or • 60 msec. or more • 0.5 sec. or more
number of error
detection
Limp Home Action • Override control mode = Normal mode • Non shutdown [default value]
by engine ECU [default value] • Output limitation: Approximately 75 % of
(system action) normal condition
Malfunction
Light
error
recovery
Remark
9Y1200199CRS0797US0
NOTE
• If any DTC occurred, automatic active regeneration is inhibited.
• In case, "Excessive PM3", "Excessive PM4" and "High frequency of regeneration", parked active
regeneration function is allowed.
9Y1200199CRS0798US0
1-S120
[2] DIAGNOSTIC PROCEDURE BY DTC

If a DTC output indicates a malfunction, locate the malfunction by following the diagnostic procedure in the
following pages.
Follow the instructions of the diagnostic procedure when required to refer to other items.
In this manual, the diagnostic procedures are listed according to the Diagnostic Trouble Code (DTC) numbers as
shown. (In exceptional cases, some procedures are given in different positions.)
ISO J1939-73
14229 Name Reference Page
P-Code SPN FMI
P0016 636 7 NE-G phase shift 1-S124

P0072 171 4
Intake air temperature built-in MAF sensor abnormality 1-S125
P0073 171 3
P0087 633 7 Pressure limiter emergency open 1-S128
P0088 157 0 High rail pressure 1-S133
P0089 1347 7 SCV stuck 1-S138
P0093 1239 1 Fuel leak (in high pressured fuel system) 1-S143
P0101 132 1 Intake air volume: Low 1-S148
P0102 132 4
MAF sensor abnormality 1-S149
P0103 132 3
P0111 172 0 Intake air temperature: high (Inter cooler model only) 1-S151
P0112 172 4
Intake air temperature error 1-S152
P0113 172 3
P0117 110 4
Coolant temperature sensor abnormality 1-S155
P0118 110 3
P0181 174 0 Fuel high temperature 1-S158
P0182 174 4
Fuel temperature sensor abnormality 1-S159
P0183 174 3
P0192 157 4
Rail pressure sensor abnormality 1-S162
P0193 157 3
P0200 523535 0 Injector charge voltage: High 1-S166
P0201 651 3
P0202 653 3
Open circuit of harness/coil 1-S168
P0203 654 3
P0204 652 3
P0217 110 0 Engine overheat 1-S171
P0219 190 0 Engine overrun 1-S173
P0237 102 4
Boost pressure sensor abnormality 1-S174
P0238 102 3
P0335 636 8
Crankshaft position sensor (NE sensor) abnormality 1-S178
P0336 636 2
P0340 723 8
Camshaft position sensor (G sensor) abnormality 1-S183
P0341 723 2
P0380 523544 3
Air heater relay driving circuit abnormality 1-S187
P0380 523544 4
1-S121
ISO J1939-73
P-Code SPN FMI
P0403 523574 3
P0404 523574 4 EGR actuator abnormality 1-S191
P0409 523572 4
P0524 100 1 Oil pressure error 1-S194
P0543 3242 4
Exhaust gas temperature sensor 1 (T1) abnormality 1-S196
P0544 3242 3
P0546 4765 4
P0547 4765 3
P0562 168 4
Battery voltage abnormality 1-S202
P0563 168 3
P0602 523538 2
QR data abnormality 1-S205
P0602 523538 7
P0605 628 2
P0606 1077 2 ECU FLASH ROM and CPU abnormality 1-S206
P0606 523527 2
P0611 523525 1 Injector charge voltage abnormality 1-S208
P0628 1347 4
SCV drive system abnormality 1-S210
P0629 1347 3
P0642 3509 4
Sensor supply voltage 1 abnormality 1-S214
P0643 3509 3
P0652 3510 4
Sensor supply voltage 2 abnormality 1-S216
P0653 3510 3
P0687 1485 2 Main relay is locked in closed position 1-S218
P1274 523539 2
Pump seizing 1-S221
P1275 523540 2
P1990 523700 13
P1991 523701 13 EEPROM check sum error 1-S226
P1992 523702 13
P2108 523580 2 Intake throttle feedback error 1-S228
P2122 91 4
Accelerator position sensor 1 abnormality 1-S230
P2123 91 3
P2127 29 4
Accelerator position sensor 2 abnormality 1-S234
P2128 29 3
P2131 523543 2 Accelerator position sensor error (CAN) 1-S238
P2135 91 2 Accelerator position sensor corelation error 1-S240
P2146 523523 2 Common 1 system injector drive circuit open 1-S241
P2147 523523 4
Common 1 TWV actuation system short 1-S244
P2148 523523 3
P2149 523524 2 Common 2 system injector drive circuit open 1-S248
P2150 523524 4
Common 2 TWV actuation system short 1-S251
P2151 523524 3
1-S122
ISO J1939-73
P-Code SPN FMI
P2228 108 4
Barometric pressure sensor error 1-S255
P2229 108 3
P2413 523575 7
P2414 523576 2 EGR (DC motor) abnormality 1-S257
P2415 523577 2
P242C 3246 4
P242D 3246 3
P2454 3251 4
Differential pressure sensor 1 abnormality 1-S263
P2455 3251 3
P2621 523582 4
Intake throttle lift sensor abnormality 1-S267
P2622 523582 3
P3001 3252 0 Emission deterioration 1-S269
P3002 4765 0 Exhaust gas temperature sensor 0: Emergency high 1-S271
P3006 3701 15 Excessive PM3 1-S277
P3007 3701 16 Excessive PM4 1-S278
P3008 3701 0 Excessive PM5 1-S279
P3011 132 15 Boost pressure low 1-S280
P3012 523589 17 Low coolant temperature in parked regeneration 1-S282
P3013 523590 16 Parked regeneration time out 1-S283
P3018 523599 0 All exhaust gas temperature sensor failure 1-S285
P3019 523600 0 Initial pump-calibration incomplete 1-S286
High exhaust gas temperature after emergency high
P3023 523601 0 1-S287
temperature DTC
P3024 523602 0 High frequency of regeneration 1-S288
P3025 523603 15 Over heat pre-caution 1-S289
U0075 523547 2 CAN2 Bus off 1-S290
U0076 523578 2 No communication with EGR 1-S292
U0077 523604 2 CAN1 Bus off 1-S294
U0081 523548 2
U0082 523591 2
U0083 523592 2
U0084 523594 2
CAN2 frame error 1-S295
U0085 523593 2
U0086 523595 2
U0087 523596 2
U0089 523598 2
9Y1200199CRS0799US0
1-S123
(1) NE - G Phase Shift (DTC P0016 / 636-7)

Behaviour during malfunction: (Invalid G signal)
Detection item:
• Large phase shift between NE (crankshaft position sensor) pulse and G (camshaft position sensor) pulse
DTC set preconditions:
• Engine is operating above low idle speed
• NE signal is normal
• G signal is normal
• Coolant temperature is 10 °C (50 °F) or higher
DTC set parameter: (Approximate)
• Phase difference between NE pulse and G pulse within ±0.26 rad (±15 °)
Engine warning light:
• ON
Limp home action by engine ECU (system action):
Recovery from error:
• Diagnostic counter = zero
9Y1200199CRS0800US0
1. Check the Crankshaft Position Sensor and Camshaft
Position Sensor Signals
1. Run the engine and check the values of the "Engine speed
active flag" and "Cam speed active flag" with the data monitor
function.
Factory
Constantly ON
specification
OK Check the DTC (speed signal phase shift) again.
OK Normal.
NG Check each pulsar for damage and deviation, and correct.
NG Refer to "Crankshaft Position Sensor (NE sensor) Abnormality" (page
1-S178) and "Camshaft Position Sensor (G sensor) Abnormality" (page
1-S183).
NOTE
(Crankshaft position sensor side)
• The NE pulsar has deviated.
• A large magnetic substance has adhered to the pulsar,
hardened and rotates together with it, or the teeth have
been ground down.
(Camshaft position sensor side)
• The G pulsar plate is disconnected.
• The cam gear unit is disconnected, etc. (large side
clearance).
• A large magnetic substance has adhered to the pulsar,
hardened and rotates together with it, or the teeth have
been ground down.
(a) CAN1 Connector
9Y1200199CRS0801US0
1-S124
(2) Intake Air Temperature Built-in MAF Sensor: Abnormality (DTC P0072 /
171-4, DTC P0073 / 171-3)
P0072 / 172-4: Intake air temperature built-in MAF sensor abnormality (Low side)
Behaviour during malfunction:
• None
Detection item:
• Ground short circuit of sensor / harness
DTC set parameter:
• Intake air temperature built-in MAF sensor voltage: 0.1 V or less
• ON
• 25 °C (77 °F) [default value]
9Y1200199CRS0802US0
P0073 / 171-3: Intake air temperature built-in MAF sensor abnormality (High side)
• None
Detection item:
• Sensor / Harness short to +B
DTC set parameter:
• Intake air temperature built-in MAF sensor voltage: 4.9 V or more
• ON
9Y1200199CRS0803US0
1-S125
(1) Terminal Power (+12 V) (4) Terminal IATS (a) Terminal Layout (c) Intake Air Temperature
(2) Terminal Ground (5) Terminal A-GND 10 (b) Mass Air Flow (MAF) Sensor (Built-in MAF)
(3) Terminal AFS (d) ECU Connector 1
(Engine Side)
9Y1200199CRS0804US0
1. Check the Intake AIr Temperature Sensor Signals
1. Place the key switch in the ON position, and check the "Intake
air temperature" and "Intake air temperature sensor output
voltage" on the diagnosis tool data monitor.
Actual intake air
Intake air temperature Output voltage
temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 3.1 V
40 °C (104 °F) 40 °C (104 °F) Approx. 2.2 V
60 °C (140 °F) 60 °C (140 °F) Approx. 1.4 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.9 V
OK Clear the DTC and check whether it is output again or not.
OK Normal.
NG Replace the ECU.
NG Go to "2. Measure the Resistance Between Terminals".
(a) CAN1 Connector

9Y1200199CRS0805US0
1-S126
2. Measure the Resistance Between Terminals
1. Place the key switch in the OFF position, unplug the ECU wiring
harness connector from the socket, and measure the resistance
between terminals V45 and V49 of the connector.
Temperature Resistance
20 °C (68 °F) Approx. 2.43 kΩ
40 °C (104 °F) Approx. 1.15 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.321 kΩ
OK Go to "4. Measure the ECU Terminal Voltage".

NG Go to "3. Check the sensor".
9Y1200199CRS0806US0
3. Check the Sensor
1. Turn the key switch OFF, remove the connector from the sensor
side and measure the resistance between the terminals on the
sensor side.
20 °C (68 °F) Approx. 2.43 kΩ
40 °C (104 °F) Approx. 1.15 kΩ
60 °C (140 °F) Approx. 0.587 kΩ
80 °C (176 °F) Approx. 0.321 kΩ
OK Wiring harness open circuit or connector fault → Check and repair.

NG Intake air temperature sensor fault → Replace the mass air flow sensor.
(1) Terminal Power (+12 V) (4) Terminal IATS

(2) Terminal Ground (5) Terminal A-GND 10
(3) Terminal AFS
9Y1200199CRS0807US0
4. Measure the ECU Terminal Voltage
1. Plug the ECU wiring harness connector into socket again,
unplug the sensor connector, and measure the voltage between
ECU terminals V45 and V49 at the ECU side.
Factory
Approx. 5 V
specification
OK The ECU connector is faulty or its wiring harness is shorted.

NG Confirm by using other sensors that there is no ground short malfunction
before replacing the ECU.
9Y1200199CRS0808US0
1-S127
(3) Pressure Limiter Emergency Open (DTC P0087 / 633-7)

Detection item:
• Open circuit or +B short circuit of sensor / harness.
DTC set parameter:
• Combination of below A and B
A: Fuel leak (P0093) is detected
B: Condition (1) or (2) is fulfilled;
(1) Rail pressure exceeds 191 MPa (1950 kgf/cm2, 27700 psi)
(2) Within 1 sec, after the rail pressure goes below 191 MPa (1950 kgf/cm2, 27700 psi)
[Before the pressure decrease, the rail pressure is above 191 MPa (1950 kgf/cm2, 27700 psi)]
• ON
• EGR stop
• Key switch turn OFF
9Y1200199CRS0809US0
1-S128
Diagnostic Procedure for Pressure System DTCs
Checking of fault conditions and actions taken
If DTCs of non-pressure system are detected (*Refer to the pressure system DTCs given below.)
First locate the non-pressure system problem indicated by DTCs, and repair the affected parts. After the repair
has been carried out, check for an output of pressure system DTCs. If so, begin the diagnosis of the affected pressure
system.
If only pressure system DTCs are detected (*Refer to the pressure system DTCs given below.)
Diagnose the affected pressure system indicated by DTCs.
If a DTC currently exists

Begin diagnosis without returning the key switch to the OFF position. However, carefully make satisfactory /
unsatisfactory judgments as the injection amount and rail pressure are limited by system actions.
If only a past DTC exists

Log the freeze-frame data, clear the DTCs, and stop the engine. Then, try to reproduce the problem using the
freeze-frame data and the trouble check sheet.
*Pressure system DTCs
[High pressure abnormality]
1. P0088: High rail pressure
[Low pressure abnormality]
1. P0087: Pressure limiter emergency open
2. P0093: Fuel leak
[Abnormal pressure]
1. P0089: SCV stuck
2. P1274: Pump seizing 1
IMPORTANT
• Multiple pressure system DTCs may be output simultaneously. Also, both abnormal high pressure and
abnormal low pressure may be reported simultaneously under certain malfunction conditions.
9Y1200199CRS0810US0
1-S129
NOTE
• If the pressure limiter is opened, it will be kept open until the engine stops running. Therefore, the rail
pressure is kept at 40 to 60 MPa (410 to 610 kgf/cm2, 5800 to 8700 psi) regardless of its target rail pressure.
This point must be considered when measuring the rail pressure.
However, when the engine is stopped and the rail pressure reduces enough, the pressure limiter is closed
and the rail pressure will start to increase again.
• Even when the problem indicated by this DTC cannot be reproduced, the high pressure will have occurred
for certain reasons. Therefore, the cause of the high pressure must be identified.
9Y1200199CRS0811US0
1. Check the Data Related to the Rail Pressure
1. Connect the diagnosis tool to the CAN1 connector, and select
the "Actual rail pressure" and "Target rail pressure" on the data
monitor.
2. Observe the data signals by operating the accelerator pedal and
others and by performing the actual run test.
pressure"
1. When idling:
2. Accelerator opening 0 → 100 % (During acceleration):
Factory Maximum value 95.0 to 130 MPa (969 to 1320 kgf/cm2,
specification 13800 to 18800 psi)
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
OK Use all of the available information and try to reproduce the problem by
operating the accelerator pedal in different ways and by changing the
environmental conditions.
NG Go to "2. Check the Fuel System for the Existence of Air".
(a) CAN1 Connector

9Y1200199CRS0812US0
2. Check the Fuel System for the Existence of Air
1. Check each joint of the fuel system for the existence of air.
To detect the existence of air effectively, replace the fuel hose
with a transparent one.
NG Locate the position of the fuel leakage in the piping and repair it.
(1) Fuel Hose

9Y1200199CRS0813US0
1-S130
CAUTION
• Visually check there is no leak in the high pressure fuel
pipe system.
• A visual check is not possible if a leak (high pressure
system) occurs inside the head cover, so check that the oil
level has not increased.
OK Go to "4. Check the Rail Pressure Sensor".
(1) Rail (3) Dipstick

(2) Supply Pump
9Y1200199CRS0814US0
4. Check the Rail Pressure Sensor (*Refer to Items P0192 and
P0193)
1. Check the rail pressure sensor.
NOTE
• Closely check sensor signals for a noise component and
an abnormality that exists for a short time.
OK Go to "5. Check the DTC Again".
NG Repair or replace the rail pressure sensor or its related parts. (Follow the
diagnostic procedure of items P0192 and P0193.) (Refer to page
1-S162)
(a) CAN1 Connector

9Y1200199CRS0815US0
5. Check the DTC Again
1. Clear the past malfunction data, and make sure that the same
DTC is output again in the reproduction test.
Factory
Normal (No DTC is output.)
specification
NOTE
• Use all of the available information and try to reproduce the
problem by operating the accelerator pedal in different
ways and by changing the environmental conditions.
OK Normal.
NG Go to "6. Check the SCV-related Data".
(a) CAN1 Connector

9Y1200199CRS0816US0
1-S131
6. Check the SCV-related Data
1. Check the "Target rail pressure", "Actual rail pressure", "Target
SCV current", "Actual SCV current", "Pump deviation learning
status", "Pump deviation learning correction value" and
"Pressure feedback integral guard execution flag" on the data
monitor.
1. The "Actual SCV current value" always follow to the
"Target SCV current value".
• When idling: Approx. 1800 mA
• Accelerator opening: 0→100 % (During
acceleration): Approx. 1400 mA minimum
• During no-load maximum speed: Approx. 1600 mA
• The numerical value is stable under normal operating
and the target value corresponds with actual
pressure value.
* The current shall be used as a reference only as
this value varies depending on the pump used.
2. The "Pressure feedback integral guard executing flag"
Factory
must be OFF.
specification
3. The "Pump deviation learning correction value" must be
within ±200 mA.
NOTE
• As the following value of A varies depending on
pump, the table above is for guideline. If the value of
A has a wider shift than the initial learning value,
there may be out of the range of the above table.
A net normal value is the value that provided by the
forced-learning several times.: Compared with A
12 V spec.: A-100 ≤ normal value ≤ A+50
Therefore, if the value is out of the range above,
perform the forced-learning.
NOTE
• "Pump difference learning status"
It must be "2" (Learning completed) or "3" (During
relearning). If not, keep idling the engine after warming up
and when the learning status becomes "2" or "3", make the
judgment. Occasionally, it does not shift from 3 to 2.
Perform pump difference learning to take into account the
above status, then compare with the status before learning.
OK After confirming that an intermittent malfunction (such as power supply
system or noise generation) does not occur in relation to the ECU,
replace the ECU.
NG Replace the supply pump.
(a) CAN1 Connector

9Y1200199CRS0817US0
1-S132
(4) High Rail Pressure (DTC P0088 / 157-0)

Detection item:
• Actual pressure exceeds the command pressure
DTC set parameter:
• Actual pressure ≥ 197 MPa (2010 kgf/cm2, 28600 psi)
• ON
• EGR stop
9Y1200199CRS0818US0
1-S133
system.


2. P0093: Fuel leak
[Abnormal pressure]
1. P0089: SCV stuck
IMPORTANT
9Y1200199CRS0810US0
1-S134

monitor.
pressure"
1. When idling:
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
(a) CAN1 Connector

9Y1200199CRS0812US0
NG Locate the position of the fuel leakage in the piping and repair it.
(1) Fuel Hose

9Y1200199CRS0813US0
CAUTION
pipe system.

(2) Supply Pump
9Y1200199CRS0814US0
1-S135
P0193)
NOTE
1-S162)
(a) CAN1 Connector

9Y1200199CRS0815US0
Factory
specification
NOTE
OK Normal.
(a) CAN1 Connector

9Y1200199CRS0816US0
1-S136
monitor.
pressure value.
Factory
must be OFF.
specification
within ±200 mA.
NOTE
NOTE
replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0817US0
1-S137
(5) SCV Stuck (DTC P0089 / 1347-7)

Detection item:
• SCV stuck at open position (Actual rail pressure continuously exceeds the command rail pressure)
• Supply pump is normal and pump calibration has been executed
• Engine is operating (Q: 4 mm3/st or higher)
• Injector is normal
DTC set parameter:
• Discharge request of supply pump goes below 0 mm3/st and the actual rail pressure is 10 MPa (100 kgf/cm2,
1400 psi) higher than command pressure
• Above state continues for 26 seconds or more
• ON
• EGR stop
9Y1200199CRS0826US0
1-S138
system.


