MC 10159332 0001

SERVICE MANUAL INFORMATION
SB-19-013 EXHAUST VALVE INSPECTION

WORKSHOP MANUAL CORRECTION
GROUP: SERVICE MANUAL UPDATE

BULLETIN NO: SB-19-013
DATE: 4-10-2019
SUBJECT VEHICLES: 16MY-20MY Cab-Over Engine (COE) Trucks
equipped with an J05E.
The following is to inform you of the above caption. This service

data should be attached to the relevant pages of the workshop
manuals for maintenance and to use for servicing.
OVERVIEW:
Change of exhaust valve inspection method.
Workshop manual correction of Diagnostic Trouble Code DTC
P0027, P0421, P2458, P24A2 and DPR cleaner.
2–136 ENGINE (J05E)/TROUBLESHOOTING
DTC: P0027
EN01H02127030602016027
P0027: Exhaust Brake Performance

INFORMATION
1. Technical description
<Description of malfunction>
• The engine ECU detected sticking of the exhaust brake valve.
2. DTC set condition

(1) DTC detection condition
• DPR regeneration is in process.
• The vehicle speed is 0 km/h {0 mile/h}.
• The time of 60 seconds has elapsed after the exhaust brake was actuated.
(2) Judgment criteria
• The difference between the fuel injection quantity while the exhaust brake is working and the fuel injection
quantity when the exhaust brake is not actuated is 5 mm3/st or less. And also, the difference between the air
flow while the exhaust brake is working and the air flow when the exhaust brake is not actuated is -50 mg/cyl
or more.
3. Reset condition
• Immediately after normal status is resumed
4. Indication, warning or system control regulation when the DTC is set.

• MIL: ON
• SVS light: OFF
5. Symptoms on the vehicle when the DTC is set
<Symptoms on the vehicle due to backup control (fail safe function)>

• –
<Symptoms on the vehicle due to malfunction>

• The exhaust brake does not work.
• DPR regeneration is not terminated successfully.
6. Pre-inspection work
• Check that the battery voltage is in the normal range.
7. After-inspection work
• Clear all past DTCs.
• Check that no DTC is detected after test drive.
8. Estimated failure factors

• Abnormality in characteristics of air flow meter
• Diesel throttle (intake throttle valve) sticking
• Bend, clogging, and crack of piping and hose
• Improper adjustment of exhaust brake valve
• Malfunction of exhaust brake valve
ENGINE (J05E)/TROUBLESHOOTING 2–137
INSPECTION PROCEDURE: P0027
1 Check the DTC detected 1 [HINO DX ൖ ]
1. Set the starter key to the "LOCK" position.
2. Connect the vehicle to HINO DX ൖ .
3. Set the starter key to the "ON" position.
4. On the screen of the diagnostic system, select [Engine], and check

any DTC listed below other than P0027.
- P0101, P04D5, P2101, P2526
SHTS021270300124
Has a DTC other than P0027 been detected?
YES NO
Perform the relevant DTC-specific trouble- Go to step 2.

shooting.
2 Inspect the exhaust brake valve piping and hose
1. Check the piping and hose, connected to the exhaust brake valve,
for bend, clogging, and crack.
Was any failure found?
YES NO
Connect securely, repair if needed. Go to step 3.

3 Inspect the exhaust brake valve
1. Check the exhaust brake valve for unease and sticking.
SHTS021270300125
YES NO
Clean the exhaust brake valve. Replace if Go to step 5.

necessary. After clearing or replacement, go
to Step 4.
1. Perform a DPR forced regeneration.
2. After completion of regeneration, on the screen of the diagnostic

system, select [Engine] and read the detected DTCs.
SHTS021270300126
Has DTC P0027 been detected?
YES NO
Go to step 5. Procedure completed.

5 Inspect the exhaust brake valve [HINO DX ൖ ]
1. Warm up the engine. (Coolant temperature:60 qC {140 qF} or

more)
2. Turn OFF the devices that place load on the engine, such as the
air conditioner.
<Inspection procedure>
(1) Turn the starter key to the "ON" position.
(2) Start HINO DX ൖ .
(3) On the HINO DX ൖ window, click [Customization].
Select the vehicle model and region, and check [Engine].
Select either Upload INF file and then [Road out] to read out.
SHTS021270300127
(4) Select [Engine], and press the click button.
SHTS021270300128
(5) Writing soot volume

HINT
Customization function • As in the window on the left, write a soot volume[2.5] using the
customization function. Record the original value not to forget.
The example in the window is [0.674].
Original value • If the soot volume is indicated between 2.5 to 5.0 from the
beginning, do not change. In such a case, do not stop regenera-
Soot volume to write tion halfway.
Writing
SHTS021270300129
(6) Turn the starter key "OFF" and then "ON" according to the
instruction.
Then, click [OK].
SHTS021270300130
CHANGE
(7) Check that ECU writing has been completed. Click [OK].
Refer to the window on the left.
SHTS021270300131
(8) Click [Diagnosis].
SHTS021270300132
(9) Select[Engine], and press the click button.
SHTS021270300133
(10) Select [Data monitor and Active test].

Select [Data monitor Setting].
Date monitor and Active test Refer to the window on the left.
Deta monitor Setting
SHTS021270300134
CHANGE
(11) From the selection window on the left, select the following 3
items. Click OK.
x Engine speed
x Engine Coolant temperature
x Injection quantity
SHTS021270300135
(12) ( i ) Click [Start] to display the window to check the data stor-
age destination.
( ii ) Click [OK] to start data monitoring.
( ii )
(i)
SHTS021270300136
(13) Start the engine.

