167-B1904-02 Service Bulletin/Repair Instructions

SERVICE MANUAL INFORMATION

SB-19-012 EXHAUST VALVE INSPECTION

WORKSHOP MANUAL CORRECTION

GROUP: SERVICE MANUAL UPDATE

BULLETIN NO: SB-19-012

DATE: 4-10-2019
SUBJECT VEHICLES: 16MY-20MY Conventional Trucks equipped
with an J08E.
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 and P24A2.
4–90
ENGINE CONTROL SYSTEM (J08E)
DTC: P0027

EN01H16F01030F03001021
P0027: Exhaust Brake Performance

INFORMATION

1.
Technical description
• 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 mph}.

• The time of 60 seconds has elapsed after the exhaust brake was actuated.

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.
(2)
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
• –
• 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 sensor

Diesel throttle sticking

Bend, clogging, and crack of piping and hose

Improper adjustment of exhaust brake valve

Malfunction of exhaust brake valve
ENGINE CONTROL SYSTEM (J08E)
4–91
INSPECTION PROCEDURE: P0027

1
Check the DTC detected 1 [HINO DX ൖ ]

1.
Set the starter switch to the "LOCK" position.
2.
Connect the vehicle to HINO DX ൖ .
3.
Set the starter switch to the "ON" position.
4.
Select [Engine], and check if any DTC listed below other than

P0027 has been detected.

P0101, P04D5, P2101
SAPH16F010300079
Has a DTC other than P0027 been detected?

YES
NO
Go to diagnosis procedure of a related DTC.
2
Go to step 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

Connect securely, repair if needed.
NO

Go to step 3.
4–92
3
ENGINE CONTROL SYSTEM (J08E)
Inspect the exhaust brake valve

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

SAPH16F010300080
Was any failure found?

YES
NO
Clean the exhaust brake valve. Replace if

needed. After clearing or replacement, go to

step 4.
4
Go to step 5.
Check the DTC detected 2 [HINO DX ൖ ]

1.
Perform a DPR forced regeneration.
2.
After completion of regeneration, reload the DTC and check if the

DTC P0027 has been detected.
SAPH16F010300081
Has DTC P0027 been detected?

YES

Go to step 5.
NO

Procedure completed.
ENGINE CONTROL SYSTEM (J08E)
4–93
CHANGE
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.
(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.
SAPH16F010300082
(4) Select [Engine], and press the click button.
SAPH16F010300083
(5) Writing soot volume

HINT

Customization function
Original value
Soot volume to write
• 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].

• 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 regeneration halfway.
Writing

SAPH16F010300084
(6) Turn the starter key "OFF" and then "ON" according to the

instruction.

Then, click [OK].
SAPH16F010300085
4–94
ENGINE CONTROL SYSTEM (J08E)
ADD
(7) Check that ECU writing has been completed. Click [OK].

Refer to the window on the left.
SAPH16F010300086
(8) Click [Diagnosis].
SAPH16F010300087
(9) Select[Engine], and press the click button.
SAPH16F010300088
Date monitor and Active test
Deta monitor Setting
SAPH16F010300089
(10) Select [Data monitor and Active test].

Select [Data monitor Setting].

Refer to the window on the left.
ENGINE CONTROL SYSTEM (J08E)
ADD
4–95
(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
SAPH16F010300090
(12) ( i ) Click [Start] to display the window to check the data storage destination.

( ii ) Click [OK] to start data monitoring.
( ii )

(i)
SAPH16F010300091
(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.
SAPH16F010300092
(16) Select [Active test Setting].
Active test Setting
SAPH16F010300093
4–96
ENGINE CONTROL SYSTEM (J08E)
ADD
(17) Select [ Target rpm ].

(18) Set to 980 r/min.