2. P0093: Fuel leak
[Abnormal pressure]
1. P0089: SCV stuck
IMPORTANT
9Y1200199CRS0810US0
1-S139

monitor.
pressure"
1. When idling:
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
(a) CAN1 Connector

9Y1200199CRS0812US0
Rotate the fuel feed pump sufficiently and bleed the air.
NG
Locate the position of the fuel leakage in the piping and repair it.
(1) Fuel Hose

9Y1200199CRS0829US0
CAUTION
pipe system.

(2) Supply Pump
9Y1200199CRS0814US0
1-S140
P0193)
NOTE
1-S162)
(a) CAN1 Connector

9Y1200199CRS0815US0
Factory
specification
NOTE
OK Normal.
(a) CAN1 Connector

9Y1200199CRS0816US0
1-S141
CAUTION
relearning). For cases other than those above, perform
pump difference learning and judge after status 2 or 3 is
entered. Occasionally, it does not shift from 3 to 2. Perform
pump difference learning to take into account the above
status, then compare with the status before learning.
monitor.
• During no-load maximum speed: Approx.1600 mA
pressure value.
Factory
must be OFF.
specification
within ±200 mA.
NOTE
3. Perform repeated sudden accelerations and decelerations, and
check that the target rail pressure and actual rail pressure
converge to approximately the same value.
Factory Converge to within 10 MPa (100 kgf/cm2, 1400 psi) within 20
specification seconds or less.
4. In addition, suddenly release the accelerator while driving at
maximum speed to test the temporary non-injection condition
without applying the brake (engine brake only) and check that
the target rail pressure and actual rail pressure converge to
approximately the same value.
Factory Converge to within 10 MPa (100 kgf/cm2, 1400 psi) within 20
specification seconds or less.

replace the ECU.
(a) CAN1 Connector

9Y1200199CRS1214US0
1-S142
(6) Fuel Leak (in High Pressured Fuel System) (DTC P0093 / 1239-1)
Detection item:
• Fuel leak from high pressured fuel system (Fuel consumption is calculated from the difference of fuel pressure of
before and after the injection, and the error will be detected when excess fuel consumption is found)
• Supply pump (SCV) is normal
• Injector and injector drive circuit are normal
• NE signal is active [Engine is operating (700 min-1 (rpm) or higher)]
• No DTC of P0087, P0088, P0089
DTC set parameter:
(a): the flow volume which is calculated from the difference of rail pressure (decrease)
(b): total volume of injection and leakage
Fuel leak is judged with following conditions:
• In case, engine speed is more than 1200 min-1 (rpm):
When the difference of (a) and (b) is 120 mm3/st or above, (a) is higher than (b), and fuel leak is not from opening
pressure limiter
• In case, engine speed is 1200 min-1 (rpm) or less:
When the difference of (a) and (b) is 400 mm3/st or above, (a) is higher than (b), and fuel leak is not from opening
pressure limiter
• ON
• EGR stop
9Y1200199CRS0834US0
1-S143
system.


2. P0093: Fuel leak
[Abnormal pressure]
1. P0089: SCV stuck
IMPORTANT
9Y1200199CRS0810US0
1-S144

monitor.
pressure"
1. When idling:
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
(a) CAN1 Connector

9Y1200199CRS0812US0
Rotate the fuel feed pump sufficiently and bleed the air.
NG
Locate the position of the fuel leakage in the piping and repair it.
(1) Fuel Hose

9Y1200199CRS0829US0
CAUTION
pipe system.

(2) Supply Pump
9Y1200199CRS0814US0
1-S145
P0193)
NOTE
OK Go to "5. Check the Pressure Limiter for a Fuel Leakage".
1-S162)
(a) CAN1 Connector

9Y1200199CRS0839US0
5. Check the Pressure Limiter for a Fuel Leakage
1. Check the temperature of the pressure limiter return pipe by
touching it.
Factory
Almost the same as the ambient temperature.
specification
(Reference)
• If the fuel leaks from the pressure limiter, the high temperature
and high pressure fuel flows through the return pipe and the
pipe becomes very hot.
OK Go to "6. Check for a Fuel Leakage".
NG Replace the common rail (pressure limiter).
(1) Pressure Limiter

9Y1200199CRS0840US0
6. Check for a Fuel Leakage
1. Increase the rail pressure by operating the accelerator pedal or
accelerator lever, and check for a fuel leakage.
Factory
No fuel leaks.
specification

NG Locate the leakage position and repair it.
(a) CAN1 Connector

9Y1200199CRS0841US0
Factory
specification
NOTE
OK Normal.
(a) CAN1 Connector

9Y1200199CRS0842US0
1-S146
monitor.
pressure value.
Factory
must be OFF.
specification
within ±200 mA.
NOTE
NOTE
relearning). For cases other than those above, perform
pump difference learning and judge after status 2 or 3 is
entered. Occasionally, it does not shift from 3 to 2. Perform
pump difference learning to take into account the above
status, then compare with the status before learning.
replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0843US0
1-S147
(7) Intake Air Volume: Low (DTC P0101 / 132-1)

Detection item:
• Engine inlet air mass flow rate lacking (Disconnect turbo blower intake hose)
• Engine is operating [1000 min-1 (rpm) or higher]
• Coolant temperature is 15 °C (59 °F) or higher (Coolant temperature sensor is normal)
DTC set parameter:
• Engine Inlet Air Mass Flow Rate: less than half of target value
• ON
• EGR stop
9Y1200199CRS0844US0
1. Check the Air Intake System
NOTE
• Check if the suction hose of the turbo blower does not
come off. If the hose comes off, install it.
• Check the clogging condition of the air cleaner. If it is very
dirty, replace the new one.
OK Go to "2. DTC Judgment".
(1) Hose Clamp (3) Turbocharger

(2) Hose
9Y1200199CRS0845US0
2. DTC Judgment
1. Place the key switch in the OFF position, and attach the
diagnosis tool to the CAN1 connector.
2. Operate the engine for 2 to 3 minutes with the engine in the idle
status.
3. Check whether the DTC is output or not.
Factory
Either DTC is output.
specification
OK Normal.
NG Replace the MAF Sensor or replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0846US0
1-S148
(8) MAF Sensor Abnormality (DTC P0102 / 132-4, P0103 / 132-3)

P0102 / 132-4: MAF sensor abnormality (Low side)
Detection item:
• Open circuit or ground short circuit of sensor / harness.
• Starter Switch signal (ECU: V12 terminal) is not activated
DTC set parameter:
• Mass air flow sensor voltage: 0.1 V or less
• ON
• Sensor output: 0.7 times of target value at normal condition [default value]
• EGR stop
9Y1200199CRS0847US0
P0103 / 132-3: MAF sensor abnormality (High side)
Detection item:
• +B short circuit of sensor / harness
• 700 min-1 (rpm) ≤ engine speed ≤ 2800 min-1 (rpm)
• Target intake mass air flow is 460 or less and it continues for 3 secs
DTC set parameter:
• Mass air flow sensor voltage: 4.9 V or more in certain operation condition
• ON
• Sensor output: 0.7 times of target value at normal condition [default value]
• EGR stop
9Y1200199CRS0848US0
1-S149
(1) Terminal Power (+12 V) (4) Terminal IATS (a) Terminal Layout (c) Intake Air Temperature
(2) Terminal Ground (5) Terminal A-GND10 (b) Mass Air Flow (MAF) Sensor Sensor (Built-in MAF)
(3) Terminal AFS (d) ECU Connector 1
(Engine Side)
9Y1200199CRS0849US0
1. Measure the Sensor Terminal Voltage
1. Move the key switch from the OFF to the ON position, and
measure the voltage between sensor terminals 1 and 2.
Factory
Approx. 10 to 16 V
specification
OK Go to "2. DTC Judgment".

NG Repair or replace the wiring harness, or replace the sensor
(1) Terminal Power (+12 V) (4) Terminal IATS

(2) Terminal Ground (5) Terminal A-GND10
(3) Terminal AFS
9Y1200199CRS0850US0
2. DTC Judgment
2. Operate the engine for 2 to 3 minutes with the engine in the idle
status.
3. Check whether the DTC is output or not.
Factory
Either DTC is output.
specification
OK Normal.
NG Replace the MAF Sensor or replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0846US0
1-S150
(9) Intake Air Temperature: High (Inter Cooler Model Only) (DTC P0111 /
172-0)
• None
Detection item:
• Intake air temperature too high
• Key switch is ON
DTC set parameter:
• Intake air temperature higher than ambient temperature +60 °C (+140 °F)
• ON
9Y1200199CRS0852US0
NOTE
• Check the clogging condition of the inter cooler. (Check
whether the inter cooler functions properly. If the inter
cooler has an electric fan, check whether it operates
properly.)
• Check whether the connection pipe of the inter cooler does
not come off.
OK Go to "2. Check the Intake Air Temperature (Refer to items P0072 and
P0073)".

(2) Hose
9Y1200199CRS0853US0
2. Check the Intake Air Temperature Sensor (*Refer to Items
P0072 and P0073)
1. Check the intake air temperature sensor. (Refer to psge
1-S125)
OK Normal.
NG Repair or replace the intake air temperature sensor or its related parts.
(Follow the diagnostic procedure of items P0072 and P0073.) (Refer to
page 1-S125)
(a) CAN1 Connector

9Y1200199CRS0854US0
1-S151
(10) Intake Air Temperature Error (DTC P0112 / 172-4, P0113 / 172-3)
P0112 / 172-4: Intake air temperature error (Low side)
• Amount of white smoke increases at low temperatures
Detection item:
DTC set parameter:
• Voltage of intake air temperature sensor is 0.05 V or less
• ON
• During start-up = −20 °C (−4 °F) [default value]
• Under other conditions = 40 °C (104 °F) [default value]
9Y1200199CRS0855US0
P0113 / 172-3: Intake air temperature error (High side)
Detection item:
• Open circuit or +B short circuit of sensor / harness
DTC set parameter:
• Voltage of intake air temperature sensor is 4.9 V or above
• ON
9Y1200199CRS0856US0
1-S152
(1) Terminal THA (2) Terminal THA RTN (a) Terminal Layout (c) ECU Connector 1
(b) Intake Air Temperature (Engine Side)
Sensor
9Y1200199CRS0857US0
1. Check the Intake Air Temperature Sensor Signals
1. Place the key switch in the ON position, and check the "Intake
air temperature" and "Intake air temperature sensor output
Actual intake air
Intake air temperature Output voltage
temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 2.4 V
40 °C (104 °F) 40 °C (104 °F) Approx. 1.5 V
60 °C (140 °F) 60 °C (140 °F) Approx. 0.9 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.5 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0858US0
1-S153
between terminals E47 and E56 of the connector.
20 °C (68 °F) Approx. 2.4 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
100 °C (212 °F) Approx. 0.18 kΩ

NG Go to "3. Check the Sensor".
9Y1200199CRS0859US0
3. Check the Intake Air Temperature Sensor
sensor side.
20 °C (68 °F) Approx. 2.4 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
100 °C (212 °F) Approx. 0.18 kΩ

NG Intake air temperature sensor fault → Replace the intake air temperature
sensor.
(1) Intake Air Temperature Sensor

9Y1200199CRS0860US0
ECU terminals E47 and E56 at the ECU side.
Factory
Approx. 5 V
specification

9Y1200199CRS0861US0
1-S154
(11) Coolant Temperature Sensor Abnormality (DTC P0117 / 110-4, P0118 /

110-3)
P0117 / 110-4: Coolant temperature sensor abnormality (Low side)
Detection item:
DTC set parameter:
• Voltage of coolant temperature sensor is 0.1 V or less
• ON
• EGR stop
9Y1200199CRS0862US0
P0118 / 110-3: Coolant temperature sensor abnormality (High side)
Detection item:
DTC set parameter:
• Voltage of coolant temperature sensor is 4.9 V or above
• ON
• EGR stop
9Y1200199CRS0863US0
1-S155
(1) Terminal THW (2) Terminal THW RTN (a) Terminal Layout (c) ECU Connector 1
(b) Coolant Temperature (Engine Side)
Sensor
9Y1200199CRS0864US0
1. Check the Coolant Temperature Sensor Signals
1. Place the key switch in the ON position, and check the "Coolant
temperature" and "Coolant temperature sensor output voltage"
on the diagnosis tool data monitor.
Actual coolant
Coolant temperature Output voltage
temperature
20 °C (68 °F) 20 °C (68 °F) Approx. 2.4 V
40 °C (104 °F) 40 °C (104 °F) Approx. 1.5 V
60 °C (140 °F) 60 °C (140 °F) Approx. 0.9 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.5 V
100 °C (212 °F) 100 °C (212 °F) Approx. 0.3 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0865US0
1-S156
20 °C (68 °F) Approx. 2.5 kΩ
40 °C (104 °F) Approx. 1.2 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
80 °C (176 °F) Approx. 0.32 kΩ
100 °C (212 °F) Approx. 0.18 kΩ

NG Go to "3. Check the sensor".
9Y1200199CRS0866US0
3. Check the Coolant Temperature Sensor
sensor side.
20 °C (68 °F) Approx. 2.5 kΩ
40 °C (104 °F) Approx. 1.2 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
80 °C (176 °F) Approx. 0.32 kΩ
100 °C (212 °F) Approx. 0.18 kΩ

NG Coolant temperature sensor fault → Replace the coolant temperature
sensor.

9Y1200199CRS0867US0
Factory
Approx. 5 V
specification

9Y1200199CRS0868US0
1-S157
(12) Fuel High Temperature (DTC P0181 / 174-0)

• None
Detection item:
• Fuel temperature high
• Passed 300 sec after cranking
• Fuel temperature sensor is normal
DTC set parameter:
• Fuel temperature higher than 90 °C (194 °F)
• ON
9Y1200199CRS0869US0
NOTE
• If the machine has a fuel fooler, check whether the fuel
cooler is installed to the proper position.
• Check whether the cooling performance does not decrease
due to dust.
• Check whether the fuel pipe is appropriate.
• Check the clogging condition of the fuel filter. If it is very
OK Go to "2. Check the Fuel Temperature sensor (Refer to items P0182 and
P0183)".
(1) Fuel Hose

9Y1200199CRS0870US0
2. Check the Fuel Temperature Sensor (*Refer to Items P0182
and P0183)
1. Check the fuel temperature sensor. (Refer to page 1-S159)
OK Normal.
NG Repair or replace the supply pump or its related parts. (Follow the
1-S159)
(a) CAN1 Connector

9Y1200199CRS0871US0
1-S158
(13) Fuel Temperature Sensor Abnormality (DTC P0182 / 174-4, P0183 / 174-3)
P0182 / 174-4: Fuel temperature sensor abnormality (Low side)
• None
Detection item:
DTC set parameter:
• Voltage of temperature sensor in supply pump is 0.1 V or less
• ON
9Y1200199CRS0872US0
P0183 / 174-3: Fuel temperature sensor abnormality (High side)
• None
Detection item:
DTC set parameter:
• Voltage of temperature sensor in supply pump is 4.9 V or above
• ON
9Y1200199CRS0873US0
1-S159
(1) Terminal THF (2) Terminal THF RTN (a) Terminal Layout (c) ECU Connector 1
(b) Fuel Temperature Sensor (Engine Side)
9Y1200199CRS0874US0
1. Check the Fuel Temperature Sensor Signals
1. Place the key switch in the ON position, and check the "Fuel
temperature" and "Fuel temperature sensor output voltage" on
the diagnosis tool data monitor.
Actual fuel temperature Fuel temperature Output voltage
20 °C (68 °F) 20 °C (68 °F) Approx. 2.4 V
40 °C (104 °F) 40 °C (104 °F) Approx. 1.5 V
60 °C (140 °F) 60 °C (140 °F) Approx. 0.9 V
80 °C (176 °F) 80 °C (176 °F) Approx. 0.5 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0875US0
1-S160
20 °C (68 °F) Approx. 2.5 kΩ
40 °C (104 °F) Approx. 1.2 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
80 °C (176 °F) Approx. 0.32 kΩ

9Y1200199CRS0876US0
3. Check the Fuel Temperature Sensor
sensor side.
20 °C (68 °F) Approx. 2.5 kΩ
40 °C (104 °F) Approx. 1.2 kΩ
60 °C (140 °F) Approx. 0.58 kΩ
80 °C (176 °F) Approx. 0.32 kΩ

NG Fuel temperature sensor fault → Replace the supply pump.
(1) Fuel Temperature Sensor

9Y1200199CRS0877US0
Factory
Approx. 5 V
specification

9Y1200199CRS0878US0
1-S161
(14) Rail Pressure Sensor Abnormality (DTC P0192 / 157-4, P0193 / 157-3)
P0192 / 157-4: Rail pressure sensor abnormality (Low side)
• Worsening running noise
• Increase in white smoke
• Engine stops
Detection item:
DTC set parameter:
• Voltage of rail pressure sensor is 0.7 V or less
• ON
• EGR stop
9Y1200199CRS0879US0
P0193 / 157-3: Rail pressure sensor abnormality (High side)
• Worsening running noise
• Engine stops
Detection item:
DTC set parameter:
• Voltage of rail pressure sensor is 4.9 V or above
• ON
• EGR stop
9Y1200199CRS0880US0
1-S162
(1) Terminal A-VCC1 (3) Terminal PFUEL RTN (a) Terminal Layout (c) ECU Connector 1
(2) Terminal PFUEL (b) Rail pressure sensor (Engine Side)
9Y1200199CRS0881US0
1. Check the Rail Pressure Sensor Signals
1. Place the key switch in the ON position, and check the "Actual
rail pressure" and "Rail pressure sensor output voltage" on the
diagnosis tool data monitor.
2. Next, start the engine, change the depressed amount of the
accelerator pedal, and check the same items again.
1. When stopped: Approx. 1.0 V
Factory
2. When idling: 1.65 to 1.80 V
specification
3. During no-load maximum speed: 2.50 to 2.85 V
4. During acceleration: 2.5 to 3.3 V
NOTE
• When idling: Approx. 40 to 50 MPa (410 to 500 kgf/cm2, 5800
to 7200 psi)
During no-load maximum speed: 95.0 to 115 MPa
(969 to 1170 kgf/cm2, 13800 to 16600 psi)
• Reference value (Factory spec.) has complete linearity.
OK Normal.
NG Replace the ECU.
NG Go to "2. Measure the ECU terminal voltage".
(a) CAN1 Connector

9Y1200199CRS0882US0
1-S163
measure the voltage between ECU terminals E68 and E78 and
between terminals E49 and E78.
Factory
specification
OK Check the harness connectors and ECU pins.
OK Faulty ECU → Replace.

NG Repair or replace the wiring harness, or replace the ECU.
NG Go to "3. Measure the voltage between rail pressure sensor terminals -
1".
9Y1200199CRS0883US0
3. Measure the Voltage Between Rail Pressure Sensor
Terminals - 1
1. Place the key switch in the ON position, and measure the
voltage between terminals (2) and (3) of the rail pressure sensor
at the wiring harness side.
Factory
specification
OK Check the wiring harness (between ECU terminals E49 / E68 and sensor
terminal (2)). → Repair the faulty area.
NG Go to "4. Measure the voltage between rail pressure sensor terminals -
2".
(1) Terminal A-VCC1 (a) Terminal Layout

(2) Terminal PFUEL
(3) Terminal PFUEL RTN
9Y1200199CRS0884US0
1-S164
4. Measure the Voltage Between Rail Pressure Sensor
Terminals - 2
1. Set the key switch to the OFF position, and unplug the rail
pressure sensor connector from the socket.
voltage between terminals (1) and (3) of the rail pressure sensor
connector (at the wiring harness side).
Factory
Approx. 5 V
specification
OK Check the wiring harness connector and sensor pins.
OK Faulty rail pressure sensor → Replace.

NG 1. Repair or replace the wiring harness.
2. Replace the rail assembly.
NG Go to "5. Measure the ECU Terminal Voltage".

(2) Terminal PFUEL
(3) Terminal PFUEL RTN
9Y1200199CRS0885US0
measure the voltage between ECU terminals E13 and E78.
Factory
Approx. 5 V
specification

NG Check the wiring harness (between ECU terminal E13 and sensor
terminal (1) and between ECU terminal E78 and sensor terminal (3)). →
Repair the faulty area.
9Y1200199CRS0886US0
1-S165
(15) Injector Charge Voltage: High (DTC P0200 / 523535-0)

NOTE
• This DTC is detected when the charge voltage in the injector actuation circuit is too high.

