SSANGYONG Musso Sports N100 2003 Manual
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SSANGYONG Musso Sports N100 2003 Manual

SSANGYONG Musso Sports N100 2003 Manual

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Table of Contents

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SECTION 1
HOW TO USE ELECTRICAL WIRING DIAGRAM
CONTENTS
1. HOW TO READ ELECTRICAL WIRING DIAGRAM ........................ 1-2
2. CIRCUIT IDENTIFICATION SYMBOL ............................................... 1-3
3. FUNCTION OF POWER SUPPLY LINE............................................ 1-3
4. WIRING HARNESS COLOR IDENTIFICATION ................................ 1-3
5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR .......... 1-3

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Summary of Contents for SSANGYONG Musso Sports N100 2003

  • Page 1 SECTION 1 HOW TO USE ELECTRICAL WIRING DIAGRAM CONTENTS 1. HOW TO READ ELECTRICAL WIRING DIAGRAM ......1-2 2. CIRCUIT IDENTIFICATION SYMBOL ..........1-3 3. FUNCTION OF POWER SUPPLY LINE..........1-3 4. WIRING HARNESS COLOR IDENTIFICATION ........ 1-3 5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR ..1-3...
  • Page 2 1-2 HOW TO USE ELECTRICAL WIRING DIAGRAM 1. HOW TO READ ELECTRICAL WIRING DIAGRAM 1) CONTENTS OF ELECTRICAL WIRING DIAGRAM (CIRCUIT) POSITION EXPLANATION - Upper horizontal lines : Power supply lines - Power supply lines : 30, 15, 15A, 15C, 58 - Ef20 or F2 : Fuse Number •...
  • Page 3 HOW TO USE ELECTRICAL WIRING DIAGRAM 1-3 2. CIRCUIT IDENTIFICATION SYMBOL 5. HOW TO CHECK TERMINAL NUMBER OF CONNECTOR IDENTIFICATION MEANING - Terminal number is given based on Female Terminal Connector SYMBOL ex) Terminal Number 4 of C901 connection Connector Diode Fuse in engine room fuse &...
  • Page 4 SECTION 2 POSITION OF CONNECTORS AND GROUNDS CONTENTS 1. POSITION OF CONNECTOR, GROUND & SPLICE PACK ....2-2 2. CONNECTOR, GROUND & SPLICE PACK INFORMATION ....2-4 3. WIRING HARNESS, CONNECTOR & GROUND LOCATION.....2-5...
  • Page 5 2-2 POSITION OF CONNECTORS AND GROUNDS 1. POSITION OF CONNECTOR, GROUND & SPLICE PACK W/H - ENG. MAIN W/H - FLOOR W/H - ENGINE W/H - T/M W/H - MAIN...
  • Page 6 POSITION OF CONNECTORS AND GROUNDS 2-3 2. CONNECTOR, GROUND AND SPLICE PACK INFORMATION 1) CONNECTOR Connector Connector Color Connecting Wiring Harness Connector Position Color Connecting Wiring Harness Connector Position Number Number Number Number C101 Colorless Main - Engine Inside The Engine Room Fuse Block C361 White Main - Co-Driver Door...
  • Page 7 POSITION OF CONNECTORS AND GROUNDS 2-5 3. WIRING HARNESS, CONNECTOR & GROUND LOCATION 1) W/H ENGINE ROOM • GSL • DSL C111 C112 C101,C102 S101, C103 C104 C101, C102 C109 S101, C103 C109 C104...
  • Page 8 2-6 POSITION OF CONNECTORS AND GROUNDS 2) W/H MAIN 4) W/H ROOF • W/H MAIN 3) W/H TAIL GATE 5) W/H TAIL GATE...
  • Page 9 POSITION OF CONNECTORS AND GROUNDS 2-7 6) W/H DOOR 7) W/H SEAT HEATER 8) W/H AIR-BAG...
  • Page 10 2-8 POSITION OF CONNECTORS AND GROUNDS 9) W/H AIR-CONDITIONER 10) W/H TRANSMISSION...
  • Page 11 POSITION OF CONNECTORS AND GROUNDS 2-9 11) SPLICE PACK S101 (DSL/GSL) S204 (DSL/GSL) Fusible Link Box Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Head Lamp Relay (Low) '30' Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' Fog Lamp Relay '30' C212 Tail Lamp Relay '30' S201 (DSL/GSL)
  • Page 12 SECTION 3 WIRING DIAGRAM FOR POWER SUPPLIES CONTENTS 1. FUSIBLE LINK FUSE BLOCK & ENGINE ROOM FUSE BLOCK POWER DISTRIBUTION ............ 3-2 2. I/P FUSE BLOCK POWER DISTRIBUTION ........3-3...
  • Page 13 3-2 WIRING DIAGRAM FOR POWER SUPPLIES 1. FUSIBLE LINK FUSE BLOCK & ENGINE ROOM FUSE BLOCK POWER DISTRIBUTION...
  • Page 14 WIRING DIAGRAM FOR POWER SUPPLIES 3-3 2. I/P FUSE BLOCK POWER DISTRIBUTION...
  • Page 15 3-4 WIRING DIAGRAM FOR POWER SUPPLIES...
  • Page 16 WIRING DIAGRAM FOR POWER SUPPLIES 3-5...
  • Page 17 3-6 WIRING DIAGRAM FOR POWER SUPPLIES...
  • Page 18 SECTION 4 USAGE AND CAPACITY OF FUSES IN FUSE BLOCK CONTENTS 1. ENGINE ROOM FUSE & RELAY BLOCK ........4-2 2. I/P FUSE BLOCK ................4-3 3. POSITION OF RELAY, CONTROL UNIT AND PARTS NUMBER .. 4-4...
  • Page 19 4-2 USAGE AND CAPACITY OF FUSES IN FUSE BOX 1. ENGINE ROOM FUSE & RELAY BOX 1) ENGINE ROOM FUSE BLOCK 2) USAGE OF FUSE IN ENGINE ROOM FUSE BOX Power Supply Fuse No Usage Capacity ABS & ABD 30 BAT(+) Generator 10 9 8 7 6 5 4 3 2 1...
  • Page 20 USAGE AND CAPACITY OF FUSES IN FUSE BOX 4-3 2. I/P FUSE BLOCK 1) POSITION OF RELAY AND FUSE 2) USAGE OF FUSE IN PASSENGER ROOM FUSE BOX Power Supply Fuse No Capacity Usage 30 BAT(+) Starter Motor Relay Air Bag IGN1 (15) ABS/ABD Outside Mirror, Audio...
  • Page 21 4-4 USAGE AND CAPACITY OF FUSES IN FUSE BOX 3. POSITION OF RELAY, CONTROL UNIT AND PARTS NUMBER 1) ENGINE ROOM FUSE BLOCK 3) CONTROL UNIT Part Name Part Number Remarks Part Name Part Number Remarks Resistor W/Diode (GSL) 4 Pin 8690005800 Below The Audio 82330-05000...