(14) Press the DPR manual regeneration switch of the vehicle.
Start regeneration.click [OK].
(15) Check the injection quantity after 1 minute. This injection
quantity is A(exhaust brake ON condition). Record the this value
not to forget.
SHTS021270300137
(16) Select [Active test Setting].
Active test Setting
SHTS021270300138
CHANGE
(17) Select [ Target rpm ].

(18) Set to 1,100r/min.
(19) Press Select.
Target rpm 1,100 rpm
Select
SHTS021270300139
(20) Press Start.
SHTS021270300140
(21) With the gear in the neutral position, apply the parking brake
confirm that the PTO is off then press OK.
SHTS021270300141

quantity is B(exhaust brake OFF condition). Record the this value
not to forget.
SHTS021270300142
CHANGE
(23) Press stop.

HINT
• If the original soot amount is less than 2.5 g / L, stop playback
by pressing the manual regeneration switch.
(24) If the amount of soot is 2.5 or less, rewrite the original amount
of soot with the customization function of (5) Writing soot volume.
SHTS021270300143
(25) Make a judgment by the difference of A(exhaust brake ON

condition) from B(exhaust brake OFF condition).
Standard values
13 – 17 mm3/st
Do the measurements meet the standard value? (There shall be a change in the injection quantity
between while the exhaust brake is working and when it is not actuated.)
YES NO
Go to step 6. Adjust the butterfly opening of the exhaust

brake.
CHANGE 6 Check the DTC detected [HINO DX ൖ ]
1. Perform a DPR forced regeneration.
2. After regeneration, on the screen of the diagnostic system, select

[Engine] and check the detected DTCs.
SHTS021270300144
YES NO
Replace the engine ECU. Procedure completed.

DTC: P0421
EN01H02127030602016082
P0421: Determination of ATC deterioration

INFORMATION
• If post injection is performed normally but the ATC (oxidation catalyst) is not generating heat, the engine ECU
detects abnormality as ATC functional deterioration.

• During DPR active regeneration
• Conditions below active continue for 35 sec
- Engine speed: 700 r/min or higher, 1,025 r/min or lower
- Fuel injection quantity: 10 mm3/st. or higher, 40 mm3/st. or lower
- Engine speed fluctuation: 156 r/min/sec or lower
- Fuel injection quantity fluctuation: 39 mm3/st./sec or less
- Post-injection quantity: 17.5 mm3/st. or more
- Exhaust gas mass flow 210 kg/h
- ATC inlet temperature: 300 qC {572 qF} or higher
- Post-injection does not have malfunction
• ATC outlet temperature – ATC inlet temperature is below the specified value.
3. Reset condition
• Immediately after normal status is resumed

• MIL: ON
• SVS light: OFF
• Engine output is restricted.

• Engine output is insufficient.

• –

• ATC deterioration caused by use of low-grade fuel
• Leak of exhaust gas from the pipe
• Exhaust gas temperature sensor 2 (ATC outlet) malfunction
• Exhaust gas temperature sensor 1 (ATC inlet) malfunction
1 Check the engine ECU
2. Check the engine ECU software part number (ECU part number)
by HINO DX ൖ .
Confirm the latest part number with Hino national service man-
ager.
Does the engine ECU have the latest software number?
YES NO
Go to step 2. Reprogram the engine ECU by using HINO

DX ൖ and then go to step 2.
2 Inspect the exhaust leaks from the exhaust pipe between exhaust gas temperature sensor 2
(ATC outlet) and the exhaust gas temperature sensor 1 (ATC inlet)
1. Check that the exhaust pipe has no looseness of flange or pipe

breakage.
YES NO
Repair or replace the faulty part. Go to step 3.

Perform "After-inspection work" of INFOR-
MATION section.

more)
air conditioner.
SHTS021270300523
SHTS021270300524

HINT
Writing
SHTS021270300525
instruction.
Then, click [OK].
SHTS021270300526
CHANGE
SHTS021270300527
SHTS021270300528
SHTS021270300529

SHTS021270300530
CHANGE
items. Click OK.
x Engine speed
SHTS021270300531
age destination.
( ii )
(i)
SHTS021270300532

not to forget.
SHTS021270300533
Active test Setting
SHTS021270300534
CHANGE

(18) Set to 1,100 r/min.
(19) Press Select.
Select
SHTS021270300535
(20) Press Start.
SHTS021270300536
SHTS021270300537

not to forget.
SHTS021270300538
CHANGE
(23) Press stop.

HINT
SHTS021270300539

Standard values
13 – 17 mm3/st
YES NO

brake.
CHANGE
4 Inspect fuel
1. Open the fuel cap and check fuel for abnormality (in color is yellow
or green).
YES NO
Replace the fuel with good quality fuel. Go to step 5.

MATION section.
5 Inspect the exhaust gas temperature sensor 1 (ATC inlet) connector
1. Check the connection of the exhaust gas temperature sensor 1

(ATC inlet) connector (looseness and poor contact).
YES NO

Go to step 6.
6 Inspect the exhaust gas temperature sensor 1 (ATC inlet)
1. Check the installation of the exhaust gas temperature sensor 1

(ATC inlet).
2. Make sure there is no dirt, damage or clogging in the sensing unit

of the exhaust gas temperature sensor 1 (ATC inlet).
YES NO
Clean the sensing unit and install it properly. Go to step 7.