• Engine stops
Detection item:
• Injector charge voltage: High
• CPU is normal
DTC set parameter:
• Injector charge voltage: High
• ON
• EGR stop
9Y1200199CRS0887US0
1. Checking Whether the DTC is Detected Again
1. Turn the key switch OFF and then ON again.
2. After clearing the DTC, turn the key switch OFF and then ON
again, and start the engine.
3. Check whether or not the same DTC (P0200) is detected.
Factory
DTC is not detected.
specification
OK It could be a temporary malfunction caused by obstructions to the radio

waves, so as long as it recovers to normal operation there is no problem.
NG Go to "2. Replacing the Injector and Checking Whether the DTC Is
Detected Again".
(a) CAN1 Connector

9Y1200199CRS0888US0
2. Replacing the Injector and Checking Whether the DTC Is
Detected Again
1. Replace the injector.
Factory
specification
OK Injector fault → Replace the injector.

NG Go to "3. Replacing the ECU and Checking Whether the DTC Is
Detected Again".
(a) CAN1 Connector

9Y1200199CRS0889US0
1-S166
3. Replacing the ECU and Checking Whether the DTC Is
Detected Again
1. Replace the ECU.
Factory
specification
OK ECU fault → Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0890US0
1-S167
(16) Open Circuit of Harness/Coil (DTC P0201 / 651-3, P0202 / 653-3, P0203 /
654-3, P0204 / 652-3)
P0201 / 651-3: Engine No. 1 cylinder injector (TWV1) wiring harness open circuit, coil open circuit

• Large vibration
Detection item:
• Open circuit of harness
• Open circuit of injector coil
• During injection
• CPU is normal
DTC set parameter:
• Open circuit of harness or open circuit of injector coil
• ON
• EGR stop
9Y1200199CRS0891US0
1-S168
(1) Terminal COMMON (a) Terminal Layout (d) Constant Amperage Circuit (f) Control Circuit
(2) Terminal TWV (b) Engine Cylinder No. (e) High Voltage Generation (g) ECU Connector 1
(c) Injectors Circuit (Engine Side)
9Y1200199CRS0892US0
1. Measure the Resistance Between ECU Terminals
each terminal of the connector.
Engine cylinder / TWV number Measurement terminal
No. 1 cylinder / TWV1 E14, E34 ←→ E15, E35
Factory
1.5 Ω or lower
specification

NG Go to "4. Measure the Resistance Between Injector Terminals".
9Y1200199CRS0893US0
2. Check the DTC
1. Plug the ECU connector into socket, and start the engine.
2. Clear the DTCs that occurred previously, and check the
currently existing trouble.
Factory
No DTC is output.
specification
OK Go to "3. Check the Connector and Wiring Harnesses for Poor Contact".
NG Faulty ECU → Replace.
(a) CAN1 Connector

9Y1200199CRS0894US0
1-S169
3. Check the Connector and Wiring Harnesses for Poor Contact
1. Set the key switch to the OFF position, and check the wiring
harness connectors and ECU pins for incorrect connection,
deformation, poor contact or other defects.
Factory Must be free from faulty connection, deformation, poor
specification contact or other defects.
NOTE
• Intermediate connector and wiring harness in head cover
should be checked, they are possible cause.
OK Check the wiring harness and connector of P- GND terminal (ECU
terminals V39, V59, V79 and V80). → Repair.
NG Check the injector wiring harnesses and connectors. → Repair.
9Y1200199CRS0895US0
4. Measure the Resistance Between Injector Terminals
1. Unplug the injector cable connector of the cylinder indicated by
the DTC, and measure the resistance between injector
terminals (1) and (2).
Factory
0.35 to 0.55 Ω
specification
OK Check the wiring harnesses and connectors for a poor contact. →

Repair.
NG Faulty injector → Replace (Using the diagnosis tool, write the ID (QR)
code of replaced injector in the ECU.)
(1) Terminal COMMON (a) Injector

(2) Terminal TWV
(3) QR Code
(4) ID Code
9Y1200199CRS0896US0
1-S170
(17) Engine Overheat (DTC P0217 / 110-0)

• Overheat
Detection item:
• Overheat of engine coolant temperature
DTC set parameter:
• Engine coolant temperature ≥ 120 °C (248 °F)
• ON
• EGR stop
9Y1200199CRS0897US0
(1) Terminal THW (2) Terminal THW RTN (a) Terminal Layout (c) ECU Connector 1
(b) Coolant Temperature (Engine Side)
Sensor
9Y1200199CRS0898US0
1-S171
1. Check the Coolant Temperature Sensor Characteristics for
An Error
1. Refer to DTC P0117, P0118, and check the ECU, wiring
harness and sensor for an error.
OK Check the cooling system. → Repair the faulty area.
If the cooling system is operating normally, ask the user about
malfunction occurrence based on the freeze-frame data to determine
whether or not the system was used improperly.
NG Check and repair or replace the faulty parts.
(1) CAN1 Connector (a) Terminal Layout

(2) Terminal THW
(3) Terminal THW RTN
9Y1200199CRS0899US0
1-S172
(18) Engine Overrun (DTC P0219 / 190-0)

• Overrun
Detection item:
• Engine speed exceeds threshold speed
DTC set parameter:
• Engine speed ≥ 3500 min-1 (rpm)
• ON
9Y1200199CRS0900US0
1. Checking Whether the DTC Is Detected Again
Factory
specification
OK Go to "2. Checking with the User".

NG It could be a temporary malfunction caused by obstructions to the radio
(a) CAN1 Connector

9Y1200199CRS0901US0
2. Checking with the User
1. The following actions may have caused the overrun.
• Towing heavy objects
• Drag phenomenon when driving downhill
• Mistaken operation when making a sudden shift change
Question the user in detail about the items above and give
guidance.
9Y1200199CRS0902US0
1-S173
(19) Boost Pressure Sensor Abnormality (DTC P0237 / 102-4, P0238 / 102-3)
P0237 / 102-4: Boost temperature sensor abnormality (Low side)
Detection item:
DTC set parameter:
• Voltage of boost pressure sensor is 0.2 V or below
• ON
• 65 kPa (0.66 kgf/cm2, 9.4 psi) [default value]
9Y1200199CRS0903US0
P0238 / 102-3: Boost temperature sensor abnormality (High side)
Detection item:
DTC set parameter:
• Voltage of boost pressure sensor is 4.9 V or above
• ON
9Y1200199CRS0904US0
1-S174
(1) Terminal A-VCC2 (3) Terminal PIM RTN (a) Terminal Layout (c) ECU Connector 1
(2) Terminal PIM (b) Boost Pressure Sensor (Engine Side)
9Y1200199CRS0905US0
1. Check the Boost Pressure Signals
1. Place the key switch in the OFF position, attach the diagnosis
tool to the CAN1 connector, and return the key switch to the ON
position again. Then, check the "Boost pressure" and "Boost
pressure sensor output voltage" on the diagnosis tool data
monitor.
Engine state Actual boost pressure Output voltage
Approx. 100 kPa
Key switch is ON Approx. 1.0 V
(1.02 kgf/cm2, 14.5 psi)
100 to 180 kPa
After engine start-up (1.02 to 1.83 kgf/cm2, 1.0 to 2.2 V
14.5 to 26.1 psi)
NOTE
• Reference value (Factory specification) has complete
linearity.
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0906US0
1-S175
Engine state Output voltage
Key switch ON Approx. 1.0 V
After engine start-up 1.0 to 2.2 V

NG Go to "3. Measure the Voltage Between Boost Pressure Sensor
Terminals".
9Y1200199CRS0907US0
3. Measure the Voltage Between Boost Pressure Sensor
Terminals
voltage between terminals (2) and (3) of the boost pressure
sensor at the wiring harness side.
After engine start-up 1.0 to 2.2 V
OK Check the wiring harness (between ECU terminal E67 and sensor
NG Go to "4. Measure the Voltage Between Boost Pressure Sensor
Terminals".

(2) Terminal PIM
(3) Terminal PIM RTN
9Y1200199CRS0908US0
1-S176
4. Measure the Voltage Between Boost Pressure Sensor
Terminals
1. Set the key switch to the OFF position, and unplug the boost
pressure sensor connector from the socket.
voltage between terminals (1) and (3) of the boost pressure
sensor connector (at the wiring harness side).
Factory
Approx. 5 V
specification
OK Faulty boost pressure sensor → Replace.

2. Replace the boost pressure sensor.

(2) Terminal PIM
(3) Terminal PIM RTN
9Y1200199CRS0909US0
Factory
Approx. 5 V
specification

NG Check the wiring harness (between ECU terminal E33 and sensor
terminal (1) and between ECU terminal E77 and sensor terminal (3)).
→ Repair the faulty area.
NOTE
• Check the hose between intake manifold and sensor, When
it is damaged, the boost pressure can not reach the sensor.
9Y1200199CRS0910US0
1-S177
(20) Crankshaft Position Sensor (NE Sensor) Abnormality (DTC P0335 / 636-8,
P0336 / 636-2)
P0335 / 636-8: No input of NE sensor pulse
Behaviour during malfunction (Running only with G signal):
• Faulty starting
• Vibration is slightly large
Detection item:
• Open circuit or short circuit of sensor / harness
• Engine is not stalled
DTC set parameter:
• No recognition of Ne sensor pulse
• ON
NOTE
• Engine will stop if both NE and G fail
9Y1200199CRS0911US0
P0336 / 636-2: NE sensor pulse number error
Behaviour during malfunction (Running only with G signal):
• Faulty starting
• Vibration is slightly large
Detection item:
• 350 min-1 (rpm) or higher
DTC set parameter:
• Pulse count per rotation is not 56 teeth
• ON
NOTE
9Y1200199CRS0912US0
1-S178
(1) Terminal A-VCC1 (3) Terminal NE− (a) Terminal Layout (c) NE Sensor Input Circuit
(2) Terminal NE+ (b) Crankshaft Position Sensor (d) ECU Connector 1
(NE Sensor) (Engine Side)
9Y1200199CRS0913US0
1. Check the Crankshaft Position Sensor Signals
1. Rotate the engine, and check the "Engine speed active flag"
value on the diagnosis tool data monitor.
Factory
Always ON
specification
OK It should be confirmed two or more times while changing the accelerator.
OK Normal.
NG Go to "2. Check the Voltage Between Crankshaft Position
Sensor Terminals".
NG Go to "2. Check the Voltage Between Crankshaft Position Sensor
Terminals".
(a) CAN1 Connector

9Y1200199CRS0914US0
1-S179
2. Check the Voltage Between Crankshaft Position Sensor
Terminals
1. Place the key switch in the OFF position, and unplug the
crankshaft position sensor connector from the socket.
voltage between A-VCC1 terminal and NE− terminal at the
wiring harness side.
Factory
Approx. 5 V
specification
OK Go to "3. Check the Connectors".


(2) Terminal NE+
(3) Terminal NE−
9Y1200199CRS0915US0
3. Check the Connectors
1. Check the sensor and wiring harness connectors for incorrect
connection, inappropriate fitting, poor contact or other faulty
areas.
Factory Must be free from incorrect connection, inappropriate fitting,
specification poor contact.
OK Go to "4. Check the Wiring Harness".

NG Repair or replace.

(2) Terminal NE+
(3) Terminal NE−
9Y1200199CRS0916US0
4. Check the Wiring Harness
1. Check the wiring harness between NE+ terminal of sensor and
ECU for a short or an open circuit.
Factory
Must be free from shorts and open circuit.
specification
OK The sensor has abnormality. → Replace.

NG Repair.

(2) Terminal NE+
(3) Terminal NE−
9Y1200199CRS0917US0
1-S180
1. Place the key switch in the OFF position, and unplug the ECU
wiring harness connector 1 (1) from the socket.
voltage between ECU terminals E13 and E72.
Factory
Approx. 5 V
specification
OK Go to "6. Check the connectors".

NG Replace the ECU.
(1) ECU Wiring Harness Connector 1 (2) ECU Wiring Harness Connector 2
(Engine Side) (Machine Side)
9Y1200199CRS0918US0

1. Check ECU terminals E13, E52 and E72 (at the ECU side) and
the connectors (at the wiring harness side) for incorrect
connection, inappropriate fitting, poor contact.
OK Go to "7. Check the wiring harness".

9Y1200199CRS0919US0

1. Check the wiring harness being connected to ECU terminals
E13, E52 and E72 for a short or an open circuit.
Factory
specification
OK Go to "8. Check the Sensor".

NG Repair.
9Y1200199CRS0920US0

1. Disconnect the sensor and check the following items.
• Is there a large amount of magnetic foreign material
adhering to the sensor surface?
• Are there interference marks of the pulsar and the sensor?
• Are there any pulsar gear abnormalities?
OK Replace the ECU and test.
NG Repair or replace the sensor.

(NE Sensor)
9Y1200199CRS0921US0
1-S181
9. Check NE sensor pull-up resister
1. Remove the pull-up resister (1 kΩ) which is connected to
harness, then check next item.
• Check if there is improper connection of 1 kΩ resistive
element and connector.
• Check if there is damage of 1 kΩ resistive element.
(measure the resistance of resistive element with tester.)
NG Replace 1 kΩ resistive element, or improve improper connection.
(1) Resister 1 kΩ 1/4 W (4) Rail Pressure Sensor

(2) Crankshaft Position Sensor (5) Intake Air Temperature Sensor
9Y1200199CRS0922US0
1-S182
(21) Camshaft Position Sensor (G Sensor) Abnormality (DTC P0340 / 723-8,

P0341 / 723-2)
P0340 / 723-8: No input of G sensor pulse
Behaviour during malfunction (Invalid G signal):
Detection item:
• Engine is not stalled
DTC set parameter:
• No recognition of G sensor pulse
• ON
• None
NOTE
9Y1200199CRS0923US0
P0341 / 723-2: G sensor pulse number error
Behaviour during malfunction (Invalid G signal):
Detection item:
• Engine speed is 350 min-1 (rpm) or higher
DTC set parameter:
• Pulse count per rotation is not 5 teeth
• ON
• None
NOTE
9Y1200199CRS0924US0
1-S183
(1) Terminal G-VCC (3) Terminal G-GND (a) Terminal Layout (c) G Sensor Input Circuit
(2) Terminal G+ (b) Camshaft Position Sensor (d) ECU Connector 1
(G Sensor) (Engine Side)
9Y1200199CRS0925US0
1. Check the Camshaft Position Sensor Signals
1. Rotate the engine, and check the "Cam speed active flag" value
on the diagnosis tool data monitor.
Factory
Always ON
specification
OK It should be confirmed two or more times while changing the accelerator.
OK Normal.
NG Go to "2. Check the Voltage Between Camshaft Position Sensor
Terminals".
NG Go to "2. Check the Voltage Between Camshaft Position Sensor
Terminals".
(a) CAN1 Connector

9Y1200199CRS0926US0
1-S184
2. Check the Voltage Between Camshaft Position Sensor
Terminals
1. Place the key switch in the OFF position, and unplug the
camshaft position sensor connector from the socket.
voltage between G-VCC and G-GND terminals at the wiring
harness side.
Factory
Approx. 5 V
specification

(1) Terminal G-VCC (a) Terminal Layout

(2) Terminal G+
(3) Terminal G-GND
9Y1200199CRS0927US0
1. Check the sensor and wiring harness connectors for incorrect
connection, inappropriate fitting, poor contact or other faulty
areas.


(2) Terminal G+
(3) Terminal G-GND
9Y1200199CRS0928US0
1. Check the wiring harness between G+ terminal of sensor and
ECU for a short or an open circuit.
Factory
specification
OK The sensor has abnormality. → Replace.

NG Repair.

(2) Terminal G+
(3) Terminal G-GND
9Y1200199CRS0929US0
1-S185
voltage between ECU terminals E53 and E54.
Factory
Approx. 5 V
specification

NG Replace the ECU.
9Y1200199CRS0930US0

1. Check ECU terminals E53, E73 and, E54 (at the ECU side) and
the connectors (at the wiring harness side) for incorrect
connection, inappropriate fitting, poor contact.

9Y1200199CRS0931US0

1. Check the wiring harness being connected to ECU terminals
E53, E73 and E54 for a short or an open circuit.
Factory
specification
OK Go to "8. Check the Sensor".

NG Repair.
9Y1200199CRS0932US0

1. Disconnect the sensor and check the following items.
• Is there a large amount of magnetic foreign material
adhering to the sensor surface?
• Are there interference marks of the pulsar and the sensor?
• Are there any pulsar gear abnormalities?
NG Repair or replace the sensor.

(G Sensor)
9Y1200199CRS0933US0
1-S186
(22) Air Heater Relay Driving Circuit Abnormality (DTC P0380 / 523544-3 /
523544-4)
NOTE
• This item is a check related to the air heater (pre) relay control. Even if it is normal, air heating may not
work. If this happens, look for the malfunction in accordance with the following procedure.
P0380 / 523544-3: +B short of air heater relay driving circuit

Behaviour during malfunction (At low temperature):
• Faulty starting
Detection item:
• +B short of air heater relay driving circuit
• During air heater relay drive command is activated
DTC set parameter:
• +B short circuit of harness
• ON
• None
9Y1200199CRS0934US0
P0380 / 523544-4: Ground short of air heater relay driving circuit
Behaviour during malfunction (At low temperature):
• Faulty starting
Detection item:
• Ground short or open circuit of air heater relay driving circuit
• Other than during air heater relay drive command is activated
DTC set parameter:
• Open circuit of harness, Ground short circuit
• ON
• None
9Y1200199CRS0935US0
1-S187
(1) Terminal +B (4) Terminal GND (a) Fuse A: To Main Air Heater Relay
(2) Terminal MAHR (b) Air heater relay
(3) Terminal GRLY (c) ECU Connector 2
(Machine Side)
9Y1200199CRS0936US0
1. Check the GLRY Signal
1. Run the engine until the coolant temperature is 10 °C (50 °F) or
higher.
2. Check the "Glow relay" data with the data monitor.
Factory
OFF
specification
3. After disconnecting the connector (2) of coolant temperature
sensor and connect the dummy resistor (1) as shown in the left
figure, and turn the key switch ON.
Dummy Resistor: 15 to 25 kΩ [Comparable to Approx. –30 to
–20 °C (Approx. –22 to –5 °F)]
4. Check the "Glow relay" data with the data monitor.
Factory
ON
specification
OK Normal.
NG Go to "2. Check the Wiring Harness / Connector".
(1) Dummy Resistor (a) Coolant Temperature Sensor

(2) Connector
9Y1200199CRS0937US0
1-S188
2. Check the Wiring Harness / Connector
1. Remove the connector from the ECU side and check the state
of the continuity between terminal V24 and (3).
2. Next, check the state of the continuity between terminal V40 /
V60 and (4).
Factory
Both have continuity
specification
3. Check the connector for poor connection, engagement and
contact.
Factory
No poor connection, engagement or contact.
specification
OK Go to "3. Check the Relay".

NG Repair or replace the faulty areas.
(1) Terminal +B (a) Air Heater Relay

(2) Terminal MAHR A: To Main Air Heater Relay
(3) Terminal GRLY
(4) Terminal GND
9Y1200199CRS0938US0
3. Check the Relay
1. After disconnecting the connector of coolant temperature
sensor and connect the dummy resistor (5) as shown in the left
figure, and turn the key switch ON.
Dummy Resistor: 15 to 25 kΩ [Comparable to Approx. −30 to
−20 °C (Approx. −22 to −5 °F)]
2. Measure the voltage between (3) and (4).
Factory When relay is ON: Battery voltage value
specification When relay is OFF: Approx. 0 V
3. Check the state of the continuity between (1) and (2).
Factory When relay is ON: Continuity
specification When relay is OFF: No continuity
4. Measure the resistance in the relay unit (between (3) and (4)).
Factory
Coil resistance value of relay to use
specification
OK Go to "4. ECU replacement check".