  • Page 22: Table Of Contents

    SECTION 5 ELECTRICAL WIRING DIAGRAMS CONTENTS 1. STARTING & CHARGING CIRCUIT ................... 5-8 1) GSL E23 MB A/T ..............................5-8 2) GSL BTRE A/T, GSL E32 MB A/T ......................... 5-10 3) DSL NA BTRE A/T, M/T ............................5-12 4) DSL LA BTRE A/T, M/T ............................5-14 2.
  • Page 23 3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, CTS, SENSOR(KNOCK, INTAKE AIR TEMP', HEATED O ) CIRCUIT ............................5-28 (1) W/O EURO III ....................................5-28 (2) W/ EURO III ....................................... 5-30 4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT ....................5-32 (1) W/O EURO III ....................................5-32 (2) W/ EURO III .......................................
  • Page 24 8. ECM(E32, HFM) .......................... 5-64 1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/ IMMOBILIZER) ........... 5-64 2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT(W/O IMMOBILIZER) ........5-66 3) SENSOR (CKP, CMP, KNOCK, MAF), CCP SOLENOID, CAM SHAFT ACTUATOR CIRCUIT .......5-68 4) THROTTLE MOTOR &...
  • Page 25 17. COOLING FAN, A/C COMPRESSURE CIRCUIT ..............5-102 1) GASOLINE-HFM ..............................5-102 2) GASOLINE-MSE ..............................5-104 3) DIESEL ...................................5-106 18. MANUAL AIR CONDITIONER CIRCUIT ................. 5-108 1) BLOWER MOTOR CIRCUIT ..........................5-108 2) INTAKE MOTOR, MODE MOTOR CIRCUIT ..................... 5-110 19.
  • Page 26 2) GSL BTRE A/T ..............................5-140 30. CLUSTER ..........................5-142 1) SPEED METER, TACHO METER, TEMP GAUGE, FUEL GAUGE CIRCUIT ..........5-142 2) WARNING LAMP(BATTERY CHARGE, BRAKE, OIL PRESSURE, SEAT BELT, AIR BAG) CIRCUIT..5-144 3) WARNING LAMP(ABS, EBD, TCS, 4WD, ECS), INDICATOR LAMP(4H, 4L, POWER)CIRCUIT ....5-146 4) WARNING LAMP(PREHEAT’G, DOOR OPEN), INDICATOR LAMP(ECONOMIC, DEFROSTER, WINTER, T/SIGNAL, FOG, HIGH BEAM) CIRCUIT ......................5-148 5) ILLUMINATION, PRND INDICATOR LAMP CIRCUIT(BTRE A/T) ..............5-150...
  • Page 27 5-6 ELECTRICAL WIRING DIAGRAMS 39. SEAT WARMER CIRCUIT ......................5-182 40. AUDIO CIRCUIT ........................5-184 41. ABS 5.3 CIRCUIT ........................5-186 42. ABD 5.3 CIRCUIT ........................5-188 1) POWER SUPPLY, GROUND, WHEEL SPEED SENSOR CIRCUIT ..............5-188 2) MODULATOR CIRCUIT ............................5-190 43.