(19) Press Select.
Target rpm
980 rpm

Select
SAPH16F010300094
(20) Press Start.
SAPH16F010300095
(21) With the gear in the neutral position, apply the parking brake

confirm that the PTO is off then press OK.
SAPH16F010300096
(22) Check the injection quantity after 1 minute. This injection

quantity is B(exhaust brake OFF condition). Record the this value

not to forget.
SAPH16F010300097
ENGINE CONTROL SYSTEM (J08E)
CHANGE
4–97
(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.
SAPH16F010300098
(25) Make a judgment by the difference of A(exhaust brake ON

condition) from B(exhaust brake OFF condition).

Standard values

11 – 15 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.
6
Adjust the butterfly opening of the exhaust

brake.
Check the DTC detected [HINO DX ൖ ]

1.
Select [Engine] and check if DTC P0027 has been detected.
SAPH16F010300099
Has DTC P0027 been detected?

YES

Replace the engine ECU.
NO

Procedure completed.
4–486
ENGINE CONTROL SYSTEM (J08E)
DTC: P0421

EN01H16F01030F03001076
P0421: Determination of ATC deterioration

INFORMATION

1.
Technical description
• If post injection is performed normally but the ATC (oxidation catalyst) is not generating heat, the engine ECU

detects abnormality as ATC functional deterioration.
2.
DTC set condition

(1) DTC detection condition

During DPR active regeneration.

Conditions below continue for 35 sec.
(2)
3.
• Engine speed: 700 r/min or higher, 1,000 r/min or lower.

• Fuel injection quantity: 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

• ATC inlet temperature: 300qC {572qF} or higher

• Post injection has no malfunction.

• Exhaust gas mass flow ” 210kg/h

Judgment criteria

Both of the following conditions must be met.

• ATC outlet temperature – ATC inlet temperature is below the specified value.
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

• Engine output is restricted.

5.
Symptoms on the vehicle when the DTC is set
• Engine output is insufficient.
• –

6.
Pre-inspection work

• Check that the battery voltage is in the normal range.
7.
After-inspection work
• Clear all past DTC.

• After starting the DPR automatic regeneration, form the DTC detection condition.

• Check that no DTC is detected after test drive.
ENGINE CONTROL SYSTEM (J08E)

8.
Estimated failure factors
•

•

•

•

•
ATC deterioration caused by use of low-grade fuel

Improper adjustment of exhaust brake valve.

Leak of exhaust gas from the pipe.

ATC inlet exhaust gas temperature sensor malfunction.

ATC outlet exhaust gas temperature sensor malfunction.
4–487
4–488
ENGINE CONTROL SYSTEM (J08E)
INSPECTION PROCEDURE: P0421

1
Check the engine ECU

1.
Set the starter switch to the "LOCK" position.
2.
Check the engine ECU software part number (ECU part number)

by HINO DX ൖ .

Confirm the latest part number with Hino national service manager.
Does the engine ECU have the latest software number?

YES
NO
Go to step 2.
2
Reprogram the engine ECU by using HINO

DX ൖ and then go to step 2.
Inspect the exhaust leaks from the exhaust pipe between exhaust gas temperature sensor 1

(ATC upstream) and the exhaust gas temperature sensor 3 (DOC inlet)

1.
Check that the exhaust pipe has no looseness of flange or pipe

breakage.
Was any failure found?

YES

Repair or replace the faulty part.

Perform "After-inspection work" of INFORMATION section.
NO

Go to step 3.
ENGINE CONTROL SYSTEM (J08E)
4–489
CHANGE
3
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.
(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.
SAPH16F010300489
(4) Select [Engine], and press the click button.
SAPH16F010300490
(5) Writing soot volume

HINT

Customization function
Original value
Soot volume to write
• 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].

• 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 regeneration halfway.
Writing

SAPH16F010300491
(6) Turn the starter key "OFF" and then "ON" according to the

instruction.

Then, click [OK].
SAPH16F010300492
4–490
ENGINE CONTROL SYSTEM (J08E)

12 3 4 5

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