NG Relay fault → Replace.
(1) Terminal +B (a) Air Heater Relay

(2) Terminal MAHR (b) Coolant Temperature Sensor
(3) Terminal GRLY
(4) Terminal GND
(5) Dummy Resistor
(6) Connector
9Y1200199CRS0939US0
1-S189
4. ECU Replacement Check
1. Replace the ECU and perform the previous "Check the GLRY
signal".
(a) CAN1 Connector

9Y1200199CRS0940US0
1-S190
(23) EGR Actuator Abnormality (DTC P0403 / 523574-3, DTC P0404 / 523574-4,
P0409 / 523572-4)
P0403 / 523574-3: EGR actuator open circuit
Detection item:
• EGR actuator open circuit
• No DTC of U0077 "CAN1 Bus off"
• EGR control line is normal
DTC set parameter:
• EGR actuator open error signal received via CAN
• ON
• EGR stop
9Y1200199CRS0941US0
P0404 / 523574-4: EGR actuator coil short
Detection item:
• EGR actuator coil short
DTC set parameter:
• EGR actuator coil short error signal received via CAN
• ON
• EGR stop
9Y1200199CRS0942US0
1-S191
P0409 / 523572-4: EGR position sensor failure
Detection item:
• EGR position sensor failure
DTC set parameter:
• EGR position sensor error signal received via CAN
• ON
• EGR stop
9Y1200199CRS0943US0
(1) Terminal CAN-H (3) Terminal Ground (a) Terminal Layout (d) ECU Connector 2
(2) Terminal CAN-L (4) Terminal Power (+12 V) (b) EGR Valve Assembly (Machine Side)
(c) Engine ECU A: To Diagnosis Tool
9Y1200199CRS0944US0
1-S192
1. DTC Judgment
2. Place the key switch in the ON position, check whether the DTC
is output or not.
3. Check the DTC again after starting up the engine with the
coolant temperature over 65 °C (149 °F).
Factory
DTC must not be output.
specification
OK Normal.
NG Replace the EGR assembly.
(a) CAN1 Connector

9Y1200199CRS0945US0
1-S193
(24) Oil Pressure Error (P0524 / 100-1)

• Engine stops
Detection item:
• Oil pressure switch
• Key switch turn ON
• 10 sec or more after engine start [700 min-1 (rpm) or higher]
DTC set parameter:
• Oil pressure switch ON: continues one sec or more
• ON
• None
(a) Oil Pressure Switch (b) Engine ECU (c) ECU Connector 2
(Machine Side)
9Y1200199CRS0946US0
1. DTC Judgment
(P0524) is output or not.
Factory
DTC (P0524) must not be output.
specification
OK Normal.
NG Go to "2. Check the Wiring Related to the Oil Pressure Switch".
(a) CAN1 Connector

9Y1200199CRS0947US0
1-S194
2. Check the Wiring Related to the Oil Pressure Switch
1. Check the connector and the wiring harness being connected to
ECU terminal V29 for a short or an open circuit.
IMPORTANT
• Refer to "6.[3] ELECTRIC SYSTEM INSPECTION
PROCEDURE - (1) Basics of Checking Electrical /
Electronic Circuit System". (Refer to page 1-S305)
OK Go to "3. Check the Oil Pressure Switch".
9Y1200199CRS0948US0
3. Check the Oil Pressure Switch
1. Replace the oil pressure switch and reconfirms it with the
service tool.
If the oil pressure can be measured, perform the oil pressure
measurement.
Factory
Operating pressure of the oil pressure switch: 0.5 kgf/cm2
specification
OK Oil pressure switch fault → Replace

NG Go to "4. Check the Oil and Oil Filter".
(1) 1 Oil Pressure Switch (2) Engine ECU

9Y1200199CRS0949US0
4. Check the Oil and Oil Filter
1. Replace specified oil and the oil filter and reconfirms it with the
service tool.
OK Deterioration of the oil and oil filter → Change
NG Go to "5. Check the Engine"
9Y1200199CRS0950US0
5. Check the Engine

1. Check the inside of the engine (oil passage).
OK Normal.
9Y1200199CRS0951US0
1-S195
(25) Exhaust Gas Temperature Sensor 1 (T1) Abnormality (DTC P0543 /

3242-4, P0544 / 3242-3)
P0543 / 3242-4: Exhaust gas temperature sensor 1 (T1) abnormality (Low side)
• None
Detection item:
DTC set parameter:
• Diesel Particulate Filter (hereinafter referred to as the "DPF") inlet temperature sensor (T1) voltage: 0.08 V or less
• ON
9Y1200199CRS0952US0
P0544 / 3242-3: Exhaust gas temperature sensor 1 (T1) abnormality (High side)
• None
Detection item:
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 10 min. after engine starting
• 100 °C (212 °F) ≤ T0 ≤ 800 °C (1472 °F): continues longer than 10 sec. or 100 °C (212°F) ≤ T2 ≤ 800 °C (1472 °F):
DTC set parameter:
• DPF inlet temperature sensor (T1) voltage: 4.92 V or more
• ON
9Y1200199CRS0953US0
1-S196
(1) Terminal A-GND3 (2) Terminal ODOC (a) Terminal Layout (c) ECU Connector 1
(b) Exhaust Gas Temperature (Engine Side)
Sensor 1 (T1)
9Y1200199CRS0954US0
1. Check the Exhaust Gas Temperature Sensor Signals
1. Place the key switch in the ON position, and check the "Exhaust
gas temperature" and "Exhaust gas temperature sensor output
Actual exhaust gas Exhaust gas
Output voltage
100 °C (212 °F) 100 °C (212 °F) Approx. 4.4 V
150 °C (302 °F) 150 °C (302 °F) Approx. 3.7 V
200 °C (392 °F) 200 °C (392 °F) Approx. 3.0 V
250 °C (482 °F) 250 °C (482 °F) Approx. 2.3 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0955US0
1-S197
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

9Y1200199CRS0956US0
3. Check the Sensor
sensor side.
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

NG Exhaust gas temperature sensor fault → Replace the exhaust gas
temperature sensor 1 (T1).
(1) Terminal A-GND3 (2) Terminal ODOC

9Y1200199CRS0957US0
Factory
Approx. 5 V
specification

9Y1200199CRS0958US0
1-S198
(26) Exhaust Gas Temperature Sensor 0 (T0) Abnormality (DTC P0546 /

4765-4, P0547 / 4765-3)
• None
Detection item:
DTC set parameter:
• DOC inlet temperature sensor (T0) voltage: 0.08 V or less
• ON
9Y1200199CRS0959US0
• None
Detection item:
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 5 min. after engine starting
• 100 °C (212 °F) ≤ T1 ≤ 800 °C (1472 °F): continues longer than 10 sec. or 100 °C (212 °F) ≤ T2 ≤ 800 °C (1472 °F):
DTC set parameter:
• DOC inlet temperature sensor (T0) voltage: 4.92 V or more
• ON
9Y1200199CRS0960US0
1-S199
(1) Terminal A-GND3 (2) Terminal IDOC (a) Terminal Layout (c) ECU Connector 1
Sensor 0 (T0)
9Y1200199CRS0961US0
Output voltage
100 °C (212 °F) 100 °C (212 °F) Approx. 4.4 V
150 °C (302 °F) 150 °C (302 °F) Approx. 3.7 V
200 °C (392 °F) 200 °C (392 °F) Approx. 3.0 V
250 °C (482 °F) 250 °C (482 °F) Approx. 2.3 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0962US0
1-S200
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

9Y1200199CRS0963US0
3. Check the Sensor
sensor side.
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

(1) Terminal A-GND3 (2) Terminal IDOC

9Y1200199CRS0964US0
Factory
Approx. 5 V
specification

9Y1200199CRS0965US0
1-S201
(27) Battery Voltage Abnormality (DTC P0562 / 168-4, P0563 / 168-3)

P0562 / 168-4: Battery voltage abnormality (Low side)
• Faulty starting
Detection item:
• Open circuit, short circuit or damage of harness
• Failure of battery
DTC set parameter:
• ECU recognition of battery voltage is below 8 V in 12 V system
• Not monitored during cranking
• ON
• EGR stop
9Y1200199CRS0966US0
P0563 / 168-3: Battery voltage abnormality (High side)
• Faulty starting
Detection item:
• Open circuit, short circuit or damage of harness
• Failure of battery
DTC set parameter:
• ECU recognition of battery voltage is above 16 V in 12 V system
• ON
• EGR stop
9Y1200199CRS0967US0
1-S202
(a) Main Relay (b) Battery (c) ECU Connector 2

(Machine Side)
9Y1200199CRS0968US0
1. Check the ECU Data
position again. Then, check the "Battery voltage" status on the
data monitor.
2. Change the engine operation status, and check the "Battery
voltage".
Factory 8 V or higher, 15 V or lower
specification (except intense cold temperature)
NOTE
• Try to change the engine speed as the generated voltage
changes accordingly.
OK Normal.
NG Replace the ECU.
NG Go to "2. Check the ECU Terminal Voltage (Part 1)".
(a) CAN1 Connector

9Y1200199CRS0969US0
1-S203
2. Check the ECU Terminal Voltage (Part 1)
1. Change the engine operation status, and measure the voltage
between ECU terminals V18 / V38 / V58 / V78 and V40 / V60
and between terminals V01 / V02 and V40 / V60.
Factory 8 V or higher, 15 V or lower
specification (except intense cold temperature)
NOTE

NG Go to "3. Check the ECU Terminal Voltage (Part 2)".
9Y1200199CRS0970US0
3. Check the ECU Terminal Voltage (Part 2)
1. Change the engine operation status, and measure the voltage
between ECU terminal V40 / V60 and chassis ground terminal.
Factory
Always 0.5 V or lower
specification
NOTE
OK 1. Check the charging system, the battery itself, wiring harness and
cables. → Repair the faulty area.
2. Locate the cause of excessively high or low voltage.
NG Check the wiring harness between ECU terminal and the body ground
terminal. → Repair the defects.
9Y1200199CRS0971US0
1-S204
(28) QR Data Abnormality (DTC P0602/523538-2, P0602/523538-7)

P0602 / 523538-2: QR data error
Detection item:
• QR data read error from EEPROM
DTC set parameter:
• QR correction data exceeds threshold value
• Multiple check error (QR correction data for each injector has been stored in three locations. When this data is
read and compared, an error is determined if there is difference in all three values.)
• ON
• Nozzle calibration is not executed
9Y1200199CRS0972US0
P0602 / 523538-7: No QR data
Detection item:
• Area of QR data on EEPROM is vacant.
DTC set parameter:
• When QR correction data fails to write to the EEPROM (When the initial ECU value is "0", an error that QR data
is not written to the disc at the time of vehicle shipment is detected.)
• ON
• Nozzle correction factor = 0 [default value]
9Y1200199CRS0973US0
1. Write the QR Codes and Read the DTC Again
1. Using the diagnosis tool, write the correct QR codes in the ECU.
2. Clear the DTC and check whether the same DTC is output
again or not.
Factory
OK
specification
OK An electromagnetic interference (EMI) may have caused the temporary

malfunction. There is no problem if the system has recovered.
NG Faulty Engine ECU.
(a) CAN1 Connector

9Y1200199CRS0974US0
1-S205
(29) ECU Flash-ROM and CPU Abnormality (DTC P0605 / 628-2, P0606 / 1077-2,
P0606/ 523527-2)
P0605 / 628-2: ECU Flash-ROM error
• Engine stops
Detection item:
• FLASH ROM error
DTC set parameter:
• 3 times or more consecutive inconsistencies in checksum
• ON
• Engine stopped without delay
9Y1200199CRS0975US0
P0606 / 1077-2: ECU CPU (Main IC) error
• Engine stops
Detection item:
• Failure of CPU
• Battery voltage is 10 V or more
DTC set parameter:
• CPU abnormality counter ≥ 5 times (RUN pulse abnormality occurs 5 times or more)
• ON
• Engine Stop
9Y1200199CRS0976US0
P0606 / 523527-2: ECU CPU (Monitoring IC) error
• Engine stops
Detection item:
• Failure of monitoring IC of CPU
• Battery voltage is 10 V or more
DTC set parameter:
• Abnormality continues for 2000 msec or more after the ECU is turned ON
• RUN pulse abnormality
• Above conditions occur continuously for 700 msec or more
• ON
• Engine Stop
9Y1200199CRS0977US0
1-S206
1. Check the DTC
position again.
2. Clear the DTC, and check whether the same DTC (P0605 or
P0606) is output again or not.
Factory
No DTC is output.
specification

NG Faulty Engine ECU → Replace.
(a) CAN1 Connector

9Y1200199CRS0978US0
1-S207
(30) Injector Charge Voltage Abnormality (DTC P0611 / 523525-1)

NOTE
• This DTC is detected when the charge voltage in the injector actuation circuit is too low.

Detection item:
• CPU is normal
DTC set parameter:
• ON
• EGR stop
9Y1200199CRS0979US0
(c) Injector Circuit (Engine Side)
9Y1200199CRS0980US0
1-S208
1. Checking Whether the DTC Is Detected Again
Factory
specification
OK It could be a temporary malfunction caused by obstructions to the radio

NG Go to "2. Replacing the Injector and Checking Whether the DTC Is
Detected Again".
(a) CAN1 Connector

9Y1200199CRS0981US0
2. Replacing the Injector and Checking Whether the DTC Is
Detected Again
1. Replace the injector.
Factory
specification
OK Injector fault → Replace the injector.

NG Go to "3. Replacing the ECU and Checking Whether the DTC Is
Detected Again".
(a) CAN1 Connector

9Y1200199CRS0982US0
3. Replacing the ECU and Checking Whether the DTC Is
Detected Again
1. Replace the ECU.
Factory
specification
(a) CAN1 Connector

9Y1200199CRS0983US0
1-S209
(31) SCV Drive System Abnormality (DTC P0628 / 1347-4, P0629 / 1347-3)
P0628 / 1347-4: SCV drive system error
Detection item:
• Open circuit or ground short circuit of SCV
DTC set parameter:
• Open circuit or ground short of SCV
• ON
• EGR stop
• Engine forcibly stopped 60 sec later
9Y1200199CRS0984US0
P0629 / 1347-3: +B short circuit of SCV
Detection item:
• +B+B short circuit of SCV
DTC set parameter:
• +B short circuit of SCV
• ON
• EGR stop
• Engine forcibly stopped 60 sec later
9Y1200199CRS0985US0
1-S210
(1) Terminal SCV+ (2) Terminal SCV- (a) Terminal Layout (c) ECU Connector 1
(b) SCV (Suction Control Valve) (Engine Side)
9Y1200199CRS0986US0
1-S211
1. Check the SCV Current
1. Place the key switch in the ON position, and check the "Target
SCV current" and "Actual SCV current" on the diagnosis tool
data monitor.
• Accelerator opening: 0→100 %
(During acceleration): Approx. 1400 mA minimum
• During no-load maximum speed: Approx.1600 mA
The numerical value is stable under normal
operating and the target value corresponds with
actual pressure value.
Factory
must be OFF.
specification
within ±200 mA.
NOTE
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0987US0
between terminals E09 / E29 and E10 / E30 of the connector.
Item Temperature Resistance
Resistance 20 °C (68 °F) Approx. 2.1 Ω
Insulation resistance
(between terminal 20 °C (68 °F) 100 MΩ or higher
valves)

NG Go to "3. Check the SCV".
9Y1200199CRS0988US0
1-S212
3. Check the SCV
1. Turn the key switch OFF, remove the connector from the SCV
SCV side.
valves)

NG SCV fault → Replace the supply pump.

9Y1200199CRS0989US0
1. Unplug the ECU wiring harness connector 1 from socket, and
measure the voltage between ECU terminals E09 / E29 and
E10 / E30 and the ground (at the wiring harness side).
Factory
Both must be approx. 0 V.
specification
OK Normal.
NG Repair the wiring harness.
9Y1200199CRS0990US0
1-S213
(32) Sensor Supply Voltage 1 Abnormality (DTC P0642 / 3509-4, P0643 /

3509-3)
P0642 / 3509-4: Sensor supply voltage 1 abnormality (Low side)
• Faulty starting
Detection item:
• Sensor supply voltage 1 error or recognition error
DTC set parameter:
• Voltage to sensor is below 4.375 V
• ON
• EGR stop
9Y1200199CRS0991US0
P0643 / 3509-3: Sensor supply voltage 1 abnormality (High side)
• Faulty starting
Detection item:
DTC set parameter:
• Voltage to sensor is above 5.625 V
• ON
• EGR stop
9Y1200199CRS0992US0
1-S214
(a) ECU Connector 2 (b) ECU Connector 1

(Machine Side) (Engine Side)
9Y1200199CRS0993US0
measure the voltage between ECU terminals E13 and V40 /
V60.
Factory
Approx. 5 V
specification
OK Check the wiring harness (ECU terminal E13) for a short. → Repair the
faulty area.
NG Check the harness connectors and ECU pins.

9Y1200199CRS0994US0
1-S215
(33) Sensor Supply Voltage 2 Abnormality (DTC P0652 / 3510-4, P0653 /

3510-3)
P0652 / 3510-4: Sensor supply voltage 2 abnormality (Low side)
• Faulty starting
Detection item:
DTC set parameter:
• Voltage to sensor is below 4.375 V
• ON
9Y1200199CRS0995US0
P0653 / 3510-3: Sensor supply voltage 2 abnormality (High side)
• Faulty starting
Detection item:
DTC set parameter:
• Voltage to sensor is above 5.625 V
• ON
9Y1200199CRS0996US0
1-S216

(Machine Side) (Engine Side)
9Y1200199CRS0997US0
measure the voltage between ECU terminals E33 and V40 /
V60.
Factory
Approx. 5 V
specification
OK Check the wiring harness (ECU terminal E33) for a short. → Repair the
faulty area.
NG Check the harness connectors and ECU pins.

9Y1200199CRS0998US0
1-S217
(34) Main Relay is Locked in Closed Position (DTC P0687 / 1485-2)

• Dead battery
Detection item:
• Failure of main relay
• Key switch is OFF
• Engine stops
DTC set parameter:
• Main relay stays active longer than 1 sec. without command
• OFF
• None
9Y1200199CRS0999US0
(1) Input Terminal (5) Terminal 1 (a) Main Relay Terminal Layout (d) Battery
(2) ACC (6) Terminal 2 (b) Key Switch (e) ECU Connector 2
(3) Output Terminal (7) Terminal 3 (c) Main Relay (Machine Side)
(4) START (8) Terminal 4
9Y1200199CRS1000US0
1-S218
1. Place the key switch in the OFF position, and measure the
voltage between ECU terminals V18 / V38 / V58 / V78 and V01
/ V21 and the chassis ground.
Factory
0V
specification
OK Clear the DTC and check whether it is detected again or not.
OK Normal.
NG Replace the ECU.
NG Go to "2. Check the Key Switch Signal".
9Y1200199CRS1001US0
2. Check the Key Switch Signal

position again.
2. Using the data monitor function of diagnosis tool, check the
"Key switch" data when the key switch is placed in the OFF
position.
Factory
OFF
specification
OK Go to "4. Check the ECU Terminal Voltage".

NG Go to "3. Check the IG-SW Signal".
(a) CAN1 Connector

9Y1200199CRS1002US0
3. Check the IG-SW Signal
1. Place the key switch in the OFF position, and measure the
voltage at ECU terminal V13 / V33.
Factory
0V
specification
OK Go to "4. Check the ECU Terminal Voltage".