  • Page 28: Gsl E23 Mb A/T

    5-8 ELECTRICAL WIRING DIAGRAMS 1. STARTING & CHARGING SYSTEM a. CONNECTOR INFORMATION 1) GSL E23 MB A/T CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block : M/T (HFM E20, E23) Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block...
  • Page 29 ELECTRICAL WIRING DIAGRAMS 5-9 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (GSL) • W/H MAIN (I/P)

  • Page 30: Gsl Btre A/T, Gsl E32 Mb A/T

    5-10 ELECTRICAL WIRING DIAGRAMS 2) GSL BTRE A/T, GSL E32 MB A/T a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block 30 (BAT +) Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block 15 (IGN 1) Genertor - Engine...
  • Page 31 ELECTRICAL WIRING DIAGRAMS 5-11 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (GSL) • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 S204 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205 TCCU C304...

  • Page 32: Dsl Na Btre A/T, M/T

    5-12 ELECTRICAL WIRING DIAGRAMS 3) DSL NA BTRE A/T, M/T a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block 30 (BAT +) Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block 15 (IGN 1) Genertor - Engine...
  • Page 33 ELECTRICAL WIRING DIAGRAMS 5-13 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (DSL) • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 S204 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205 TCCU C304...

  • Page 34: Dsl La Btre A/T, M/T

    5-14 ELECTRICAL WIRING DIAGRAMS 4) DSL LA BTRE A/T, M/T a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block 30 (BAT +) Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block 15 (IGN 1) Genertor - Engine...
  • Page 35 ELECTRICAL WIRING DIAGRAMS 5-15 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (DSL) • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 S204 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205 TCCU C304...

  • Page 36: Preheat'g Unit Circuit

    5-16 ELECTRICAL WIRING DIAGRAMS 2. PREHEAT'G UNIT CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block IGN 1 Genertor - Engine C106 (4Pin, Black)
  • Page 37 ELECTRICAL WIRING DIAGRAMS 5-17 c. POSITION OF CONNECTORS AND GROUNDS • W/H ENGINE (DSL) • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 S204 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205 TCCU C304 C206B, C206, C207, C208, C208B, C209,C210...
  • Page 38 5-18 ELECTRICAL WIRING DIAGRAMS 3. EGR CONTROL UNIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C109 (16Pin, Black) Inside The Engine Room Fuse Block : M/T Main - T/M C208 (12Pin, Black) Upper The T/C (DSL) Main - T/M IGN 1 C209 (8Pin, Black)
  • Page 39 ELECTRICAL WIRING DIAGRAMS 5-19 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H T/M S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 •...