If damaged, replace the exhaust gas temper-
ature sensor 1 (ATC inlet).
Go to step 7.
7 Inspect the exhaust gas temperature sensor 1 (ATC inlet) unit
2. Disconnect the exhaust gas temperature sensor 1 (ATC inlet) con-

nector.
3. Use the electrical tester to measure the resistance between the

terminals of the exhaust gas temperature sensor 1 (ATC inlet).
Measurement Tester
Standard values
conditions connections
20 qC {68 qF}:
Exhaust gas tem-
SHTS021270300540 13.7 – 29.8 k:
perature sensor 1
50 qC {122 qF}:
Starter key: LOCK (ATC inlet)
7.13 – 13.7 k:
1st terminal – 2nd
80 qC {176 qF}:
terminal
4.1 – 7.13 k:
Do the measurements meet the standard value?
YES NO
Go to step 8. Replace the exhaust gas temperature sensor

1 (ATC inlet).
Go to step 8.
8 Inspect the exhaust gas temperature sensor 1 (ATC inlet) power supply
2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust gas temperature sensor 1 (ATC inlet) vehicle-
side connector.
Measurement Tester
Standard values
Exhaust gas tem-

perature sensor 1
(ATC inlet) vehicle-
Starter key: ON 4.5 – 5.5 V
SHTS021270300541 side connector
terminal
YES NO
Go to step 11. Go to step 9.

If any failure was found at the step 5 – 7, per-
form "After-inspection work" of INFORMA-
TION section.
9 Inspect for short-circuit of the exhaust gas temperature sensor 1 (ATC inlet) harness

E43
D E58
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

terminals of the engine ECU and ground.
Measurement Tester
Standard values
Engine ECU (sig-

SHTS021270300542 nal check har-
ness)
Starter key: LOCK THO1 (E43)– f:
Ground
ETHW (E58) –
Ground
YES NO
Go to step 10. Repair or replace the harness.

Go to step 10.
10 Inspect disconnection of the exhaust gas temperature sensor 1 (ATC inlet) harness
1. Connect the exhaust gas temperature sensor 1 (ATC inlet) con-

nector.
E43 D
E58
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
20 qC {68 qF}:
Engine ECU (sig-
13.7 – 29.8 k:
nal check har-
50 qC {122 qF}:
Starter key: LOCK ness)
SHTS021270300543 7.13 – 13.7 k:
THO1 (E43) –
80 qC {176 qF}:
ETHW (E58)
4.1 – 7.13 k:
YES NO

If any failure was found at the step 5 – 9, per- Perform "After-inspection work" of INFOR-
form "After-inspection work" of INFORMA- MATION section.
TION section.
11 Inspect the exhaust gas temperature sensor 2 (ATC outlet) connector
1. Check the connection of the exhaust gas temperature sensor 2

(ATC outlet) connector (looseness and poor contact).
YES NO

Go to step 12.
12 Inspect the exhaust gas temperature sensor 2 (ATC outlet)
1. Check the installation of the exhaust gas temperature sensor 2

(ATC outlet).
2. Make sure there is no dirt, damage or clogging in the sensing unit

of the exhaust gas temperature sensor 2 (ATC outlet).
YES NO

If damaged, replace the exhaust gas temper-
ature sensor 2 (ATC outlet).
Go to step 13.
13 Inspect the exhaust gas temperature sensor 2 (ATC outlet) unit
2. Disconnect the exhaust gas temperature sensor 2 (ATC outlet)

connector.

terminals of the exhaust gas temperature sensor 2 (ATC outlet).
Measurement Tester
Standard values
20 qC {68 qF}:
Exhaust gas tem-
SHTS021270300544 13.7 – 29.8 k:
perature sensor 2
50 qC {122 qF}:
Starter key: LOCK (ATC outlet)
7.13 – 13.7 k:
80 qC {176 qF}:
terminal
4.1 – 7.13 k:
YES NO

2 (ATC outlet).
Go to step 14.
14 Inspect the exhaust gas temperature sensor 2 (ATC outlet) power supply
2. Use the electrical tester to measure the voltage between the termi-
nals of the exhaust gas temperature sensor 2 (ATC outlet) vehicle-
side connector.
Measurement Tester
Standard values
Exhaust gas tem-

perature sensor 2
(ATC outlet) vehi-
Starter key: ON 4.5 – 5.5 V
SHTS021270300545 cle-side connector
terminal
YES NO
Go to step 17. Go to step 15.

If any failure was found at the step 11 – 13,
perform "After-inspection work" of INFOR-
MATION section.
15 Inspect for short-circuit of the exhaust gas temperature sensor 2 (ATC outlet) harness
M50
F D E58
2. Connect the signal check harness to the engine ECU. (Do not con-
nect harness to the ECU.)

terminals of the engine ECU and ground.
Measurement Tester
Standard values
Engine ECU (sig-

SHTS021270300546 nal check har-
ness)
Starter key: LOCK THO (M50) – f:
Ground
ETHW (E58) –
Ground
YES NO