NG 1. Check the wiring harness and the key switch. → Repair.
2. Locate the cause of constant voltage supply to the wiring harness.
9Y1200199CRS1003US0
4. Check the ECU Terminal Voltage

1. Keep the key switch in the OFF position, and measure the
voltage at ECU main relay terminals V03 and V23.
Factory
10 V or higher
specification
OK Go to "5. Measure the Resistance Between Relay Terminals (for

Confirmation)".
NG 1. Check the wiring harness between relay and ECU and connectors. →
Repair.
2. Locate the cause of constant shorted wiring harness to the ground.
9Y1200199CRS1004US0
1-S219
5. Measure the Resistance Between Relay Terminals (for
Confirmation)
1. Remove the main relay, and measure the resistance between
each relay terminal.
Example of main relay terminal layout
Between terminals (3) and (4):
Factory
Coil resistance value of relay to use
specification
Between terminals (1) and (2): Infinity
NG Faulty main relay → Replace.
(1) Terminal 1 (Contact Terminal) (a) Terminal Layout

(2) Terminal 2 (Contact Terminal)
(3) Terminal 3
(Coil Operating Terminal)
(4) Terminal 4
(Coil Operating Terminal)
9Y1200199CRS1005US0
1-S220
(35) Pump Seizing (DTC P1274 / 523539-2, P1275 / 523540-2)

P1274 / 523539-2: Pump seizing 1
Detection item:
• High pressure 1 error
DTC set parameter (Approximate parameter):
• Rail pressure of 230 MPa (2350 kgf/cm2, 33400 psi) or more continues 1 second under the condition of above
800 min-1 (rpm)
• Rail pressure of 220 MPa (2250 kgf/cm2, 31900 psi) or more continues 1 second under the condition of below
800 min-1 (rpm) [Threshold changes depending on the engine speed. 700 min-1 (rpm) should be used as a
reference]
• ON
• EGR stop
9Y1200199CRS1006US0
P1275 / 523540-2: Pump seizing 2
Detection item:
• High pressure 2 error
• Rail pressure of above 197 MPa (2010 kgf/cm2, 28600 psi), and below 230 MPa (2350 kgf/cm2, 33400 psi)
continues total time for 35 seconds under condition of above 800 min-1 (rpm) [Threshold changes depending on
the engine speed. 2000 min-1 (rpm) should be used as a reference]
• Or, rail pressure of above 220 MPa (2250 kgf/cm2, 31900 psi) continues total time for 1.7 second under condition
of below 800 min-1 (rpm) [Threshold changes depending on the engine speed. 700 min-1 (rpm) should be used as
a reference]
• ON
• EGR stop
9Y1200199CRS1007US0
1-S221
system.


2. P0093: Fuel leak
[Abnormal pressure]
1. P0089: SCV stuck
IMPORTANT
9Y1200199CRS0810US0
1-S222
(1) Terminal SCV+ (2) Terminal SCV- (a) Terminal Layout (c) ECU Connector 1
(b) SCV (Suction Control Valve) (Engine Side)
9Y1200199CRS1009US0
1. Measure the Resistance Between SCV Terminals
between terminals E09 / E29 and E10 / E30 of the connector.
and valve)
OK Go to "3. Check the Fuel System for the Existence of Air".

NG Go to "2. Measure the Resistance Between Terminals of SCV Unit".
9Y1200199CRS1010US0
2. Measure the Resistance Between Terminals of SCV Unit
1. Refer to the SCV unit inspection procedures.
NG Faulty SCV → Repair or replace the pump.

9Y1200199CRS1011US0
1-S223
NG 1. Rotate the fuel feed pump sufficiently and bleed the air.
2. Locate the position of the fuel leakage in the piping and repair it.
(1) Fuel Hose

9Y1200199CRS1012US0
CAUTION
pipe system.
OK 5. Check the data related to the rail pressure

(2) Supply Pump
9Y1200199CRS1013US0
monitor.
pressure"
1. When idling:
95.0 to 115 MPa (969 to 1170 kgf/cm2, 13800 to
16600 psi)
NG Go to "6. Check the Rail Pressure Sensor".
(a) CAN1 Connector

9Y1200199CRS1014US0
1-S224
P0193)
NOTE
OK Go to "7. Check the SCV-related Data".
1-S162)
(a) CAN1 Connector

9Y1200199CRS1015US0
7. Check the SCV-related data
monitor.
• Accelerator opening: 0→100 %
(During acceleration): Approx. 1400 mA minimum
pressure value.
Factory
must be OFF.
specification
within ±200 mA.
NOTE
NOTE
replace the ECU.
(a) CAN1 Connector

9Y1200199CRS1016US0
1-S225
(36) EEPROM Check Sum Error (DTC P1990 / 523700-13, P1991 / 523701-13,
P1992 / 523702-13)
P1990 / 523700-13: EEPROM check sum error
• None
Detection item:
• KBT-EEPROM check sum error
DTC set conditions (Guideline):
• EEPROM check sum error
• ON
• None
9Y1200199CRS1017US0
P1991 / 523701-13: EEPROM check sum error (DST1)
• None
Detection item:
• DST1-EEPROM check sum error
• EEPROM check sum error (DST1)
• ON
• None
9Y1200199CRS1018US0
P1992 / 523702-13: EEPROM check sum error (DST2)
• None
Detection item:
• DST2-EEPROM check sum error
• EEPROM check sum error (DST2)
• ON
• None
9Y1200199CRS1019US0
1-S226
1. Check the DTC
position again.
2. Clear the DTC, and check whether the same DTC is output
again or not.
Factory
No DTC is output.
specification

NG Go to "2. Write the Trim Data and Read the DTC Again".
(a) CAN1 Connector

9Y1200199CRS1020US0
2. Write the Trim Data and Read the DTC Again
1. Using the diagnosis tool, write the correct trim data in the ECU.
2. Clear the DTC and check whether the same DTC is output
again or not.
Factory
No DTC is output.
specification

NG Faulty Engine ECU → Replace.
(a) CAN1 Connector

9Y1200199CRS1021US0
1-S227
(37) Intake Throttle Feedback Error (DTC P2108 / 523580-2)

• None
Detection item:
• Intake throttle feedback error
• Deviation of throttle position is not corrected in 20 times
• ON
9Y1200199CRS1022US0
(1) No Connection (4) Terminal Ground (a) Terminal Layout (c) ECU Connector 1
(2) Terminal Power (+5 V) (5) Terminal ITV+ (b) Intake Throttle Valve (Engine Side)
(3) Terminal ITS (Output) (6) Terminal ITV– (d) ECU Connector 2
(Machine Side)
9Y1200199CRS1023US0
1-S228
1. Check the Intake Throttle Signal
1. After operating the engine, perform an active test.
Monitor the "Actual intake throttle valve opening" and "Intake
throttle opening output voltage", and check the values.
* For details, refer to the active test section.
2. Clear the DTC and check whether it is output again or not.
Factory
No DTC is output.
specification
OK Normal.
NG Replace the intake throttle assembly.
(a) CAN1 Connector

9Y1200199CRS1024US0
1-S229
(38) Accelerator Position Sensor 1 Abnormality (DTC P2122 / 91-4, P2123 /

91-3)
P2122 / 91-4: Accelerator position sensor 1 abnormality (Low side)
Detection item:
• Sensor / wiring harness open circuit, ground short
• Sensor supply voltage (A-VCC11) is normal
DTC set parameter:
• Accelerator position sensor voltage 1 is 0.3 V or lower
• ON
• Accelerator opening limit: ACCPF ≤ 25 %
9Y1200199CRS1025US0
P2123 / 91-3: Accelerator position sensor 1 abnormality (High side)
Detection item:
• Sensor / wiring harness power supply short
• Sensor supply voltage (A-VCC11) is normal
DTC set parameter:
• Accelerator position sensor voltage 1 is 4.8 V or higher
• ON
• Accelerator opening limit: ACCPF ≤ 25 %
9Y1200199CRS1026US0
1-S230
(1) Terminal A-VCC11 (4) Terminal A-VCC10 (a) Terminal Layout (c) ECU Connector 2
(2) Terminal APS1 (5) Terminal APS2 (b) Accelerator Position Sensor (Machine Side)
(3) Terminal APS1 GND (6) Terminal APS2 GND
9Y1200199CRS1027US0
1. Check the Accelerator Position Sensor Signals
1. Place the key switch in the ON position, and check the
"Accelerator position" and "Accelerator position sensor 1 output
Actual accelerator pedal Accelerator pedal
Output voltage
position position
1.35 V or lower (1.1)
Fully close 0% ( ): Follow the OEM
adjusted value
4.0 V or higher (4.2)
Fully open 100 % ( ): Follow the OEM
adjusted value
NOTE
• "Full close" and "Full open" are with the accelerator
position sensor, not with the accelerator pedal or hand
accelerator.
OK Normal.
NG Replace the ECU.
NG Go to "2. Measure the Voltage Between Sensor Terminals".
(a) CAN1 Connector

9Y1200199CRS1028US0
1-S231
2. Measure the Voltage Between Sensor Terminals
1. Place the key switch in the OFF position, unplug the accelerator
position sensor connector from the socket, and return the key
switch to the ON position again.
2. Measure the voltage between terminals (1) and (3) of
accelerator position sensor connector (at the machine wiring
harness side).
Factory
4.5 to 5.5 V
specification

NG Go to "3. Measure the Terminal Voltage".

(2) Terminal APS1
(3) Terminal APS1 GND
(4) Terminal A-VCC10
(5) Terminal APS2
9Y1200199CRS1029US0
3. Measure the Terminal Voltage
1. Measure the voltage between ECU terminals V46 and V51.
Factory
4.5 to 5.5 V
specification
OK The wiring harness between the ECU and sensor is faulty. → Repair.
NG Check the ECU connectors.

NG Repair the ECU connectors.
9Y1200199CRS1030US0
1. Place the key switch in the OFF position, and plug the
accelerator position sensor connector into the socket.
voltage between ECU terminals V47 and V46.
Accelerator pedal fully closed: 1.35 V or lower (1.1)
Factory
Accelerator pedal full throttle: 4.0 V or higher (4.2)
specification
( ): Follow the OEM adjusted value
NOTE
accelerator.
OK Check the ECU connectors.

9Y1200199CRS1031US0
1-S232
1. Keep the accelerator position sensor connector plugged into
socket.
harness side).
Factory
specification
OK Wiring harness open circuit, short → Check and repair.

NG Faulty accelerator sensor → Replace.

(2) Terminal APS1
(5) Terminal APS2
9Y1200199CRS1032US0
1-S233
(39) Accelerator Position Sensor 2 Abnormality (DTC P2127 / 29-4, P2128 /

29-3)
P2127 / 29-4: Accelerator position sensor 2 abnormality (Low side)
Detection item:
• Ground short circuit / open circuit of sensor / harness
• Sensor supply voltage VCC1 is normal
DTC set parameter:
• Voltage of accelerator position sensor 2 is 0.3 V or less
• ON
• Forced Idle (Accelerator = 0 %)
9Y1200199CRS1033US0
P2128 / 29-3: Accelerator position sensor 2 abnormality (High side)
Detection item:
• Battery short circuit out of sensor / harness
• Sensor supply voltage VCC1 is normal
DTC set parameter:
• Voltage of accelerator position sensor 2 is 4.8 V or less
• ON
9Y1200199CRS1034US0
1-S234
(1) Terminal A-VCC11 (4) Terminal A-VCC10 (a) Terminal Layout (c) ECU Connector 2
(2) Terminal APS1 (5) Terminal APS2 (b) Accelerator Position Sensor (Machine Side)
(3) Terminal APS1 GND (6) Terminal APS2 GND
9Y1200199CRS1035US0
1. Check the Accelerator Position Sensor Signals
"Accelerator position" and "Accelerator position sensor 2 output
Actual accelerator pedal Accelerator pedal
Output voltage
position position
1.35 V or lower (1.1)
Fully close 0% ( ): Follow the OEM
adjusted value
4.0 V or higher (4.2)
Fully open 100 % ( ): Follow the OEM
adjusted value
NOTE
accelerator.
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS1036US0
1-S235
1. Place the key switch in the OFF position, unplug the accelerator
position sensor connector from the socket, and return the key
switch to the ON position again.
harness side).
Factory
4.5 to 5.5 V
specification

NG Go to "3. Measure the Terminal Voltage".

(2) Terminal APS1
(5) Terminal APS2
9Y1200199CRS1037US0
3. Measure the Terminal Voltage
1. Measure the voltage between ECU terminals V50 and V66.
Factory
4.5 to 5.5 V
specification
OK The wiring harness between the ECU and sensor is faulty. → Repair.
NG Check the ECU connectors.

9Y1200199CRS1038US0
1. Place the key switch in the OFF position, and plug the
accelerator position sensor connector into the socket.
voltage between ECU terminals V66 and V67.
Factory
specification
NOTE
accelerator.
OK Check the ECU connectors.

9Y1200199CRS1039US0
1-S236
1. Keep the accelerator position sensor connector plugged into
socket.
harness side).
Factory
specification
OK Wiring harness open circuit, short → Check and repair.

NG Faulty accelerator sensor → Replace.

(2) Terminal APS1
(5) Terminal APS2
9Y1200199CRS1040US0
1-S237
(40) Accelerator Position Sensor Error (CAN) (DTC P2131 / 523543-2)

Detection item:
• Accelerator position sensor signal error (sensor / harness open circuit, short to ground etc)
• Key switch turn OFF to ON
• No ST signal
DTC set parameter:
• When accelerator position sensor error signal received by CAN
• ON
• Not applicable
• Diagnostic counter = zero (CAN signal recovers)
9Y1200199CRS1041US0
(a) ECU for Machine (b) Engine ECU (c) ECU Connector 2 A: To Other ECU
(Machine Side)
9Y1200199CRS1042US0
1-S238
1. DTC Judgment
2. Turn the key switch to the ON position, check whether the DTC
(P2131) is output or not.
Factory
No DTC (P2131) is output.
specification
OK Normal.
NG Go to "2. Check the Monitor of the Machine".
(a) CAN1 Connector

9Y1200199CRS1043US0
2. Check the Monitor of the Machine
1. Turn on the key switch and confirm that no defects except those
in the engine occur.
Factory
No defects except that in the engine occur.
specification
OK Possible defects in the ECU for the machine. Execute the diagnosis
according to the workshop manual for the machine.
NG Defects in the accelerator sensor signal. Execute the diagnosis
according to the workshop manual for the machine.
9Y1200199CRS1044US0
1-S239
(41) Accelerator Position Sensor Correlation Error (DTC P2135 / 91-2)

Detection item:
• Deviation from designed correlation in two sensors
• Accelerator position sensor 1 is normal
• Accelerator position sensor 2 is normal
DTC set parameter:
• Deviation from designed correlation in two sensors
• It depends on engine application
• ON
9Y1200199CRS1045US0
1. Check the Accelerator Position Sensor 1 and 2 (Refer to
items P2122, P2123, P2127 and P2128)
1. Check the accelerator position sensor 1 and 2. (Refer to page
1-S230)
NOTE
• This DTC is used to detect the characteristic difference
between the two sensors' output. So, check the both
sensors in the same way as the procedure of the
"Accelerator Position Sensor 1 (or 2) Abnormality"
• The adjustment value of the sensor signal needs to be
followed by the specification of the machine.
OK Normal
NG Replace the accelerator position sensor 1 or 2.
(a) CAN1 Connector

9Y1200199CRS1046US0
1-S240
(42) Common 1 System Injector Drive Circuit Open (DTC P2146 / 523523-2)
• Large vibration
Detection item:
• Wiring harness open circuit
• CPU is normal
DTC set parameter:
• When wiring harness open circuit
• ON
• EGR stop
9Y1200199CRS1047US0
9Y1200199CRS1048US0
1-S241
1. DTC Judgment
(P2146, P2149) is output or not.
Factory
Either DTC P2146 or P2149 is output.
specification
OK Go to "4. Measure the Resistance Between ECU Terminals".

NG Go to "2. Check the "P- GND" Wiring Harness".
(a) CAN1 Connector

9Y1200199CRS1049US0
2. Check the "P- GND" Wiring Harness
between each ECU terminal and the chassis ground (at the
wiring harness side).
Factory
1.5 Ω or lower
specification
OK Go to "3. Check the "P- GND" Wiring Harness Connector and ECU Pins".
NG 1. Check the "P- GND" wiring harness → Repair.
2. Locate the cause of open circuit, or increase its resistance value.
9Y1200199CRS1050US0
3. Check the "P- GND" Wiring Harness Connector and ECU
Pins
1. Place the key switch in the OFF position, unplug the ECU
connector from the socket, and check the ECU pins for faulty
connection, deformation, poor contact or other defects.

NG Repair wiring harness connectors and ECU pins, or replace them if
defective.
9Y1200199CRS1051US0
harness connector, and measure the resistance between each
terminal at the connector side as shown on the following table.
DTC ECU Terminals Measured
No. 1 cylinder E15, E35
P2146 E14, E34
P2149 E18, E38
Factory
Both system cables must have 1.5 Ω or lower.
specification
OK Go to "6. Check the Wiring Harness Connectors and ECU Pins".

NG Go to "5. Check the Wiring Harness → Repair or Replace the Faulty
Area".
9Y1200199CRS1052US0
1-S242
5. Check the Wiring Harness → Repair or Replace the Faulty
Area
Check the wiring harness between ECU terminals E14 / E34 or
E18 / E38 and each injector terminal (E15 / E35, E16 / E36, E19 /
E39 or E20 / E40), and locate the open harness,
9Y1200199CRS1053US0
6. Check the Wiring Harness Connectors and ECU Pins

1. Check the wiring harness connectors of each ECU terminal and
the ECU pins for faulty connection, deformation or other
defects.
NG The connectors or ECU pins are faulty. → Repair them or replace the
ECU.
9Y1200199CRS1054US0
7. Check the DTC

2. Start the engine, and clear the past DTCs.
3. Read the DTC again.
Factory
specification
OK Normal.
(a) CAN1 Connector

9Y1200199CRS1055US0
1-S243
(43) Common 1 TWV Actuation System Short (DTC P2147 / 523523-4, P2148 /
523523-3)
P2147 / 523523-4: Common 1 TWV actuation system ground short
• Large vibration
Detection item:
• Wiring harness short to ground
DTC set parameter:
• When wiring harness short to ground occurs
• ON
• Injectors which have DTC stop injection
• EGR stop
9Y1200199CRS1056US0
P2148 / 523523-3: Common 1 TWV actuation system +B short
• Large vibration
Detection item:
• Wiring harness short to +B
DTC set parameter:
• When wiring harness short to +B occurs
• ON
• EGR stop
9Y1200199CRS1057US0
1-S244
(1) Terminal COMMON (a) Terminal Layout (d) Rated amperage circuit (f) Control circuit
(2) Terminal TWV (b) Engine Cylinder No. (e) High-voltage generating (g) ECU Connector 1
(c) Injector circuit (Engine Side)
9Y1200199CRS1058US0
1, Check the "P- GND" Wiring Harness
harness connector 2 (machine side) from the socket, and
measure the resistance between each of ECU terminals V39,
V59, V79 or V80 and the chassis ground (at the wiring harness
side).
Factory
1.5 Ω or lower
specification

NG Check the "P- GND" wiring harness. → Repair.
Locate the cause of open circuit, or increase its resistance value.
9Y1200199CRS1059US0
connector 1 (engine side) from the socket, and check the ECU
pins for faulty connection, deformation, poor contact or other
defects.
OK Go to "3. Measure the ECU Terminal Voltage (Part 1)".

defective.
9Y1200199CRS1060US0
1-S245
3. Measure the ECU Terminal Voltage (Part 1)
voltage between ECU terminal E14 / E34 or E18 / E38 and "P-
GND" terminal.
Factory
Approx. 6 V
specification

NG Go to "5. Measure the ECU Terminal Voltage (Part 2)".
9Y1200199CRS1061US0
4. Check the DTC

Factory
specification
OK Normal.
(a) CAN1 Connector

9Y1200199CRS1062US0
harness connector 1 (engine side) from the socket, return the
key switch to the ON position again, and measure the voltage
between each of ECU terminal pins E14 / E34 and E18 / E38
and the "P -GND" terminal (at the wiring harness side).
Factory
Approx. 6 V
specification

9Y1200199CRS1063US0
1-S246
Locate the cause of wiring harness ground short, and repair the
faulty area.
Shorted Harness
DTC Relating ECU Terminals
Side
Terminal E14 / E34 or E18 / E38
P2147 (E15 / E35, E16 / E36, E19 / E39, E20 / Ground
E40 occurring simultaneously)
P2148 (E15 / E35, E16 / E36, E19 / E39, E20 / Power supply
NOTE
• If DTC P2147 (Shorted injector actuation circuit to the
ground) has occurred, be sure to check the insulation of
injector itself in the following procedure.
1. Place the key switch in the OFF position, unplug each injector
connector from socket, and visually check the connector status.
Factory
Must be free from sludge and sparks.
specification
2. Using an insulation resistance tester (megger tester), measure
the resistance between each of terminals (1) and (2) and the
chassis ground (at the injector side).
Factory
10 MΩ or higher
specification
OK The injector functions normally. Locate another cause.