  • Page 40: Ecm (E23, Mse)

    5-20 ELECTRICAL WIRING DIAGRAMS 4. ECM (E23, MSE) a. CONNECTOR INFORMATION 1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION (1) W/O EURO III Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel...
  • Page 41 ELECTRICAL WIRING DIAGRAMS 5-21 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL) C111 C112 C101, C102 S101, C103 C109 C104...
  • Page 42 5-22 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel IGN 1 Engine Main - ECM Main C112 (6Pin, Gray)
  • Page 43 ELECTRICAL WIRING DIAGRAMS 5-23 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 44 5-24 ELECTRICAL WIRING DIAGRAMS 2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, MAP, CKP), CAM SHAFT a. CONNECTOR INFORMATION ACTUATOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION (1) W/O EURO III Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank...
  • Page 45 ELECTRICAL WIRING DIAGRAMS 5-25 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 46 5-26 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel...
  • Page 47 ELECTRICAL WIRING DIAGRAMS 5-27 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 48 5-28 ELECTRICAL WIRING DIAGRAMS 3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, CTS, SENSOR (KNOCK, a. CONNECTOR INFORMATION INTAKE AIR TEMP', HEATED O ) CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION (1) W/O EURO III Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel Throttle Motor &...
  • Page 49 ELECTRICAL WIRING DIAGRAMS 5-29 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 50 5-30 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION 1 2 3 4 5 6 C111 PEDAL MODULE...
  • Page 51 ELECTRICAL WIRING DIAGRAMS 5-31 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 52 5-32 ELECTRICAL WIRING DIAGRAMS 4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT a. CONNECTOR INFORMATION (1) W/O EURO III CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column Main S201 (Black) Behind The Cluster IGN 1 Main S205 (Colorless)
  • Page 53 ELECTRICAL WIRING DIAGRAMS 5-33 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S205 (COLORLESS)
  • Page 54 5-34 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column IGN 1 Main - Fuell Tank C206B (6Pin, Black) Upper The T/C (GSL) Main S201 (Black) Behind The Cluster...
  • Page 55 ELECTRICAL WIRING DIAGRAMS 5-35 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S205 (COLORLESS)

  • Page 56: Ovpr, Fuel Pump, Ccp Solenoid Circuit

    5-36 ELECTRICAL WIRING DIAGRAMS 5. ECM (E32. MSE) a. CONNECTOR INFORMATION 1) OVPR, FUEL PUMP, CCP SOLENOID CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION (1) W/O EURO III Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block Engine Main - ECM Main BAT+ C111 (40Pin, Black)
  • Page 57 ELECTRICAL WIRING DIAGRAMS 5-37 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)

  • Page 58: Ecm (E32, Mse)

    5-38 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel IGN 1 Engine Main - ECM Main C112 (6Pin, Gray)
  • Page 59 ELECTRICAL WIRING DIAGRAMS 5-39 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)

  • Page 60: Resonance Flap Circuit

    5-40 ELECTRICAL WIRING DIAGRAMS 2) IGNITION COIL, SENSOR (CAM SHAFT POSITION, HFM, CKP), CAM SHAFT a. CONNECTOR INFORMATION ACTUATOR, RESONANCE FLAP CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank...
  • Page 61 ELECTRICAL WIRING DIAGRAMS 5-41 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H A/C Auto Amp Blower Relay D203(SATC) C212 Blower High Relay Incar Sensor Air Con Relay Blower Motor Relay(SATC) Resistor(SATC) Power TR(FATC) Water Sensor • W/H MAIN (GSL)

  • Page 62: Circuit

    5-42 ELECTRICAL WIRING DIAGRAMS 3) PEDAL MODULE, THROTTLE MOTOR & SENSOR, CTS, SENSOR (KNOCK, ECT, a. CONNECTOR INFORMATION HEATED O ) CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION (1) W/O EURO III Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel Throttle Motor &...
  • Page 63 ELECTRICAL WIRING DIAGRAMS 5-43 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)
  • Page 64 5-44 ELECTRICAL WIRING DIAGRAMS (2) W/ EURO III a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Engine Main - ECM Main C111 (40Pin, Black) Center The Engine Room Dash Panel Main - Fuel Tank C206B (6Pin, Black) Upper The T/C (GSL) Throttle Motor &...
  • Page 65 ELECTRICAL WIRING DIAGRAMS 5-45 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)

  • Page 66: Vss, Clutch Switch, Immobilizer Circuit

    5-46 ELECTRICAL WIRING DIAGRAMS 4) VSS, CLUTCH SWITCH, IMMOBILIZER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION DLC Connector - Main C211 (14Pin, Black) Baside The Steering Column IGN 1 Main S201 (Black) Behind The Cluster (M/T) Main S205 (Colorless) Upper Left The Audio G201...
  • Page 67 ELECTRICAL WIRING DIAGRAMS 5-47 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S205 (COLORLESS)