Go to step 16.
16 Inspect disconnection of the exhaust gas temperature sensor 2 (ATC outlet) harness
1. Connect the exhaust gas temperature sensor 2 (ATC outlet) con-

nector.
M50
F D E58
terminals of the engine ECU (signal check harness).
Measurement Tester
Standard values
20 qC {68 qF}:
Engine ECU (sig-
13.7 – 29.8 k:
nal check har-
50 qC {122 qF}:
Starter key: LOCK ness)
SHTS021270300547 7.13 – 13.7 k:
THO (M50) –
80 qC {176 qF}:
ETHW (E58)
4.1 – 7.13 k:
YES NO

If any failure was found at the step 11 – 15, Perform "After-inspection work" of INFOR-
perform "After-inspection work" of INFOR- MATION section.
MATION section.
17 Test drive
2. Change the [DPR soot amount] using the HINO DX ൖ .
4. Monitor the [DPR mode] set.
5. Start the test drive.
6. Once the [DPR mode] reads any of "6, 7, 15, 23, 24, 27 or 28",
bring vehicle speed to "0" and keep idling for 60 seconds.
Measurement conditions Standard values
During the DPR automatic Vehicle interdiction o Vehi-

regeneration cle start
YES NO
Replace the ATC. Procedure completed. (Temporary loose con-

nection.)
DTC: P2458
EN01H02127030602016191
P2458: Fault in manual regeneration

INFORMATION
• The DPR performs PM regeneration by increasing DOC temperature using the engine warm up control.
• During a manual regeneration, warm up control is carried out by idle up, exhaust brake closing, VNT control, after
injection, post injection and aftertreatment fuel injector injection.
• In a manual regeneration, the DOC and ATC temperatures do not increase to the post injection-enabled region
even after the specified time.

• Battery voltage is in the range of 10 to 16 V.
• The engine speed remains at 500 r/min or more.
• DPR manual regenerating.
• Do not detect the exhaust gas temperature sensor 4 (DPR inlet) of failure.
• After a manual DPR regeneration is started, the DOC temperature is still below 200 qC {392 qF} and the ATC
temperature is still below 230 qC {446 qF} even after 30 minutes.
3. Reset condition
• DPR memory is reset by the diagnostic tool (HINO DX ൖ ).

• MIL: OFF
• SVS light: ON


• Do not DPR regeneration.

• Soot clogging of the DPR dosing injector (fuel addition valve) housing.
Drop in injection rate of fuel injection system

Failure of VNT system
Exhaust gas temperature sensor 4 (DPR inlet):
• Loose/disconnected sensor of failure in sensing area (contamination, clogging or damaged)
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
Exhaust gas temperature sensor 1 (ATC inlet)

• Loose/disconnected sensor of failure in sensing area (contamination, clogging or damaged)
• Abnormal resistance of sensor
• Failure in engine ECU sensor power supply
Exhaust brake
• Malfunction of exhaust brake
• Improper adjustment of exhaust brake (The difference between the injection quantities in active and inactive condi-
tions is out of the standard)
Gas leaks in the middle of the exhaust system

Failure of coolant temperature sensor (low temperature stuck)
4. Select [Engine] and check if any DTC other than P2458 has been
detected.
SHTS021270301278
Have DTCs other than P2458 been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.

2 Inspect the exhaust pipe
1. Check for exhaust pipe crack (between the turbocharger and

EXHAUST PIPE DPR), exhaust gas leak (soot contamination) and improper cou-
(ATC) EXHAUST BRAKE pling flange tightening.
EXHAUST PIPE
(ATC) BRACKET
CLAMP
SHTS021270301279
YES NO
Repair of exhaust pipe (replace gasket, Go to step 3.

retighten), replace if needed.
3 Inspect the aftertreatment fuel injector housing is for soot clogging.
1. Remove the aftertreatment fuel injector housing.

HINT
Refer to the section "AFTERTREATMENT FUEL INJECTOR,
REMOVING THE AFTERTREATMENT FUEL INJECTOR" in the
chapter "EXHAUST (J05E)".
2. Clean the aftertreatment fuel injector housing.

HINT
CLEANING CARBON" in the chapter "EXHAUST (J05E)".
3. Reinstall the aftertreatment fuel injector housing.

HINT
MOUNTING THE AFTERTREATMENT FUEL INJECTOR" in the
chapter "EXHAUST (J05E)".
YES NO
If excessive carbon buildup has removed Go to step 4.

from the exhaust pipe, fuel injector housing,
or aftertreatment fuel injector, clear the DTC
and reset for normal DPR regeneration. If
problems persist, go to step 4.
After cleaning or replacement, go to step 4.
4 Inspect the exhaust brake valve
1. Check the exhaust brake valve for unease and sticking.
SHTS021270301280
YES NO
Clean the exhaust brake valve. Go to step 5.

Replace if necessary.
After cleaning or replacement, go to step 5.

more)
air conditioner.
SHTS021270301281
SHTS021270301282

HINT
Writing
SHTS021270301283
instruction.
Then, click [OK].
SHTS021270301284
CHANGE
SHTS021270301285
SHTS021270301286
SHTS021270301287

SHTS021270301288
CHANGE
items. Click OK.
x Engine speed
SHTS021270301289
age destination.
( ii )
(i)
SHTS021270301290

not to forget.
SHTS021270301291
Active test Setting
SHTS021270301292
CHANGE

(18) Set to 1,100 r/min.
(19) Press Select.
Select
SHTS021270301293
(20) Press Start.
SHTS021270301294
SHTS021270301295

not to forget.
SHTS021270301296
CHANGE
(23) Press stop.