NG Faulty injector → Replace.

(2) Terminal TWV
9Y1200199CRS1064US0
1-S247
(44) Common 2 System Injector Drive Circuit Open (DTC P2149 / 523524-2)
• Large vibration
Detection item:
• Wiring harness open circuit
• CPU is normal
DTC set parameter:
• When wiring harness open circuit
• ON
• EGR stop
9Y1200199CRS1065US0
9Y1200199CRS1066US0
1-S248
1. DTC Judgment
(P2146, P2149) is output or not.
Factory
Either DTC P2146 or P2149 is output.
specification

NG Go to "2. Check the "P- GND" Wiring Harness".
(a) CAN1 Connector

9Y1200199CRS1049US0
2. Check the "P- GND" Wiring Harness
between each ECU terminal and the chassis ground (at the
wiring harness side).
Factory
1.5 Ω or lower
specification
OK Go to "3. Check the "P- GND" Wiring Harness Connector and ECU Pins".
NG 1. Check the "P- GND" wiring harness → Repair.
2. Locate the cause of open circuit, or increase its resistance value.
9Y1200199CRS1050US0
3. Check the "P- GND" Wiring Harness Connector and ECU
Pins
connector from the socket, and check the ECU pins for faulty
connection, deformation, poor contact or other defects.

defective.
9Y1200199CRS1051US0
harness connector, and measure the resistance between each
terminal at the connector side as shown on the following table.
DTC ECU Terminals Measured
P2146 E14, E34
P2149 E18, E38
Factory
Both system cables must have 1.5 Ω or lower.
specification

NG Go to "5. Check the Wiring Harness → Repair or Replace the Faulty
Area".
9Y1200199CRS1052US0
1-S249
5. Check the Wiring Harness → Repair or Replace the Faulty
Area
Check the wiring harness between ECU terminals E14 / E34 or
E18 / E38 and each injector terminal (E15 / E35, E16 / E36, E19 /
E39 or E20 / E40), and locate the open harness,
9Y1200199CRS1053US0

1. Check the wiring harness connectors of each ECU terminal and
the ECU pins for faulty connection, deformation or other
defects.
NG The connectors or ECU pins are faulty. → Repair them or replace the
ECU.
9Y1200199CRS1054US0
7. Check the DTC

Factory
specification
OK Normal.
(a) CAN1 Connector

9Y1200199CRS1055US0
1-S250
(45) Common 2 TWV Actuation System Short (DTC P2150 / 523524-4, P2151 /
523524-3)
P2150 / 523524-4: Common 2 TWV actuation system ground short
• Large vibration
Detection item:
• Wiring harness short to ground
DTC set parameter:
• When wiring harness short to ground occurs
• ON
• EGR stop
9Y1200199CRS1074US0
P2151 / 523524-3: Common 2 TWV actuation system +B short
• Large vibration
Detection item:
• Wiring harness short to +B
DTC set parameter:
• When wiring harness short to +B occurs
• ON
• EGR stop
9Y1200199CRS1075US0
1-S251
(1) Terminal COMMON (a) Terminal Layout (d) Rated amperage circuit (f) Control circuit
(2) Terminal TWV (b) Engine Cylinder No. (e) High-voltage generating (g) ECU Connector 1
(c) Injector circuit (Engine Side)
9Y1200199CRS1076US0
1, Check the "P- GND" Wiring Harness
harness connector 2 (machine side) from the socket, and
measure the resistance between each of ECU terminals V39,
V59, V79 or V80 and the chassis ground (at the wiring harness
side).
Factory
1.5 Ω or lower
specification

NG Check the "P- GND" wiring harness. → Repair.
Locate the cause of open circuit, or increase its resistance value.
9Y1200199CRS1059US0
connector 1 (engine side) from the socket, and check the ECU
pins for faulty connection, deformation, poor contact or other
defects.
OK Go to "3. Measure the ECU Terminal Voltage (Part 1)".

defective.
9Y1200199CRS1060US0
1-S252
voltage between ECU terminal E14 / E34 or E18 / E38 and "P-
GND" terminal.
Factory
Approx. 6 V
specification

NG Go to "5. Measure the ECU Terminal Voltage (Part 2)".
9Y1200199CRS1061US0
4. Check the DTC

Factory
specification
OK Normal.
(a) CAN1 Connector

9Y1200199CRS1062US0
harness connector 1 (engine side) from the socket, return the
key switch to the ON position again, and measure the voltage
between each of ECU terminal pins E14 / E34 and E18 / E38
and the "P -GND" terminal (at the wiring harness side).
Factory
Approx. 6 V
specification

9Y1200199CRS1063US0
1-S253
Locate the cause of wiring harness ground short, and repair the
faulty area.
Shorted Harness
DTC Relating ECU Terminals
Side
P2147 (E15 / E35, E16 / E36, E19 / E39, E20 / Ground
P2148 (E15 / E35, E16 / E36, E19 / E39, E20 / Power supply
NOTE
• If DTC P2147 (Shorted injector actuation circuit to the
ground) has occurred, be sure to check the insulation of
injector itself in the following procedure.
1. Place the key switch in the OFF position, unplug each injector
connector from socket, and visually check the connector status.
Factory
Must be free from sludge and sparks.
specification
2. Using an insulation resistance tester (megger tester), measure
the resistance between each of terminals (1) and (2) and the
chassis ground (at the injector side).
Factory
10 MΩ or higher
specification
OK The injector functions normally. Locate another cause.

NG Faulty injector → Replace.

(2) Terminal TWV
9Y1200199CRS1064US0
1-S254
(46) Barometric Pressure Sensor Error (DTC P2228 / 108-4, P2229 / 108-3)
P2228 / 108-4: Barometric pressure sensor error (Low side)
Behaviour during malfunction (At high altitude):
Detection item:
• Sensor / ECU internal circuit short to ground
DTC set parameter:
• Barometric pressure sensor voltage: 1.6 V or less
• ON
9Y1200199CRS1083US0
P2229 / 108-3: Barometric pressure sensor error (High side)
Behaviour during malfunction (At high altitude):
Detection item:
• Sensor / ECU internal circuit short to +B
DTC set parameter:
• Barometric pressure sensor voltage: 4.4 V or more
• ON
9Y1200199CRS1084US0
1. Check the Atmospheric Pressure Signals
"Atmospheric pressure" on the diagnosis tool data monitor.
Atmospheric pressure
Factory
Actual atmospheric pressure (Approx. 100 kPa
specification
(1.02 kgf/cm2, 14.5 psi))
OK Normal.
NG Replace the ECU.
NG Go to "2. Check the DTC".
(a) CAN1 Connector

9Y1200199CRS1085US0
1-S255
2. Check the DTC
1. Place the key switch to the OFF position first, then return it to
the ON position again.
2. Clear the past DTCs, and check whether the same DTC (P2228
or P2229) is output again or not.
Factory
OK
specification

NG Faulty atmospheric pressure sensor → Replace the engine ECU.
(a) CAN1 Connector

9Y1200199CRS1086US0
1-S256
(47) EGR (DC Motor) Abnormality (DTC P2413 / 523575-7, P2414 / 523576-2,
P2415 / 523577-2)
P2413 / 523575-7: EGR actuator valve stuck
Detection item:
• EGR actuator valve stuck
DTC set parameter:
• EGR actuator valve stuck error signal received via CAN
• ON
• Output limitation: Approximately 75 % of normal condition EGR stop
9Y1200199CRS1087US0
P2414 / 523576-2: EGR (DC motor) overheat
Detection item:
• EGR (DC motor) overheat
DTC set parameter:
• EGR (DC motor) temperature error signal (thermistor: 125 °C (257 °F) or more) received via CAN
• ON
• EGR stop
9Y1200199CRS1088US0
1-S257
P2415 / 523577-2: EGR (DC motor) temperature sensor failure
Detection item:
• EGR (DC motor) temperature sensor failure
DTC set parameter:
• EGR (DC motor) temperature sensor error signal received via CAN
• ON
• EGR stop
9Y1200199CRS1089US0
9Y1200199CRS0944US0
1-S258
1. DTC Judgment
is output or not.
3. Check the DTC again after starting up the engine with the
coolant temperature over 65 °C (149 °F).
Factory
specification
OK Normal.
(a) CAN1 Connector

9Y1200199CRS0945US0
1-S259
(48) Exhaust Gas Temperature Sensor 2 (T2) Abnormality (DTC P242C /

3246-4, P242D / 3246-3)
P242C / 3246-4: Exhaust gas temperature sensor 2 (T2) abnormality (Low side)
• None
Detection item:
• Sensor / Harness short to ground
DTC set parameter:
• DPF outlet temperature sensor (T2) voltage: 0.08 V or less
• ON
9Y1200199CRS1092US0
P242D / 3246-3: Exhaust gas temperature sensor 2 (T2) abnormality (High side)
• None
Detection item:
• Sensor / Harness open circuit and short to +B
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 10 min.100 °C (212 °F) ≤ T0 ≤ 800 °C
(1472 °F): continues longer than 10 sec. or 100 °C (212°F) ≤ T1 ≤ 800 °C (1472 °F): continues longer than 10 sec.
DTC set parameter:
• DPF outlet temperature sensor (T2) voltage: 4.92 V or more
• ON
• Recovers when the key switch is OFF
9Y1200199CRS1093US0
1-S260
(1) Terminal A-GND3 (2) Terminal ODPF (a) Terminal Layout (c) ECU Connector 1
Sensor 2 (T2)
9Y1200199CRS1094US0
Output voltage
100 °C (212 °F) 100 °C (212 °F) Approx. 4.4 V
150 °C (302 °F) 150 °C (302 °F) Approx. 3.7 V
200 °C (392 °F) 200 °C (392 °F) Approx. 3.0 V
250 °C (482 °F) 250 °C (482 °F) Approx. 2.3 V
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS0962US0
1-S261
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

9Y1200199CRS1096US0
3. Check the Sensor
sensor side.
100 °C (212 °F) Approx. 18.3 kΩ
150 °C (302 °F) Approx. 7.88 kΩ
200 °C (392 °F) Approx. 4.00 kΩ
250 °C (482 °F) Approx. 2.30 kΩ

(1) Terminal A-GND3 (1) Terminal ODPF

9Y1200199CRS1097US0
Factory
Approx. 5 V
specification

9Y1200199CRS1098US0
1-S262
(49) Differential Pressure Sensor 1 Abnormality (DTC P2454 / 3251-4, P2455 /

3251-3)
P2454 / 3251-4: Differential pressure sensor 1 abnormality (Low side)
• None
Detection item:
• Sensor / Harness short to ground
• No ST signal
DTC set parameter:
• DPF differential pressure sensor voltage: 0.21 V or less
• ON
9Y1200199CRS1099US0
P2455 / 3251-3: Differential pressure sensor 1 abnormality (High side)
• None
Detection item:
• Sensor / Harness open circuit and short to +B
• No ST signal
DTC set parameter:
• DPF differential pressure sensor voltage: 4.7 V or more
• ON
9Y1200199CRS1100US0
1-S263
(1) Terminal A-VCC12 (3) Terminal DPS (a) Terminal Layout (c) ECU Connector 1
(2) Terminal A-GND11 (b) Differential Pressure Sensor (Engine Side)
(d) ECU Connector 2
(Machine Side)
9Y1200199CRS1101US0
1-S264
1. Check the Differential Pressure Signals
position again. Then, check the "Differential pressure" and
"Differential pressure sensor output voltage" on the diagnosis
tool data monitor.
Actual differential
pressure
Approx. 0 Pa
Key switch is ON Approx. 0.7 V
(0 kgf/cm2, 0 psi)
OK Normal.
NG Replace the ECU.
(a) CAN1 Connector

9Y1200199CRS1102US0
measure the voltage between ECU terminals E45 and V71.

NG Go to "3. Measure the Voltage Between Differential Pressure Sensor
Terminals".

9Y1200199CRS1103US0
3. Measure the Voltage Between Differential Pressure Sensor
Terminals
voltage between terminals (2) and (3) of the differential pressure
sensor at the wiring harness side.
OK Check the wiring harness (between ECU terminal E45 and sensor
NG Go to "4. Measure the Voltage Between Differential Pressure Sensor
Terminals".
(1) Terminal A-VCC12 (a) Differential Pressure Sensor

(2) Terminal A-GND11 Connector
(3) Terminal DPS
9Y1200199CRS1104US0
1-S265
4. Measure the Voltage Between Differential Pressure Sensor
Terminals
1. Set the key switch to the OFF position, and unplug the
differential pressure sensor connector from the socket.
voltage between terminals (1) and (2) of the differential pressure
sensor connector (at the wiring harness side).
Factory
Approx. 5 V
specification
OK Faulty differential pressure sensor → Replace.

2. Replace the differential pressure sensor.

(3) Terminal DPS
9Y1200199CRS1105US0
measure the voltage between ECU terminals V65 and V71.
Factory
Approx. 5 V
specification

NG Check the wiring harness (between ECU terminal V65 and sensor
terminal (2) and between ECU terminal V71 and sensor terminal (1)).
→ Repair the faulty area.
NOTE
• Check the pipe between diesel particulate filter (DPF) and
sensor, When it is damaged, the differential pressure can
not reach the sensor.
9Y1200199CRS1106US0
1-S266
(50) Intake Throttle Lift Sensor Abnormality (DTC P2621 / 523583-4, P2622 /
523582-3)
P2621 / 523583-4: Intake throttle lift sensor (Low side)
• None
Detection item:
• Intake throttle lift sensor low
DTC set parameter:
• Intake throttle lift sensor voltage: 0.1 V or less
• ON
9Y1200199CRS1107US0
P2622 / 523582-3: Intake throttle lift sensor (High side)
• None
Detection item:
• Intake throttle lift sensor high
DTC set parameter:
• Intake throttle lift sensor voltage: 4.89 V or more
• ON
9Y1200199CRS1108US0
1-S267
(1) No Connection (4) Terminal Ground (a) Terminal Layout (c) ECU Connector 1
(2) Terminal Power (+5 V) (5) Terminal ITV+ (b) Intake Throttle Valve (Engine Side)
(3) Terminal ITS (Output) (6) Terminal ITV– (d) ECU Connector 2
(Machine Side)
9Y1200199CRS1023US0
1. Check the Intake Throttle Signal
1. After operating the engine, perform an active test.
Monitor the "Actual intake throttle valve opening" and "Intake
throttle opening output voltage", and check the values.
* For details, refer to the active test section.
2. Clear the DTC and check whether it is output again or not.
Factory
No DTC is output.
specification
OK Normal.
NG Replace the intake throttle assembly.
(a) CAN1 Connector

9Y1200199CRS1024US0
1-S268
(51) Emission Deterioration (DTC P3001 / 3252-0)

Detection item:
• DOC is heated up due to unburned fuel
• Not in the Regeneration mode
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 5 min
DTC set parameter:
• T1 − T0 ≥ 250 °C (482 °F)
• ON
• EGR stop
9Y1200199CRS1111US0
NOTE
• Check the suction path for leaks. (Suction path joints,
suction pipes, hoses)
• Check the installation of all exhaust gas temperature
sensors (T0, T1 and T2).
• Check the engine oil level.
• Check the engine coolant level.
• Check whether turbo has abnormality. (sound and
externals)

(2) Hose
9Y1200199CRS1112US0
1-S269
2. Check the DTC
2. Turn the key switch to the ON position and select the "Exhaust
Gas Temperature sensor 0", "Exhaust gas temperature sensor
1" and "Exhaust gas temperature sensor 2" on the data
monitor.function.
3. Check whether the DTC is output or not after starting up the
engine by monitoring the data signals.
Factory
No DTC is output.
specification
OK Normal.
NG Go to "3. Check the Exhaust Gas Temperature Sensor".
(a) CAN1 Connector

9Y1200199CRS1113US0
3. Check the Exhaust Gas Temperature Sensors
1. Check the exhaust gas temperature sensors (T0, T1 and T2).
OK Normal.
NG Repair or replace the exhaust gas temperature sensor or engine
combustion main parts. (Follow the diagnostic procedure of items P0543,
P0546 and P242C)
(1) Terminal A-GND3 (a) Exhaust Gas Temperature

(2) Terminal IDOC, ODOC or ODPF Sesnsor (T0, T1 and T2)
9Y1200199CRS1114US0
1-S270
(52) Exhaust Gas Temperature Sensor 0: Emergency High (DTC P3002 /

4765-0)
• Engine stops
• Inhibit cranking until down to 300 °C (572 °F)
Detection item:
• DOC inlet temperature (T0) high
• Exhaust gas temperature sensor T0, T1 and T2 are normal
DTC set parameter:
• DOC inlet temperature (T0): 700 °C (1292 °F) or more
• ON
• Engine stop
• Inhibit starter relay activation until Exhaust Gas Temperature reduces down to 300 °C (572 °F)
• Under 300 °C (572 °F) & key switch turn OFF
9Y1200199CRS1115US0
IMPORTANT
• If the two errors occur from "Emergency exhaust gas
temperature sensor T0 high", "Emergency exhaust gas
temperature sensor T1 high", and "Emergency exhaust gas
temperature T2 high" at the same time, check the exhaust
gas temperature starting from a bigger number.
NOTE
OK Go to "2. Check the Exhaust Gas Temperature".

(2) Hose
9Y1200199CRS1116US0
1-S271
2. Check the Exhaust Gas Temperature
gas temperature Sensor 0", "Exhaust gas temperature Sensor
1" and "Exhaust gas temperature Sensor 2" on the data
monitor.function.
3. If the exhaust gas temperature is above 300 °C (572 °F), wait till
the temperature decreases below 300 °C (572 °F).
Factory The actual exhaust gas temperature and monitoring exhaust
specification gas temperature should be approximately the same.

NG Go to "3. Check the Exhaust Gas Temperature Sensors (Refer to items
P0543, P0546 and P242C)".
(a) CAN1 Connector

9Y1200199CRS1117US0
3. Check the Exhaust Gas Temperature Sensors (Refer to items
P0543, P0546 and P242C)
P0546 and P242C)

9Y1200199CRS1118US0
4. Check the DTC
1. Check the engine noise and vibration after starting up the
engine.
Check whether turbo has abnormality. (sound and externals)
2. Check whether the other DTC is output or not by operating the
engine in the normal condition.
3. If it is OK, restart and operate the engine for 10 minutes with the
engine in the no-load maximum speed status.
Check whether the DTC is output or not.
Factory
No DTC is output.
specification
OK Normal.
P0546 and P242C)
(a) CAN1 Connector

9Y1200199CRS1119US0
1-S272

3242-0)
• Engine stops
Detection item:
• DPF inlet temperature (T1) high
DTC set parameter:
• DPF inlet temperature (T1): 715 °C (1319 °F) or more
• ON
• Engine stop
• Inhibit starter relay activation until Exhaust Gas Temperature reduces down to 300 °C (572 °F)
9Y1200199CRS1120US0
IMPORTANT
NOTE

(2) Hose
9Y1200199CRS1116US0
1-S273
Gas Temperature Sensor 0", "Exhaust Gas Temperature
Sensor 1" and "Exhaust Gas Temperature Sensor 2" on the
data monitor function.

P0543, P0546 and P242C)".
(a) CAN1 Connector

9Y1200199CRS1122US0
P0543, P0546 and P242C)
P0546 and P242C)

9Y1200199CRS1123US0
4. Check the DTC
engine. Check whether turbo has abnormality. (sound and
externals)
Factory
No DTC is output.
specification
OK Normal.
NG Replace the DPF assembly.
(a) CAN1 Connector

9Y1200199CRS1124US0
1-S274

3246-0)
• Engine stops
Detection item:
• DPF outlet temperature (T2) high
DTC set parameter:
• DPF outlet temperature (T2): 820 °C (1508 °F) or more
• ON
• Engine stop
• EGR stop
• Intake throttle 0 % open (Close)
• Inhibit starter relay activation until exhaust gas temperature reduces down to 300 °C (572 °F)
9Y1200199CRS1125US0
IMPORTANT
NOTE

(2) Hose
9Y1200199CRS1116US0
1-S275
data monitor.function.