  • Page 68: Sensor(1,2,3,4)

    5-48 ELECTRICAL WIRING DIAGRAMS 5) HEATED O SENSOR (1,2,3,4) b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION • W/ EURO III 2 1 6 7 5 3 4 8 Heated O2 Sensor 2 Heated O2 Sensor 4 OVPR HEATED SENSOR Heater Heater ECM(MSE)

  • Page 69: Ecm (E20, Hfm)

    5-50 ELECTRICAL WIRING DIAGRAMS 6. ECM (E20. HFM) a. CONNECTOR INFORMATION 1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM) IGN1...
  • Page 70 ELECTRICAL WIRING DIAGRAMS 5-51 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H T/M Oil Pressure Swich Speed Sensor TP Sensor Connector (BTRE A/T) Micro Switch (EGR) Starter Motor "ST" C210, C209 C206, C206B C207 C208, C208B PNP Switch 'P' Position Sensor...

  • Page 71: Ccp Solenoid, Sensor (Maf, Ckp) Circuit

    5-52 ELECTRICAL WIRING DIAGRAMS 2) CCP SOLENOID, SENSOR (MAF, CKP) CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT + Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM) IGN1 Main...
  • Page 72 ELECTRICAL WIRING DIAGRAMS 5-53 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL) C111 C112 C101, C102 S101, C103 C109 C104...

  • Page 73: Throttle Motor & Sensor, Ect Sensor, Vss, Heated Osensor Circuit

    5-54 ELECTRICAL WIRING DIAGRAMS 3) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O SENSOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Enginex - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank IGN1...
  • Page 74 ELECTRICAL WIRING DIAGRAMS 5-55 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 •...

  • Page 75: Ecm(E23, Hfm)

    5-56 ELECTRICAL WIRING DIAGRAMS 7. ECM (E23. HFM) a. CONNECTOR INFORMATION 1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT (W/ IMMOBILIZER) CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM)
  • Page 76 ELECTRICAL WIRING DIAGRAMS 5-57 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL) C111 C112 C101, C102 S101, C103 C109 C104...

  • Page 77: Injector, Ovpr, Ignition Coil, Fuel Pump Circuit(W/O Immobilizer)

    5-58 ELECTRICAL WIRING DIAGRAMS 2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT (W/O IMMOBILIZER) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM) IGN1...
  • Page 78 ELECTRICAL WIRING DIAGRAMS 5-59 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL) C111 C112 C101, C102 S101, C103 C109 C104...
  • Page 79 5-60 ELECTRICAL WIRING DIAGRAMS 3) SENSOR (CKP,CMP, KNOCK, MAF),CCP SOLENOID, CAM SHAFT a. CONNECTOR INFORMATION ACTUATOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM) IGN1...
  • Page 80 ELECTRICAL WIRING DIAGRAMS 5-61 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL) C111 C112 C101, C102 S101, C103 C109 C104...

  • Page 81: Throttle Motor & Sensor, Ect Sensor, Vss, Heated Osensor Circuit

    5-62 ELECTRICAL WIRING DIAGRAMS 4) THROTTLE MOTOR & SENSOR, ECT SENSOR, VSS, HEATED O SENSOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block : W/O Immobilizer Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank...
  • Page 82 ELECTRICAL WIRING DIAGRAMS 5-63 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H T/M Oil Pressure Swich Speed Sensor TP Sensor Connector (BTRE A/T) Micro Switch (EGR) Starter Motor "ST" C210, C209 C206, C206B C207 C208, C208B PNP Switch 'P' Position Sensor •...

  • Page 83: Ecm(E32, Hfm)

    5-64 ELECTRICAL WIRING DIAGRAMS 8. ECM (E32. HFM) a. CONNECTOR INFORMATION 1) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT (W/ IMMOBILIZER) CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block...
  • Page 84 ELECTRICAL WIRING DIAGRAMS 5-65 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)

  • Page 85: Injector, Ovpr, Ignition Coil, Fuel Pump Circuit(W/O Immobilizer)

    5-66 ELECTRICAL WIRING DIAGRAMS 2) INJECTOR, OVPR, IGNITION COIL, FUEL PUMP CIRCUIT (W/O IMMOBILIZER) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block IGN1 Engine Main - ECM Main...
  • Page 86 ELECTRICAL WIRING DIAGRAMS 5-67 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (GSL)