HINT
SHTS021270301297

Standard values
13 – 17 mm3/st
YES NO

brake.
CHANGE
6 Inspect the exhaust gas temperature sensor 4 (DPR inlet)
1. Inspect the exhaust gas temperate sensor (DPF inlet) for improper
installation.
2. Check the sensing area of the exhaust gas temperature sensor 4

(DPR inlet) for dirt, clogging, and damage.
YES NO
Clean the sensing area and install the sensor Go to step 7.

properly.
If damage is found, replace the sensor.
7 Inspect the exhaust gas temperature sensor 4 (DPR inlet) unit
1. Disconnect the exhaust gas temperature sensor 4 (DPR inlet) con-

nector.
THCI E2
terminals of the exhaust gas temperature sensor 4 (DPR inlet).
Measurement Tester
Standard values
20 qC {68 qF}:
Exhaust gas tem- 13.7 – 29.8 k:
perature sensor 4 50 qC {122 qF}:
SHTS021270301298 Starter key: LOCK
(DPR inlet) 7.13 – 13.7 k:
THCI – E2 80 qC {176 qF}:
4.1 – 7.13 k:
YES NO

4 (DPR inlet).
MATION section.
8 Inspect the exhaust gas temperature sensor 1 (ATC inlet)
1. Inspect the exhaust gas temperature sensor 1 (ATC inlet) for

improper installation.

(ATC inlet) for dirt, clogging, and damage.
YES NO

properly.
9 Inspect the exhaust gas temperature sensor 1 (ATC inlet) unit
THG0 GND 2. Disconnect the exhaust gas temperature sensor 1 (ATC inlet) con-
nector.

terminals of the exhaust gas temperature sensor 1 (ATC inlet).
Measurement Tester
Standard values
20 qC {68 qF}:
SHTS021270301299 Exhaust gas tem- 13.7 – 29.8 k:
Starter key: LOCK
(ATC inlet) 7.13 – 13.7 k:
THG0 – GND 80 qC {176 qF}:
4.1 – 7.13 k:
YES NO

1 (ATC inlet).
MATION section.
10 Inspect the DPR filter
1. Remove DPR filter and check that there is no soot leaking at the
rear edge of the DPR filter, no damage, and no other abnormality.
2. Insert the check probe from the rear surface to inspect the inside.
Damage
SHTS021270301300
Soot leakage
SHTS021270301301
PIANO WIRE
GRIP FOR DEPTH CHECK

GAS FLOW
REAR SIDE
DOC DPR
FILTER TARGET PART OF INSERTION

INSPECTION (PART WITH )
INSPECT ONLY BLACK
PARTS WHEN
THE FILTER IS PARTIALLY
BLACK.
SHTS021270301302
YES NO
Replace DPR. Go to step 11.

After replace, perform DPR manual regenera-
tion.
11 Inspect the coolant temperature sensor
1. Inspect the coolant temperature sensor for improper installation.
2. Check the sensing area of the coolant temperature sensor for dirt,
clogging, and damage.
YES NO
properly.
12 Inspect the coolant temperature sensor unit

E THW
2. Disconnect the engine coolant temperature sensor connector.

terminals of the engine coolant temperature sensor.
Measurement Tester
Standard values
Engine coolant 20 qC {68 qF}:

temperature sen- 2.59 – 2.32 k:
Starter key: LOCK
SHTS021270301303 sor 80 qC {176 qF}:
THW – E 0.326 – 0.310 k:
YES NO
Go to step 13. Replace the coolant temperature sensor.

13 Perform a basic engine check [HINO DX ൖ ]
1. Perform a basic engine check using the ENGINE BASIC INSPEC-

TION SHEET. (Check the fuel injection amount, check the VNT
activate.)
YES NO
Repair or replace the faulty part. Go to step 14.

MATION section.
14 Check QR code of fuel injector
1. Check the DX report.
2. Check the QR code of the fuel injector and make sure that the
default code "80" in not entered.
(Example)
Troubleshooting report
VIN : JHNKDM2HXKK001001
Work date: : 2018/03/20 08:32:52
Operator : USAHMS010069
Communication interface : DST-i
DX2 version : 1.1.18.4
23 Engine shutdown setting identification Enabled Enabled
Injector correction information
No. Target Manufacturer set value At the end of work
158 Injector variation correction data #1
This is the default setting. Correct

SHTS021270301304
Is the QR code the default?

YES NO
Input the QR code of the fuel injector. Go to step 15.
15 DPR manual regeneration
1. Perform DPR manual regeneration, and check succeeded.
Was DPR regeneration succeeded?
YES NO
Procedure completed. Replace DPR.

tion.
DTC: P24A2
EN01H02127030602016200
P24A2: Excessive fuel dosing quantity

INFORMATION
• The engine ECU monitors accumulate post fuel injection quantity at DPR regeneration.

• While the engine is in operation
• Accumulate post fuel injection quantity exceeds 2,000 cc.
3. Reset condition
• Immediately after normal status is resumed.

• MIL: ON
• SVS light: OFF

• DPR regeneration prohibited.
• Aftertreatment long idling control.

• –
• Check that no DTC is stored after test drive.

• Exhaust gas leakage
• DPR filter damage
• Abnormality in fuel injection quantity
• Malfunction of EGR valve
• Malfunction of VNT actuator
• Failure of exhaust gas temperature sensor 4 (DPR inlet)
INSPECTION PROCEDURE: P24A2
1 Check the DTC detected [HINO DX ൖ ]
4. Select [Engine] and check if any below DTC other than P24A2 has
been detected.
• P0005, P0006, P0007, P20D8, P20CE
SHTS021270301354
Has DTC other than P24A2 been detected?
YES NO
Go to diagnosis procedure of a related DTC. Go to step 2.