P0543, P0546 and P242C)".
(a) CAN1 Connector

9Y1200199CRS1127US0
P0543, P0546 and P242C)
P0546 and P242C)

9Y1200199CRS1128US0
4. Check the DTC
engine. Check whether turbo has abnormality. (sound and
externals)
Factory
No DTC is output.
specification
OK Normal.
NG Go to "5. Check the DPF".
(a) CAN1 Connector

9Y1200199CRS1129US0
5. Check the DPF
1. Visually check if soot is not attached to the tail pipe which is
connected to the DPF assembly.
2. Check whether the intake throttle opens completely after
starting up the engine.
3. Check whether the coolant temperature is over 65 °C (149 °F)
by operating the engine in the normal condition.
OK Replace the ECU.
(1) DPF Assembly

9Y1200199CRS1130US0
1-S276
(55) Excessive PM3 (DTC P3006 / 3701-15)

Detection item:
• PM accumulation level3
DTC set parameter:
Regeneration level = 3
• ON
9Y1200199CRS1131US0
1. DPF Manual Regeneration
1. Start DPF Manual Regeneration immediately.
NOTE
• This DTC means the warning to urge to start regeneration
rather than error. (Basically, Service Call is not necessary.)
• Followings are potential causes.
– A low load operation has been continuing.
– An engine is often left idling.
– A short time operation below 30 minutes has been
continuing.
(a) DPF Manual Regeneration
Reguest Button
9Y1200199CRS1132US0
1-S277

Detection item:
DTC set parameter:
• ON
9Y1200199CRS1133US0
1. DPF Manual Regeneration Reguest Function
1. Perform the diagnosis tool active test ("DPF Manual
Regeneration").
NOTE
– A manual regeneration has not been carried out. Start
DPF manual regeneration immediately when the
manual regeneration warning light comes ON.
(a) CAN1 Connector
9Y1200199CRS1134US0
1-S278

Detection item:
DTC set parameter:
• ON
9Y1200199CRS1135US0
1. Replace of DPF
1. Replace the DPF.
NOTE
– A manual regeneration has not been carried out.
(1) DPF Outlet Body (4) DPF Gasket
(2) DPF Filter Comp (5) DPF Gasket
(3) DOC Catalyst
9Y1200199CRS1136US0
1-S279
(58) Boost Pressure Low (DTC P3011 / 132-15)

Detection item:
• Dismount the hose between the turbo blower out and intake flange
• Not in the Regeneration mode
• Engine speed is 1600 rpm or more
• Target intake air flow value is 950 mg/cyl or more
• Boost pressure sensor is normal
• Barometric pressure sensor is normal
DTC set parameter:
• Boost pressure sensor output is below target level in high air flow operating condition
• ON
• EGR stop
9Y1200199CRS1137US0
NOTE
come off.
• Check if the hose of the boost pressure sensor does not
come off.
OK Go to "2. Check the Boost Pressure Sensor (Refer to items P0237 and
P0238)".

(2) Hose
9Y1200199CRS1138US0
2. Check the Boost Pressure Sensor (Refer to items P0237 and
P0238)
1. Check the boost pressure sensor.
NG Repair or replace the boost pressure sensor or its related parts. (Follow
the diagnostic procedure of items P0237 and P0238)
(1) Terninal A-VCC2 (a) Boost Pressure Sensor

(2) Terninal PIM
(2) Terninal PIM RTN
9Y1200199CRS1139US0
1-S280
3. Check the DTC
engine.
Check whether turbo has abnormality. (sound and externals)
engine in the no-load maximum speed status. Check whether
the DTC is output or not.
Factory
No DTC is output.
specification
OK Normal.
NG Replace the ECU
(a) CAN1 Connector

9Y1200199CRS1140US0
1-S281
(59) Low Coolant Temperature in Parked Regeneration (DTC P3012 /

523589-17)
• None
Detection item:
• During regeneration mode, engine warm-up condition is not formed (coolant temperature is low)
• In the manual Regeneration mode [DPFSTATUS = 5]
DTC set parameter:
• Engine coolant temperature stays below 65 °C (149 °F) under parked regeneration process. when the state above
continues for 1500 seconds or more
• ON
• None
• Diagnostic counter = zero (Leaving from parked active regeneration status)
9Y1200199CRS1141US0
1. Check the Coolant Temperature
1. Perform the DPF Manual Regeneration again after warming up
the engine.
2. Monitor the coolant temperature in the no-load maximum speed
status with the diagnosis tool.
Factory The coolant temperature should be 65 °C (149 °F) or more
specification within 10 minutes.
OK Normal.
NG Go to "2. Check the Thermostat".
(a) CAN1 Connector

9Y1200199CRS1142US0
2. Check the Thermostat
1. Check the thermostat.
OK Go to "3. Check the Coolant Temperature Sensor (Refer to items P0117
and P118)"
NG Replace the thermostat.
(1) Thermostat Cover (3) Thermostat Assembly

(2) Thermostat Cover Gasket
9Y1200199CRS1143US0
3. Check the Coolant Temperature Sensor (Refer to items

P0117 and P118)
1. Check the coolant temperature sensor.
OK Normal.
NG Repair or replace the coolant temperature sensor or engine coolant
system. (Follow the diagnostic procedure of items P0117 and P118)

9Y1200199CRS1144US0
1-S282
(60) Parked Regeneration Time Out (DTC P3013 / 523590-16)

• None
Detection item:
• Time out error: regeneration imcomplete due to low temperature of DPF
• In the manual Regeneration mode [DPFSTATUS = 7]
DTC set parameter:
• Coolant temperature is 65 °C (149 °F) or more and Regeneration was not completed within target time
(approximately 30 min.) when the state above continues for 2700 seconds or more
• ON
• None
9Y1200199CRS1145US0
1. Check the Installation of Exhaust Gas Temperature sensor
1. Check the installation of all exhaust gas temperature sensors
(T0, T1 and T2).
2. Check the installation condition of the thermostat, and whether
rust is not occurred.
3. Reinstall or replace the thermostat as necessary.
OK Go to "2. 2. DPF Manual Regeneration".
NG Repair or replace the exhaust gas temperature sensor or thermostat.
(Follow the diagnostic procedure of items P0543, P0546 and P242C)
(1) Exhaust Gas Temperature (A) Exhaust Inlet Side

Sensor T0 (B) Exhaust Outlet Side
(2) Exhaust Gas Temperature
Sensor T1
Sensor T2
9Y1200199CRS1146US0
2. DPF Manual Regeneration
data monitor.function.
3. Perform the diagnosis tool active test ("DPF Manual
Regeneration").
Factory
No DTC is output.
specification
OK Normal.
NG Go to 3. Check the Exhaust Gas Temperature Sensors (Refer to items
P0543, P0546 and P242C)".
(a) CAN1 Connector

9Y1200199CRS1147US0
1-S283
P0543, P0546 and P242C)
OK Normal.
P0546 and P242C)

9Y1200199CRS1148US0
1-S284
(61) All Exhaust Gas Temperature Sensor Failure (DTC P3018 / 523599-0)
• None
Detection item:
• All exhaust gas temperature sensor failure simultaneously
• Quantity of injection is 30 mm3/st or more
• Coolant temperature is 65 °C (149 °F) or more: continues longer than 300 sec.
• Intake air temperature is 0 °C (32 °F) or more
• It continues longer than 100 sec. after cranking mode
DTC set parameter:
• All exhaust gas temperature sensor failure (sensor low) simultaneously
• ON
9Y1200199CRS1149US0
1. Check the Installation of Exhaust Gas Temperature sensor
1. Check the installation of all exhaust gas temperature sensors
(T0, T1 and T2).
OK Go to "2. Check the Exhaust Gas Temperature Sensors (Refer to items
P0543, P0546 and P242C)".
P0546 and P242C)
(1) Exhaust Gas Temperature (A) Exhaust Inlet Side

Sensor T0 (B) Exhaust Outlet Side
Sensor T1
Sensor T2
9Y1200199CRS1150US0
P0543, P0546 and P242C)
OK Normal.
P0546 and P242C)

9Y1200199CRS1151US0
1-S285
(62) Initial Pump-calibration Incomplete (DTC P3019 / 523600-0)

• None
Detection item:
• Pump-calibration history
DTC set parameter:
• Initial pump calibration incomplete
• ON
• None
9Y1200199CRS1152US0
1. Initial Pump-calibration
tool the CAN1 connector, and perform the supply pump
difference learning on the utility function.
NOTE
• This warning indicates that supply pump difference
learning not performed after replacing ECU on the site.
(a) CAN1 Connector
9Y1200199CRS1153US0
1-S286
(63) High Exhaust Gas Temperature After Emergency High Temperature DTC
(DTC P3023 / 523601-0)
• None
Detection item:
• Exhaust gas temperature sensor 0, 1, 2 output
DTC set parameter:
• All exhaust gas temperature (T0, T1 and T2) reduces down to 300 °C (572 °F)
• ON
• Engine stop
• Inhibit starter relay activation until all exhaust gas temperature (T0, T1 and T2) reduces down to 300 °C (572 °F)
9Y1200199CRS1154US0
1. Check the DTC
1. If DTC is output when the key switch is ON, do not start-up the
engine. (Engine can not be started-up)
2. Engine can be started up after the DTC goes off.
NOTE
• This DTC does not mean error.
This warning indicates that error of emergency exhaust gas
temperature sensor has been continuing.
(a) CAN1 Connector
9Y1200199CRS1155US0
1-S287
(64) High Frequency of Regeneration (DTC P3024 / 523602-0)

• Worsening exhaust gas performance (NOx)
Detection item:
• Time interval from the end time to the start time of the regeneration
DTC set parameter:
• Regeneration time interval within 30 min. occurs three times continuously
• ON
• EGR stop
9Y1200199CRS1156US0
NOTE
• Check the installation of the differential pressure sensor
pipes.
• Check the engine oil maintenance history
(Oil consumption).
OK Go to "2. Check the Differential Pressure Sensor (Refer to items P2454
and P2455)".

(2) Hose
9Y1200199CRS1157US0
2. Check the Differential Pressure Sensor (Refer to items P2454
and P2455)
1. Check the differential pressure sensor.
OK Go to "3. Check the Function of DPF".
NG Repair or replace the differential pressure sensor or its related parts.
(Follow the diagnostic procedure of items P2454 and P2455).

(3) Terminal DPS
9Y1200199CRS1158US0
3. Check the Function of DPF
1. Operate the engine for 30 minutes in the normal condition.
Factory "DPF Regeneration Request" is not detected within 30
specification minutes.
OK Normal.
(a) DPF Manual Regeneration

Reguest Button
9Y1200199CRS1159US0
1-S288
(65) Over Heat Pre-caution (DTC P3025 / 523603-15)

• Worsening exhaust gas performance (NOx)
Detection item:
• Limitation of EGR valve activation due to High temperature AECD
DTC set parameter:
• Engine coolant temperature ≥ 110 °C (230 °F)
• ON
• None
9Y1200199CRS1160US0
1. Check the DTC
1. This DTC does not mean error.
The EGR operation is restricted when the coolant temperature
rises above 110 °C (230 °F).
So, this warning indicates that emission could worsen due to the
limitation.
(a) CAN1 Connector
9Y1200199CRS1161US0
1-S289
(66) CAN2 Bus Off (DTC U0075 / 523547-2)

• Transmitted data is invalid
Detection item:
• CAN2 + B/GND open circuit or high traffic error
DTC set parameter:
• CAN2 Bus off
• ON
(Machine Side)
9Y1200199CRS1162US0
1. DTC Judgment
(U0075) is output or not.
Factory
DTC (U0075) must not be output.
specification
OK Normal.
NG Go to "2. Check the Wiring Related to the CAN of the Common Rail
System".
(a) CAN1 Connector

9Y1200199CRS1163US0
1-S290
2. Check the Wiring Related to the CAN of the Common Rail
System
1. Check the wiring harness and connectors being connected to
ECU terminals V17 and V37 for a short or an open circuit.
IMPORTANT
Electronic Circuit Systems". (Refer to page 1-S305)
OK Replace the ECU.
9Y1200199CRS1164US0
1-S291
(67) No Communication with EGR (DTC U0076 / 523578-2)

Detection item:
• No communication with EGR
• No ST signal
DTC set parameter:
• Interruption of CAN
• ON
• EGR stop
9Y1200199CRS1165US0
9Y1200199CRS0944US0
1-S292
System
ECU terminal V16 and V36 for a short or an open circuit.
IMPORTANT
NOTE
• If the "CAN 1 Bus off error" is output at the same time, carry
out this inspection first.
OK Go to "2. Measure the EGR Terminal Voltage".
9Y1200199CRS1167US0
2. Measure the EGR Terminal Voltage
voltage between EGR terminals (3) and (4).
Factory
Approx. 10 to 16 V
specification

(1) Terminal CAN-H (3) Terminal Ground

(2) Terminal CAN-L (4) Terminal Power (+12 V)
9Y1200199CRS1168US0
Factory
specification
NOTE
• Check the DTC again after starting up the engine with the
engine with the coolant temperature over 65 °C (149 °F).
OK Normal.
(a) CAN1 Connector

9Y1200199CRS1169US0
1-S293
(68) CAN1 Bus Off (DTC U0077 / 523604-2)

• Transmitted data is invalid
Detection item:
• CAN1 +B/GND open circuit or high traffic error
DTC set parameter:
• CAN1 Bus off
• ON
• EGR stop
9Y1200199CRS1170US0
(a) EGR Valve Assembly (b) Engine ECU (c) ECU Connector 2 A: To Diagnosis Tool
(Machine Side)
9Y1200199CRS1171US0
System
ECU terminal V16 and V36 for a short or an open circuit.
IMPORTANT
OK Replace the ECU.
9Y1200199CRS1172US0
1-S294
(69) CAN2 Frame Error (DTC U0081 / 523548-2, U0082 / 523591-2, U0083 /
523592-2, U0084 / 523593-2, U0085 / 523594-2, U0086 / 523595-2, U0087 /
523596-2, U0089 / 523598-2)
U0081 / 523548-2: CAN-KBT frame error
Detection item:
• CAN-KBT original frame error
• Key switch turn OFF to ON
• No ST signal
• No error of "CAN2 Bus off"
DTC set parameter:
• CAN2 KBT frame error open circuit or short circuit
• ON
9Y1200199CRS1173US0
U0082 / 523591-2: CAN CCVS (Parking SW and Vehicle Speed) frame error
• None
Detection item:
• CAN_CCVS communication stopping
• No ST signal
DTC set parameter:
• CAN CCVS frame time out error
• ON
• Parking SW = OFF, Vehicle speed = 0 [default value]
9Y1200199CRS1174US0
U0083 / 523592-2: CAN CM1 (Regen SW) frame error
• None
Detection item:
• CAN_CM1 communication stopping
• No ST signal
DTC set parameter:
• CAN CM1 frame time out error
• ON
• Regeneration inhibit = ON, Parked regeneration switch = OFF [default value]
9Y1200199CRS1175US0
1-S295
U0084 / 523593-2: CAN DDC1 (Transmission) frame error
• None
Detection item:
• CAN_DDC1 communication stopping
• No ST signal
DTC set parameter:
• CAN DDC1 frame time out error
• ON
• Accelerator non-linear processing flag = 0 [default value]
• Accelerator non-linear processing invalid
9Y1200199CRS1176US0
U0085 / 523594-2: CAN ETC2 (Neutral SW) frame error
• None
Detection item:
• CAN_ETC2 communication stopping
• No ST signal
DTC set parameter:
• CAN ETC2 frame time out error
• ON
• Neutral SW = OFF [default value]
9Y1200199CRS1177US0
U0086 / 523595-2: CAN ETC5 (Neutral SW) frame error
• None
Detection item:
• CAN_ETC5 communication stopping
• No ST signal
DTC set parameter:
• CAN ETC5 frame time out error
• ON
• Neutral SW = OFF [default value]
9Y1200199CRS1178US0
1-S296
U0087 / 523596-2: CAN TSC1 frame error
• None
Detection item:
• CAN_TSC1 communication stopping
• No ST signal
DTC set parameter:
• When not receive the request to "TSC1 buffer" 3 times continuously at each timing after receiving over-ride control
request (other than 0x00)
• ON
• Override control mode = Normal mode [default value]
9Y1200199CRS1179US0
U0089 / 523598-2: CAN EBC1 frame error
• None
Detection item:
• CAN_EBC1 communication stopping
• No ST signal
DTC set parameter:
• CAN EBC1 frame time out error
• ON
• Non shutdown [default value]
9Y1200199CRS1180US0
1-S297
(Machine Side)
9Y1200199CRS1181US0
1. DTC Judgment
is output or not.
NOTE
• If the "CAN 2 Bus off error" is output at the same time, carry
out this inspection first.
• Make sure that the ECU on the machine side operates
properly.
Factory
specification
OK Normal.
NG Go to "2. Check the Wiring Related to the CAN of the Common Rail
System".
(a) CAN1 Connector

9Y1200199CRS1182US0
System
1. Check the wiring harness and connectors being connected to
ECU terminals V17 and V37 for a short or an open circuit.
IMPORTANT
OK Replace the ECU.
9Y1200199CRS1183US0
1-S298
6. INSPECTION PROCEDURE FOR EACH SYSTEM

[1] AIR INTAKE SYSTEM INSPECTION PROCEDURE
1. Check the Air Cleaner
1. Check the air cleaner for clogging.
• Clean air cleaner element (Primary and Secondary) every 250
hours.
• Replace air cleaner element:
Once yearly or after every sixth cleaning, whichever comes first.
OK Go to "2. Check the Suction Path".
NG Clean or replace.
9Y1200199CRS1184US0
2. Check the Suction Path

1. Check the suction path for leaks. (including EGR valve,
turbocharger, intercooler, etc.)
• Suction path joints.
• Suction pipes, hoses.
NOTE
• A small amount of gas and water bleeds from the valve
chamber gas bleeding hole of the EGR valve. This is
normal.
OK Normal.

