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Hino P041D Fault Code: EGR Gas Temperature Sensor – Out Of Range (Out Of Range High)

29/11/2024

Technical description

The installed EGR cooler outlet temperature sensor consistently measures temperature at the outlet of the EGR cooler

Description of malfunction

The EGR cooler outlet temperature cannot be correctly recognized

DTC set condition

DTC Detection Condition:

Starter switch ON
Battery voltage is in the range of 10 V to 16 V
Above conditions continue for at least 5 seconds

Judgment Criteria:

Output of the EGR cooler outlet temperature sensor remains at 4.97 V or higher (-40°C {-40°F} or lower) for 3 seconds or longer

Reset condition

After restoration to normal condition

Indication, warning or system control regulation when the dtc is set

MIL: ON
SVS light: OFF

Pre-inspection work

Check that the battery voltage is in the normal range

After-inspection work

Clear all past DTCs
Check that no DTC is stored after test drive

Possible causes

Abnormal resistance of sensor
Short-circuit in the sensor
Malfunction of the sensor power supply in the engine ECU
Malfunction the circuit in the engine ECU
Disconnect and short-circuit of the harness
Irregular contact of the connector

Inspection procedure

Troubleshooting steps

Step 1: Inspect the EGR cooler outlet temperature sensor connector

Check the connection of the EGR cooler outlet temperature sensor connector (Looseness and poor contact)

Were any failures found?

Yes	Connect securely, repair if needed. Clear all past DTCs. Check that no DTC is detected after test drive
No	Go to Step 2

Step 2: Inspect the EGR cooler outlet temperature sensor

Check the installation of the EGR cooler outlet temperature sensor
Make sure there is no dirt or damage to the EGR cooler outlet temperature sensor

Were any failures found?

Yes	Clean the EGR cooler outlet temperature sensor and install it properly. If damaged, replace the EGR cooler outlet temperature sensor. Clear all past DTCs. Check that no DTC is detected after test drive
No	Go to Step 3

Step 3: Inspect the EGR cooler outlet temperature sensor

Set the starter switch to the “LOCK” position
Disconnect the EGR cooler outlet temperature sensor connector
Use the electrical tester to measure the resistance between the terminals of the EGR cooler outlet temperature sensor

MEASUREMENT CONDITIONS	TESTER CONNECTIONS	STANDARD VALUES
Starter switch: LOCK	EGR cooler outlet temperature sensor THG – E2	20°C {68°F}: 13.7 – 29.8 kΩ 50°C {122°F}: 7.13 – 13.7 kΩ 80°C {176°F}: 4.1 – 7.13 kΩ

Do the measurements meet the standard value?

Yes	Go to Step 4
No	Replace the EGR cooler outlet temperature sensor. Clear all past DTCs. Check that no DTC is detected after test drive

Step 4: Inspect the EGR cooler outlet temperature sensor power supply

Set the starter switch to the “ON” position
Use the electrical tester to measure the voltage between the terminals of the EGR cooler outlet temperature sensor vehicle-side connector

MEASUREMENT CONDITIONS	TESTER CONNECTIONS	STANDARD VALUES
Starter switch: ON	EGR cooler outlet temperature sensor vehicle-side connector THG – E2	4.5 – 5.5 V

Do the measurements meet the standard value?

Yes	Go to Step 7
No	Go to Step 5

Step 5: Check for short-circuit in wire harness of EGR cooler outlet temperature sensor

Set the starter switch to the “LOCK” position
Connect the signal check harness to the engine ECU vehicle-side harness. (Do not connect the harness to the ECU)
Use the electrical tester to measure the resistance between the EGR cooler outlet temperature sensor terminals and ground

MEASUREMENT CONDITIONS	TESTER CONNECTIONS	STANDARD VALUES
Starter switch: LOCK	Engine ECU (signal check harness) ETH2(E45) – Ground AGD7(M56) – Ground	∞ Ω

Do the measurements meet the standard value?

Yes	Go to Step 6
No	Repair or replace the harness. Clear all past DTCs. Check that no DTC is detected after test drive

Step 6: Check for disconnection in wire harness of EGR cooler outlet temperature sensor.

Connect the EGR cooler outlet temperature sensor connector
Use the electrical tester to measure the resistance between the terminals of the engine ECU (signal check harness)

MEASUREMENT CONDITIONS	TESTER CONNECTIONS	STANDARD VALUES
Starter switch: LOCK	Engine ECU (signal check harness) ETH2(E45) – AGD7(M56)	20°C {68°F}: 13.7 – 29.8 kΩ 50°C {122°F}: 7.13 – 13.7 kΩ 80°C {176°F}: 4.1 – 7.13 kΩ

Do the measurements meet the standard value?

Yes	Go to Step 7
No	Repair or replace the harness. Clear all past DTCs. Check that no DTC is detected after test drive

Step 7: Check the DTC detected (Engine ECU) [Diagnostic Tool]

Warm up the Engine. (Engine coolant temperature: 60°C {140°F} or more)
Stop the engine and set the starter switch to the “LOCK” position
Connect the vehicle to the diagnostic tool
Set the starter switch to the “ON” position
Select [Engine] and check if the DTC P041C or P041D has been detected

Has DTC P041C or P041D been detected?

Yes	Replace the engine ECU. Clear all past DTCs. Check that no DTC is detected after test drive
No	Procedure completed. Clear all past DTCs. Check that no DTC is detected after test drive

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