MATION section.
2 Inspect the engine oil level
1. Check the oil level gauge and make sure the engine oil quantity is
Engine damage will occur. within the stipulated value.
2. Check the engine oil condition (dirt, viscosity).

Rivet Oil level gauge
FULL ADD
Preferred level
Gauge end
SHTS021270301355
YES NO
Adjust the engine oil quantity according so Go to step 3.

that it is within the stipulated value.
Change the oil if it is dirty.
MATION section.
3 Inspect the exhaust pipe
1. Check for exhaust pipe crack, exhaust gas leak (soot contamina-
EXHAUST PIPE tion) and improper coupling flange tightening.
(ATC) EXHAUST BRAKE
EXHAUST PIPE
(ATC) BRACKET
CLAMP
SHTS021270301356
YES NO
Repair or replace the exhaust pipe. Go to step 4.

MATION section.
4 Inspect the injector [HINO DX ൖ ]
Check the injection quantity and the rotational fluctuation.
1. Start the engine
2. Select [Injection quantity] from the [Data monitor and Active test]
and measure the amount of fuel injection.
3. Select [Engine revolution] from the [Data monitor Setting] and

measure the rotational fluctuation.
SHTS021270301357
Measurement conditions
NE Rotational fluctuation
@1,500 r/min (measurement by HINO DX II) • Engine revolution: 1,500 r/min
• No-load
• T/M shift lever: Neutral position
Ne (r/min)
• A/C off and Air compressor un-operating

• Engine coolant temperature: more than 80 qC {176 qF}
Engine
Standard values
SHTS021270301358
Type of Q (mm3/st)
AT 5.0q

(Both the injection quantity and the rotational fluctuation are within the standard values)
YES NO
Go to step 5. Replace the faulty injector.

MATION section.

more)
air conditioner.
SHTS021270301360
SHTS021270301361

HINT
Writing
SHTS021270301362
instruction.
Then, click [OK].
SHTS021270301363
CHANGE
SHTS021270301364
SHTS021270301365
SHTS021270301366

SHTS021270301367
CHANGE
items. Click OK.
x Engine speed
SHTS021270301368
age destination.
( ii )
(i)
SHTS021270301369

not to forget.
SHTS021270301370
Active test Setting
SHTS021270301371
CHANGE

(18) Set to 1,100 r/min.
(19) Press Select.
Select
SHTS021270301372
(20) Press Start.
SHTS021270301373
SHTS021270301374

not to forget.
SHTS021270301375
CHANGE
(23) Press stop.

HINT
SHTS021270301376

Standard values
13 – 17 mm3/st
YES NO

brake.
CHANGE
6 Check the response delay of the EGR valve [HINO DX ൖ ]
1. Stop engine.
(1)
(3)
(2)
(4)
(5) 4. Select [Inspection Menu] and then [EGR inspection] from the
menu, then inspect the response delay at the Target EGR position
and Actual EGR position.
! CAUTION
Perform the inspection while the engine is stopped to avoid dam-
ages.
SHTS021270301377
(1) Select [Inspection Menu].
(2) Select [EGR inspection].
(3) Select [Start inspection].
(4) Select [EGR opening UP]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 0 to 90%.
(5) Select [EGR opening DOWN]:
• Inspect the response delay at each step of the Target EGR position
and Actual EGR position from 90 to 0%.
HINT
The EGR opening position changes of around 10% per step
between 0 – 90%.
Standard values
From the Target EGR position to the Actual EGR position,

the response delay should be within 5 seconds.
YES NO
Go to step 7. Replace the EGR valve.

MATION section.
7 Check the response delay of the VNT controller [HINO DX ൖ ]
1. Select [Inspection Menu] from the menu, then inspect the

(1) response delay at the Target VNT position and Actual VNT posi-
tion.
(3)
! CAUTION
(2) Perform the inspection while the engine is stopped to avoid dam-
(4)
ages.
(5)
(1) Select [Inspection Menu].
(2) Select [VNT inspection].
(3) Select [Start inspection].
(4) Select [VNT UP]:
SHTS021270301378
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 0 to 90%.
(5) Select [VNT DOWN]:
• Inspect the response delay at each step of the Target VNT position
and Actual VNT position from 90 to 0%.
HINT
The VNT opening position changes of around 10% per step
between 0 – 90%.
Standard values
From the Target VNT position to the Actual VNT position,

the response delay should be within 3 seconds.
YES NO
Go to step 8. Replace the turbocharger.

MATION section.
8 Inspect the exhaust gas temperature sensor 4 (DPR inlet)
1. Inspect the exhaust gas temperature sensor 4 (DPR inlet) for

improper installation.