(2) Hose (4) EGR Valve
9Y1200199CRS1185US0
1-S299
[2] FUEL SYSTEM INSPECTION PROCEDURE

Fuel:
Fuel is flammable and can be dangerous.
You should handle fuel with care.
• Cetane Rating: The minimum recommended Fuel Cetane Rating is 45.
A cetane rating greater than 50 is preferred, especially for ambient temperatures below –20 °C (–4 °F) or
elevations above 1500 m (5000 ft).
• Diesel Fuel Specification Type and Sulfur Content % (ppm) used, must be compliant with all applicable emission
regulations for the area in which the engine is operated.
• DO NOT USE Fuels that have sulfur content greater than 0.0015 % (15 ppm).
• Diesel fuels specified to EN 590 or ASTM D975 are recommended.
• No.2-D is a distillate fuel of lower volatility for engines in industrial and heavy mobile service. (SAE J313 JUN87)
• These engines utilize Interim Tier 4 standards, the use of ultra low sulfur fuel is mandatory for these engines,
when operated in US EPA regulated areas.
Therefore, please use No.2-D S15 diesel fuel as an alternative to No.2-D, and use No.1-D S15 diesel fuel as an
alternative to No.1-D for ambient temperatures below −10 °C (14 °F).
1. SAE: Society of Automotive Engineers
2. EN: European Norm
3. ASTM: American Society of Testing and Materials
4. US EPA: United States Environmental Protection Agency
5. No.1-D or No.2-D, S15: Ultra Low Sulfur Diesel (ULSD) 15 ppm or 0.0015 wt.%
• When biodiesel fuel is used, change the fuel filter cartridge, fuel rubber piping and clamp bands with new ones at
intervals half of the usual ones.
IMPORTANT
• Be sure to use a strainer when filling the fuel tank, or dirt or sand in the fuel may cause trouble.
• Do not run the fuel tank level too low or completely out of fuel. Additionally, fuel system bleeding may be
necessary if air enters the fuel system.
Biodiesel fuel:
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN590 (European) standard and that
the B100 blend conforms to the updated EN14214 (European) standard.
Be also sure that the mineral oil diesel fuel, if used, conforms to the updated EN590 (European) standard or the ASTM
D975 (U.S.) standard and that the B100 blend conforms to the updated EN14214 (European) standard or the ASTM
D6751 (U.S.) standard.
(To be continued)
1-S300
(Continued)
[Precautions in handling Biodiesel fuels]
1. Keep the fuel tank full whenever possible to prevent water vapor from accumulating inside the fuel tank.
Tighten up the fuel tank filler cap to avoid the entry of moisture.
2. Routinely check the oil level before the operation.
Also strictly follow the specified oil change intervals.
3. Biodiesel fuels (BDF) during the supply process or in the machine easily deteriorate due to oxygen, water, heat
and other foreign substances. With this in mind, take the following precautions.
• Do not leave those fuels in the fuel tank or a metallic drum longer than 3 months.
• Before storing the engine for a prolonged period, change such fuel for a conventional type of diesel fuel and
run the engine for 30 minutes or longer to clean up the fuel system.
4. Bear it in mind that Biodiesel fuels have the characteristics below.
Referring to the servicing intervals specified in the KUBOTA product's Operator's Manuals, be sure to maintain
and clean up the fuel system, replace the fuel rubber piping with new ones and take other necessary measures.
It is advisable to replace the fuel filter, fuel rubber piping and clamp bands with new ones after half the specified
replacement intervals.
(Compared with the use of mineral oil diesel fuels, the filtration performance of fuel filters gets degraded earlier
than expected.)
• Biodiesel fuels easily induce the growth of microorganisms and foul themselves.
This may get the fuel system corroded and the fuel filter clogged.
• In cold weather, some problems may occur: the clog of the fuel line or fuel system, starting failure, and other
unforeseen troubles.
• Biodiesel fuels easily soak up moisture, which means that they may contain higher moisture content than
conventional diesel fuels.
5. Palm oil-based Biodiesel fuels are inferior in low temperature fluidity to soy-based and rapeseed-based Biodiesel
fuels.
In cold season in particular, this may clog the fuel filter.
6. If Biodiesel fuels are spilt on a coated surface, the coating may get damaged.
Immediately wipe the spill off the surface.
Fuel filter:
• At least, filter mesh below is required.
5 µm dust - dust collecting efficiency 95 % or more (Standard spec. filter)
– An additional filter which has higher cleaning efficiency may be required depending on the spec. (working
condition) or area. Even the maximum period of operation time is same, in case the cleaning efficiency has
improved, it is required to expand the size of a filter (A filter needs to be bigger.).
Criteria at the entrance of supply pump:

• Water content: Less than 0.05 % (500ppm)
– Use to compare with the analysis result by the third-party organization.
• Air: No existence (Do not modify the specific fuel pipe)
– Visually check is possible by using clear hose. Pay sufficient caution to contamination.
• Critical load: (at all operating conditions) −30 kPa or more
– Perform a measurement of the pressure depending on the situation.
9Y1200199CRS1186US0
1-S301
1. Check the Fuel System (Remaining Fuel Quantity and
Properties)
1. Check the amount of fuel remaining in the tank.
2. Check properties of fuel. Request fuel analysis from a third party
as necessary.
• Color (no color, brownish, white turbidit).
• Odor (kerosene, heavy oil, irritating odor).
• Separation of materials (water, foreign objects).
• Viscosity (high / low viscosity, wax consistency).
NOTE
• Always use the specified fuel.
OK Go to "2. Check the Inside of the Tank (Checking for Tank Modification /
Additions, Position of Fuel Pipe Inlet / Outlet, Clogging and Holes)".
NG Add fuel or change fuel (clean tank).
9Y1200199CRS1187US0
2. Check the Inside of the Tank (Checking for Tank Modification
/ Additions, Position of Fuel Pipe Inlet / Outlet, Clogging and
Holes)
1. Check the tank for modifications or additions. Consult with the
customer.
• Fuel inlet / outlet position, tank piping.
• Foreign material inside the tank, water separation, rust.
NOTE
• Use resin tanks when making tank additions.
2. Check the tank internal fuel piping for the following.
• Inlet / outlet position (below position "Empty").
• Inlet clogging, whether there is bent or deformed piping
(crushed pipe).
• Crushing at pipe connections.
OK Go to "3. Tank External Fuel Path Conditions (Crushed Hose, Clogging,
Air Introduction at Hose Connection)".
NG Restore the fuel tank.
9Y1200199CRS1188US0
3. Tank External Fuel Path Conditions (Crushed Hose,
Clogging, Air Introduction at Hose Connection)
1. Check the condition of the hose.
• Crushing around bands, over bending.
• Pinched or crushed by other parts.
2. Check the connection (air introduction).
• Looseness.
• Hose deterioration (verify that there is no rubber hardening /
splitting by hand or visually).
NOTE
• Be cautious when vacuum pressure is present, as air will
be drawn into the hose.
OK Go to "4. Check the Water Separator".
NG Repair or replace the hose.
(1) Fuel Hose

9Y1200199CRS1189US0
1-S302
4. Check the Water Separator
1. Check the water level of the water separator and discharge
some water as necessary.
2. Check for element deformation and dirt.
Clean or replace the element as necessary.
OK Go to "5. Check the Fuel Feed Pump".
NG Replace the filter and drain the water from the water separator.
(1) Water Separator

9Y1200199CRS1190US0
5. Check the Fuel Feed Pump
1. Set the key switch to the ON position, check the fuel feed pump
alone, and check and repair the wiring harnesses.
2. Check the operation of the fuel feed pump by touching it directly
by hand.
NOTE
• If there is a fuel feed pump malfunction, the fuel cannot be
supplied and so there is greater likelihood of improper
recognition of DTC codes related to the pressure and
injector. (Items where improper recognition is possible.)
• Injector COM1 TWV actuation system short
• SCV actuation system abnormality
• Others
OK Go to "6. Fuel Filter Clogged".
NG Repair the wiring harness, and replace the fuel feed pump.
(1) Fuel Feed Pump

9Y1200199CRS1191US0
6. Fuel Filter Clogged
1. Check the fuel filter for clogging and dirt.
NOTE
• Replace the fuel filter every 500 operation hours.
OK Go to "7. Engine Oil Level Increase (Engine Internal Leak)".
NG Clean or replace the fuel filter and fuel pipe system.
(1) Fuel Filter

9Y1200199CRS1192US0
7. Engine oil Level Increase (Engine Internal Leak)

1. Check the engine oil level increase with dipstick.
2. Request fuel dilution analysis or oil analysis from a third party as
necessary.
OK Go to "8. Check the High Pressure Piping and CRS Components (Such
as the Fuel Injector and the Supply Pump) for Fuel Leakage (Engine
External Leak)".
NG Check and repair interior pipes.
(1) Dipstick
9Y1200199CRS1193US0
1-S303
8. Check the High Pressure Piping and CRS Components
(Such as the Fuel Injector and the Supply Pump) for Fuel
Leakage (Engine External Leak)
1. Visually check and specify areas leaking fuel.
2. Be cautious because there may be oil leaks in the high pressure
pipe and injector areas.
OK Normal.
NG Repair leaking high pressure pipe, etc. or replace leaking parts.

(2) Injection Pipe
9Y1200199CRS1194US0
1-S304
[3] ELECTRIC SYSTEM INSPECTION PROCEDURE

(1) Basics Of Checking Electrical / Electronic Circuit Systems
Measure the ECU Terminal Voltage and Resistance
1. When measuring the voltage and resistance of each terminal,
insert the multimeter probe into the rear side of the wiring
harness connector. If connectors are small making it difficult to
insert the probe, insert a fine metal wire into the rear of the
connector and touch the wire to the probe.
IMPORTANT
• When inserting a fine metal wire for measurement
purposes, ensure that the connector waterproof rubber is
not damaged.
(2) ECU Connector 1 (Engine Side) (5) EO1 Position
(3) ECU Connector 2 (Machine Side) (6) VO1 Position
9Y1200199CRS1195US0
Open Circuit Check
1. When dealing with a wiring harness open circuit like that
depicted in Figure A-1, check continuity or voltage to determine
the location of the open circuit.
(1) Sensor (3) ECU
(2) Open Circuit
9Y1200199CRS1196US0
Check for Continuity

1. Remove connectors "A" and "C" and measure resistance
between the two.
Factory
Less than 1 Ω
specification
(Reference)
• Measure resistance while gently shaking the wiring harness up
and down, and side-to-side.
2. In the case of Figure A-2, there is no continuity (open circuit)
between terminal 1 of connector "A" and terminal 1 of
connector "C". However, there is continuity between terminal 2
of connector "A" and terminal 2 of connector "C". As a result, it
can be said that there is an open circuit between terminal 1 of
connector "A" and terminal 1 of connector "C".
3. Remove connector "B" and measure the resistance in the
connector.
4. In the case of Figure A-3, there is continuity between terminal 1
of connector "A" and terminal 1 of connector "B1". However,
there is no continuity (open circuit) between terminal 1 of
connector "B2" and terminal 1 of connector "C". As a result, it
can be said that there is an open circuit between terminal 1 of
connector "B2" and terminal 1 of connector "C".
(1) Sensor (2) ECU
9Y1200199CRS1197US0
1-S305
Check Voltage
1. In the case of the circuit that supplies voltage to the ECU
connector terminals, check for an open circuit by performing a
voltage check.
2. As depicted in Figure A-4, measure the voltage of the ECU 5 V
output terminal between the body ground and terminal 1 of
connector "A" with all connectors connected. Next, measure in
order the voltage between terminal 1 of connector "B" and the
body ground, and terminal 1 of connector "C" and the body
ground.
3. The faulty circuit and measurement results are as per below.
(Measurement Results)
• Voltage between terminal 1 of connector "A" and the body
ground is 5 V.
• Voltage between terminal 1 of connector "B" and the body
ground is 5 V.
• Voltage between terminal 1 of connector "C" and the body
ground is 0 V.
(Faulty Circuit)
• There is an open circuit between terminal 1 of connector "B"
and terminal 1 of connector "C".
(1) Sensor (2) ECU
9Y1200199CRS1198US0
Short Circuit Check
1. As per Figure A-5, if there is a short in the wiring harness
ground, perform a "Ground continuity check" to determine
the source of the short.
(1) Sensor (3) ECU
(2) Short Circuit
9Y1200199CRS1199US0
1-S306
Ground Continuity Check
1. Remove connector "A" and connector "C", then measure the
resistance between terminals 1 and 2 of connector "A" and
ground.
Factory
No continuity
specification
(Reference)
• Measure resistance while gently shaking the wiring harness up
and down, and side-to-side.
2. In the case of Figure A-6, there is continuity between terminal 1
of connector "A" and the body ground (short circuit). However,
there is no continuity between terminal 2 of connector "A" and
the body ground. As a result, it can be said that there is an open
circuit between terminal 1 of connector "A" and terminal 1 of
connector "C" .
3. Remove connector "B" and measure the resistance between
terminal 1 of connector "A" and the body ground, and between
terminal 1 of connector "B2" and the body ground.
4. The faulty circuit and measurement results are as per below.
(Measurement Results)
• No continuity between terminal 1 of connector "A" and the body
ground.
• Continuity between terminal 1 of connector "B2" and the body
ground.
(Faulty Circuit)
• There is a short circuit between terminal 1 of connector "B2"
and terminal 1 of connector "C".
(1) Sensor (2) ECU
9Y1200199CRS1200US0
1-S307
(2) Connector Connection Fault Verification Method
(1) Diagnosis Tool Data Monitor (2) Voltage Measurement (A) Sensor Example (a) CAN1 Connector
(Sensor Output Voltage) (b) ECU Connector 1
(Engine Side)
(c) ECU Connector 2
(Machine Side)
As per the diagram above, measure both the data monitor and connector voltage simultaneously.
Ex.) Coolant temperature sensor
a) Read in the "Coolant Temperature Output Voltage" value from the data monitor.
b) Measure the voltage directly from the corresponding ECU terminal.
Judge as a connector connection fault if b) is satisfactory and a) is unsatisfactory. Since some malfunctions only
occur intermittently, measure voltage while pulling and shaking the wires in order to try to get the malfunction to
reoccur.
9Y1200199CRS1201US0
1-S308
(3) Checking The Power And Ground System (Main Relay, ECU Circuit)
If the ECU is not operating, check the following.
Malfunction symptoms:
• Engine does not start.
• Engine warning light is not lit.
• A diagnosis tool communication error occur.
(1) Input Terminal (5) Terminal 1 (a) Main Relay Terminal Layout (d) Battery
(2) ACC (6) Terminal 2 (b) Key Switch (e) ECU Connector 2
(3) Output Terminal (7) Terminal 3 (c) Main Relay (Machine Side)
(4) START (8) Terminal 4
9Y1200199CRS1202US0
1-S309
1. Measure the ECU +BP and Ground Voltage
1. Turn the key switch ON and measure the voltage between the
ECU +BP terminals (V18 / V38 / V58 / V78) and ground (body /
battery terminal). Then measure voltage between the ECU
ground terminals (V40 / V60) and ground (body / battery
terminal).
Factory +BP terminal - Ground; greater than or equal to 10 V
specification P-GND terminal - Ground; Less than or equal to 0.5 V
+BP terminal unsatisfactory

OK Normal.
NG Check battery, wiring harness, ground wire.
OK Go to "2. Check the Relay Terminal Voltage -1".

Ground terminal unsatisfactory

OK Normal.
NG Check ECU wiring harness ground.
9Y1200199CRS1203US0
2. Check the Relay Terminal Voltage -1
1. Turn the key switch ON and measure voltage at relay terminal
2 (2).
Factory
10 V or higher
specification
OK Check wiring between relay and ECU. → Repair.

Check for connector connection fault. → Repair.
NG Go to "3. Check the Relay Terminal Voltage - 2".
(1) Terminal 1 (a) Main Relay Terminal Layout

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
9Y1200199CRS1204US0
3. Check the Relay Terminal Voltage - 2
1. Measure voltage at relay terminal 1 (1).
Factory
10 V or higher
specification
OK Go to "4. Check the Relay Terminal Voltage - 3".

NG Check for a wiring harness open circuit and / or connector connection
fault. → Repair.
Inspect fuse. → Replace.

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
9Y1200199CRS1205US0
1-S310
1. Measure voltage at relay terminal 3 (3).
Factory
10 V or higher
specification

NG Check for a wiring harness open circuit and / or connector connection
fault. → Repair.
Inspect fuse. → Replace.

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
9Y1200199CRS1206US0
1. Turn the key switch OFF and measure voltage at relay terminal
4 (4).
NOTE
• Perform measurement two seconds after cycling the key
switch ON → OFF.
Factory
10 V or higher
specification

NG Check the relay. → Repair.

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
9Y1200199CRS1207US0
1. With the key switch OFF, measure voltage at the ECU main
relay terminals (V03 / V23).
Factory
10 V or higher
specification

NG Check wiring harness between relay and ECU and connectors. →
Repair.
9Y1200199CRS1208US0

1. Turn the key switch ON and measure voltage at relay terminal
4 (4).
Factory
Approx. 0 V
specification
OK Faulty relay contacts → Replace.

NG Go to "8. Check the Key Switch Signal -1".

(2) Terminal 2
(3) Terminal 3
(4) Terminal 4
9Y1200199CRS1209US0
1-S311
8. Check the Key Switch Signal -1
1. Connect the diagnosis tool to diagnostic connector (CAN1
connector) and turn the key switch ON.
2. Using the diagnosis tool data monitor function, verify the "Key
Switch" data when the key switch is turned ON then OFF.
Factory When the key switch is set to the ON and OFF, the data
specification output is turned ON and OFF respectively.
IMPORTANT
• Do not keep the key switch in the OFF position for more
than 2 seconds, otherwise a communication error will
occur.
OK ECU internal fault → Replace the ECU.
NG Con- ECU internal fault → Replace the ECU.
stantly
ON
Consis- Go to "9. Check the Key Switch Signal -2".
tently
OFF
(a) CAN1 Connector

9Y1200199CRS1210US0
9. Check the Key Switch Signal -2
voltage at ECU terminal V13 / V33.
Factory
10 V or higher
specification
OK Check whether the connector is poorly connected.

OK Replace the ECU.
NG Repair the connector.
NG Go to "10. Check the Key Switch -1".
9Y1200199CRS1211US0
10. Check the Key Switch -1
1. Set the key switch to the ON position, and measure the voltage
at the key switch output terminal (3).
Factory
10 V or higher
specification
OK Check the wiring harness between the key switch output terminal and
ECU terminal (V13 / V33), and the fuse. → Repair or replace.
NG Go to "11. Check the Key Switch - 2".
(1) Input Terminal (a) Key Switch

(2) ACC
(3) Output Terminal
(4) START
9Y1200199CRS1212US0
1-S312
11. Check the Key Switch - 2
1. Measure the voltage at the key switch input terminal (1).
Factory
10 V or higher
specification
OK Check the key switch. → Replace.

NG Check the wiring harness between the battery and key switch, and the
fuse. → Repair or replace.
(1) Input Terminal (a) Key Switch

(2) ACC
(3) Output Terminal
(4) START
9Y1200199CRS1213US0
1-S313

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647470EN (01/04/2019)

DATE OF ISSUE OBSERVATION

11 / 06 / 2014 - 1st ISSUE

01 / 04 / 2019 - Update + DIAGNOSIS MANUAL

MANITOU BF S.A Limited liability company with a Board of Directors.

KiSC issued 04, 2017 A

KiSC issued 04, 2017 A

4. MAINTENANCE CHECK LIST G-6

KiSC issued 04, 2017 A

KiSC issued 04, 2017 A

1. SAFETY FIRST .............................................................................................................................. I-1

KiSC issued 04, 2017 A

PROTECT AGAINST HIGH PRESSURE SPRAY

EXHAUST FILTER CLEANING

KEEP A GOOD AIRFLOW IN THE WORK AREA

PREVENT ACID BURNS

PREPARE FOR EMERGENCIES

Model V2607-CR-TIE4B V3307-CR-TIE4B

(1) − CAN and EGR

(1) − CAN and EGR

[2] INJECTOR INTERMEDIATE HARNESS

(1) CN306 Injector Intermediate Connector

[3] ECU INTERMEDIATE HARNESS (OEM SIDE HARNESS)

(1) CN501 ECU (1)

(1) − Power Unit

(1) − Diesel Particulate Filter (DPF)

[4] SYSTEM WIRING DIAGRAM

KiSC issued 04, 2017 A

1. ENGINE IDENTIFICATION .......................................................................................................... G-1

KiSC issued 04, 2017 A

(1) Engine Model Name and Serial

* Alphabetical letters "I" and "O" are not used.

[2] E4B ENGINE

Category (2) Engine output classification EPA regulation

(1) EU regulation engine output classification category

[3] CYLINDER NUMBER

2. MUFFLER FULL ASSEMBLY IDENTIFICATION

4. MAINTENANCE CHECK LIST

5. CHECK AND MAINTENANCE

(1) Fan Belt (A) OK

[2] INITIAL 50 HOURS

(1) Drain Plug (a) Upper Line

[3] EVERY 50 HOURS

[4] EVERY 250 HOURS

(1) Fan Belt (A) OK

[5] EVERY 500 HOURS

(1) Drain Plug (a) Upper Line

(1) Fan Belt (A) Deflection

[6] EVERY 1000 HOURS

When No. 1 piston is at compression top 2 

9.81 to 11.2 N·m

(1) Adjusting Screw A: Valve Clearance

[7] EVERY 1500 HOURS

(1) Exhaust Gas Inlet (a) Air Pressure

(1) Oil Separator Assembly (4) O-ring

Check of PCV (Positive Crankcase Ventilation) Valve

[8] EVERY 3000 HOURS

(1) Screw of Muffler Flange (11) DPF Mounting Bracket

(1) Nut of Muffler Flange (12) DPF Mounting Screw

(A) Exhaust Inlet Side (a) Serial Number

Check of EGR System

0.90 to 1.2 in. Aq

(2) Ring [A] V2607-CR-E4B