(DPR inlet) for dirt, clogging, and damage.
YES NO

If damaged, replace the sensor.
9 Inspect the exhaust gas temperature sensor 4 (DPR inlet) unit
1. Disconnect the exhaust gas temperature sensor 4 (DPR inlet) con-

nector.
THCI E2
terminals of the exhaust gas temperature sensor 4 (DPR inlet).
Measurement Tester
Standard values
20 qC {68 qF}:
Exhaust gas tem- 13.7 – 29.8 k:
SHTS021270301379 Starter key: LOCK
(DPR inlet) 7.13 – 13.7 k:
THCI – E2 80 qC {176 qF}:
4.1 – 7.13 k:
YES NO

4 (DPR inlet).
MATION section.
10 Inspect the DPR filter
1. Remove the DPR filter and check if there is no soot, damages or

other abnormalities at its end.
2. Insert the check probe from rear surface to inspect the inside.
Damage
SHTS021270301380
Soot leakage
SHTS021270301381
PIANO WIRE
GRIP FOR DEPTH CHECK

GAS FLOW
REAR SIDE
DOC DPR
FILTER TARGET PART OF INSERTION

INSPECTION (PART WITH )
INSPECT ONLY BLACK
PARTS WHEN
THE FILTER IS PARTIALLY
BLACK.
SHTS021270301382
YES NO
Replace the DPR filter and the PM sensor. Go to step 11.

tion.
MATION section.
11 DPR manual regeneration
1. Perform DPR manual regeneration, and check succeeded.
Was DPR regeneration succeeded.
YES NO
Procedure completed. Replace DPR.

11–28 EXHAUST (J05E)
DPR CLEANER
COMPONENT LOCATOR
EN01F02127100402002001
B 7
1 x4 x4 1
x4
B x2
x2
6
B x9 x8
1 1 8
7 B
2
B x9
x4
x4 x4 3
x2
x8 4 C
x2
A
SHTS021271000041
1 Support bracket 5 Clip

2 DPR cleaner 6 Center pipe No.1
3 Gasket * 7 Washer
4 Differential pressure pipe 8 DOC unit
*: Nonreusable part
Tightening torque Unit: Nm {kgfcm, lbfft}

A 20-30 {204-306, 14.7-22.1} C 30-36 {306-367, 22.1-26.5}
B 43-59 {438-602, 31.7-43.5} D 31 {316, 22.9}
EXHAUST (J05E) 11–29
DPR INSPECTION
EN01F02127100402002002
1. ROUTINE INSPECTION ITEMS

(1) Check the exhaust system tightening portions (exhaust pipe,
main unit flange) for looseness or exhaust leakage.
(2) Check external appearance of the harness of the exhaust
temperature sensor for trouble (cracks in coating or missing
clip).
(3) Inspect the hose of the back pressure sensor and check the
hose for deterioration or cracks. Replace a hose which has
been used for three years or more with a new one.
(4) Check for a blown indicator light or wire break in the DPR-
cleaner switch and meter. (Stop the engine, turn ON the
starter switch, and press the DPR-cleaner switch. If both the
light in the switch and indicator light in the meter illuminate,
the lights are normal.)
INSPECTION PROCEDURE FOLLOWED WHEN “EXHAUST GAS AFTER

TREATMENT SYSTEM MAINTENANCE REQUIREMENT LIGHT” LIGHT UP
EN01F02127100402002003
NORMAL TRAVELING
EXHAUST GAS AFTER TREATMENT

SYSTEM MAINTENANCE
REQUIREMENT LIGHT LIGHT UP
RECEIVING THE VEHICLE

FOR SAFETY CHECK
CONNECT HINO DXⅡ

<Checking a fault code against HINO DXⅡ>
1. CHECKING THE PAST FAULT CHECK
CURRENT CONDITION DPR STATE MONITOR CHECK
(If the engine has a past fault history, inspect the engine before inspecting DPR.)
2. DIAGNOSIS
ENGINE INSPECTION
As a damage in the engine may degrade DPR performance, first check condition of the engine.
Injection system inspection: Fuel injection quantity at idling speed and at idling-up speed
Fuel system inspection: Clogging in the fuel filter
Air intake system inspection: Clogging in the air filter element; air flow meter inspection
EGR system inspection: Connect HINO DXⅡ to run the forced driving mode and check opening followability.
VNT inspection: Connect HINO DXⅡ to run the forced driving mode and check nozzle opening followability.
Exhaust brake operation check: Check a difference in injection quantity between in ON mode and in OFF
mode. (Refer to Page 11-32)
Aftertreatment fuel injector system:
Check that connectors are not disconnected, exhaust gas is not emitted and fuel or water is not leaking.
Fuel shutoff valve system: Check that connectors are not disconnected and fuel is not leaking.
< Engine inspection found normal >
If normal manual regeneration is not complete, check and clean the aftertreatment fuel injector.
(Refer to Page 11-53, 54)
<Forced regeneration by way of HINO DXⅡ>
3. FORCED REGENERATION Execution of manual regeneration
Confirm the combustible doesn't exist near the exhaust pipe.
4. FORCED REGENERATION
COMPLETION
(Regeneration is not complete and

5. DIAGNOSIS FILTER CLEANING
the malfunction indicator light comes on.)
<Check the back pressure sensor value while raising
the engine revolution up to the no load maximum revolution.>
6. MEASUREMENT OF
Monitor the back pressure value of the back pressure sensor.
BACK PRESSURE
Monitor the engine revolution.
The display will be cleared by HINO DXⅡ.
COMPLETION
SHTS021271000042
INSPECTION BY WAY OF HINO DX ൖ

EN01F02127100402002004
1. DPR STATUS CHECK

(1) Select the "DPR check" in the "Inspection Menu" menu of
HINO DX ൖ .
(2) Confirm Data View of the "DPR check" display (monitor), if
the value for all the items are "OFF", DPR functions normally.
Then "Manual forced regeneration" and "DPR differential
pressure check" can be done.
(3) In case "ON" is displayed in Data View of the "DPR check"
display (monitor), check according to the procedure on page.
Reference: EXHAUST (J05E), DPR CLEANER, DETERMI-
NATION BY WAY OF DPR STATE DETERMINATION
MONITOR OF HINO DX ൖ (Page 11-38)
SHTS021271000043
2. FORCED REGENERATION
(1) Forced regeneration is done by the "Manual forced regenera-
tion" screen.
! CAUTION
• Confirm safety of the surrounding area, then press DPR regen-
eration switch inside the cabin to execute the regeneration.
• Confirm the PTO switch is OFF.
(2) When the "Regeneration switch ON identification" value is

ON, wash or replace the filter.
When the value is OFF, DPR functions normally.
SHTS021271000044
3. DPR DIFFERENTIAL PRESSURE CHECK

(1) Check the DPR differential pressure through the "DPR
check" display.
(2) Check and confirm the exhaust gas temperature (in and out)
is less than 200qC {392qF}.
(3) Engine speed will rise automatically, then record the indi-
cated maximum DPR differential pressure.
(4) In case the central value of the recorded DPR differential
pressure value exceeds the specific value, clean or replace
the filter.
Then "Stop" the DPR differential pressure check.
Engine speed Differential pressure inspection standard value

(no load maximum revolution) (kPa {kgf/cm2, lbf/in.2})
2,800 r/min. 5.0 {0.05, 0.7}

(5) When the differential pressure is unchanged check the fol-

lowing.
If the following are normal, the differential pressure sensor
should be replaced.
a. Check the differential pressure hose for cracks or hole
openings.
b. Check that the hose clamp is neither loose nor discon-
nected.
c. Check whether there is clogging in the differential pressure
pipe (DPR cleaner side).
Use the compressed air from one end of the pipe to check
for clogging. If the air passes to the other side easily, it is
clear.
SHTS021271000045
4. EXHAUST BRAKE OPERATION CHECK

CHANGE (1) Check the difference in injection quantity with ON mode and
OFF mode by data monitor.
HINT
Refer to TROUBLE SHOOTING ENGINE (J05E) of "Inspect the
exhaust brake valve [HINO DX ൖ ]" of DTC cord P0027, P0421,
P2458 or P24A2.
Engine coolant temperature More than 60rC {140rF}
Exhaust brake valve to OFF Engine speed 1,100 r/min

(Adjust the engine speed by idle set knob) Injection quantity B mm3/st
Engine speed 1,100 r/min

Exhaust brake valve to ON
Injection quantity A mm3/st
Difference of adjustable range of fuel injection Optimum injection quantity 8-12 mm3/st
(A-B) Adjustment target quantity 13-17 mm3/st

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SERVICE MANUAL INFORMATION

SB-19-013 EXHAUST VALVE INSPECTION

GROUP: SERVICE MANUAL UPDATE

The following is to inform you of the above caption. This service

P0027: Exhaust Brake Performance

2. DTC set condition

4. Indication, warning or system control regulation when the DTC is set.

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe function)>

<Symptoms on the vehicle due to malfunction>

8. Estimated failure factors

INSPECTION PROCEDURE: P0027

1 Check the DTC detected 1 [HINO DX ൖ ]

1. Set the starter key to the "LOCK" position.

2. Connect the vehicle to HINO DX ൖ .

3. Set the starter key to the "ON" position.

4. On the screen of the diagnostic system, select [Engine], and check

Has a DTC other than P0027 been detected?

Perform the relevant DTC-specific trouble- Go to step 2.

2 Inspect the exhaust brake valve piping and hose

Was any failure found?

Connect securely, repair if needed. Go to step 3.

3 Inspect the exhaust brake valve

1. Check the exhaust brake valve for unease and sticking.

Was any failure found?

Clean the exhaust brake valve. Replace if Go to step 5.

4 Check the DTC detected 2 [HINO DX ൖ ]

1. Perform a DPR forced regeneration.

2. After completion of regeneration, on the screen of the diagnostic

Has DTC P0027 been detected?

Go to step 5. Procedure completed.

5 Inspect the exhaust brake valve [HINO DX ൖ ]

1. Warm up the engine. (Coolant temperature:60 qC {140 qF} or

(4) Select [Engine], and press the click button.

(5) Writing soot volume

(8) Click [Diagnosis].

(9) Select[Engine], and press the click button.

(10) Select [Data monitor and Active test].

Deta monitor Setting

(13) Start the engine.

(16) Select [Active test Setting].

Active test Setting

(17) Select [ Target rpm ].

Target rpm 1,100 rpm

(20) Press Start.

(22) Check the injection quantity after 1 minute. This injection

(23) Press stop.

(25) Make a judgment by the difference of A(exhaust brake ON

Go to step 6. Adjust the butterfly opening of the exhaust

CHANGE 6 Check the DTC detected [HINO DX ൖ ]

1. Perform a DPR forced regeneration.

2. After regeneration, on the screen of the diagnostic system, select

Has DTC P0027 been detected?

Replace the engine ECU. Procedure completed.

P0421: Determination of ATC deterioration

2. DTC set condition

4. Indication, warning or system control regulation when the DTC is set.

5. Symptoms on the vehicle when the DTC is set

<Symptoms on the vehicle due to backup control (fail safe function)>

<Symptoms on the vehicle due to malfunction>

8. Estimated failure factors

INSPECTION PROCEDURE: P0421

1 Check the engine ECU