  • Page 87: Sensor (Ckp, Cmp, Knock, Maf), Ccp Solenoid, Cam Shaft Actuator Circuit

    5-68 ELECTRICAL WIRING DIAGRAMS 3) SENSOR (CKP, CMP, KNOCK, MAF), CCP SOLENOID, CAM SHAFT ACTUATOR a. CONNECTOR INFORMATION CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT + Main - Engine Main C110 (6Pin, Black) Behind The ABS Module (HFM) Main - T/M...
  • Page 88 ELECTRICAL WIRING DIAGRAMS 5-69 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H T/M • W/H MAIN (GSL)

  • Page 89: Vss, Circuit (Unlead)

    5-70 ELECTRICAL WIRING DIAGRAMS 4) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT, HEATED O ), VSS, CIRCUIT a. CONNECTOR INFORMATION (UNLEAD) CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block : W/O Immobilizer Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block...
  • Page 90 ELECTRICAL WIRING DIAGRAMS 5-71 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H T/M • W/H MAIN (GSL) d. SPLICE PACK S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204...

  • Page 91: Throttle Motor & Sensor, Sensor (Iat, Ect), Co Potentio Meter, Vss Circuit(Lead)

    5-72 ELECTRICAL WIRING DIAGRAMS 5) THROTTLE MOTOR & SENSOR, SENSOR (IAT, ECT), CO POTENTIO METER, VSS a. CONNECTOR INFORMATION CIRCUIT(LEAD) CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block : W/O Immobilizer Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block...
  • Page 92 ELECTRICAL WIRING DIAGRAMS 5-73 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 •...

  • Page 93: Dlc Circuit

    5-74 ELECTRICAL WIRING DIAGRAMS 9. DLC CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block Main - Air Bag C203 (4Pin, Colorless) Left The Audio DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column C303 (14Pin, White)
  • Page 94 ELECTRICAL WIRING DIAGRAMS 5-75 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S202 (GRAY)

  • Page 95: Tcm(Gsl, Btre)

    5-76 ELECTRICAL WIRING DIAGRAMS 10. TCM (GSL, BTRE) a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, INDICATION LAMP CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column Main S205 (Colorless) Upper Left The Audio IGN 1 Main G201...
  • Page 96 ELECTRICAL WIRING DIAGRAMS 5-77 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H T/M S205 (COLORLESS) ECM '38' '37' ECM TCM 'A23' 'A24' TCM TOD 'A10' 'A11' TOD RESISTOR (M/T) • W/H MAIN (I/P)
  • Page 97 5-78 ELECTRICAL WIRING DIAGRAMS 2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION CIRCUT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C207 (16Pin, Black) Main - T/M Upper The T/C Transmission G201 Main Right The I/P Fuse Block Temp Main SOL 1...
  • Page 98 ELECTRICAL WIRING DIAGRAMS 5-79 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H MAIN (I/P)

  • Page 99: Tcm(Dsl, Btre)

    5-80 ELECTRICAL WIRING DIAGRAMS TCM (DSL, BTRE) a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, INDICATION LAMP, SENSOR (TR, ENGINE SPEED) CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION CIRCUIT C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block IGN 1 C208 (12Pin, Black) Main - T/M Upper The T/C (DSL)
  • Page 100 ELECTRICAL WIRING DIAGRAMS 5-81 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H MAIN (I/P)

  • Page 101: Kick Down Switch, Select Lever Position Sensor, Transmission Circuit

    5-82 ELECTRICAL WIRING DIAGRAMS 2) KICK DOWN SWITCH, SELECT LEVER POSITION SENSOR, TRANSMISSION a. CONNECTOR INFORMATION CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C207 (16Pin, Black) Main - T/M Upper The T/C G201 Main Right The I/P Fuse Block Main G202 Beside The STICS Main...
  • Page 102 ELECTRICAL WIRING DIAGRAMS 5-83 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H MAIN (I/P)

  • Page 103: Kick Down Relay, 'B' Switch Circuit (Mb A/T)

    5-84 ELECTRICAL WIRING DIAGRAMS 12. KICK DOWN RELAY, 'B' POSITION SWITCH CIRCUIT (MB A/T) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C208 (16Pin, Black) Main - T/M Upper The T/C IGN 1 C208B (15Pin, Black) Main - T/M Upper The T/C (GSL) Main S201 (Black)
  • Page 104 ELECTRICAL WIRING DIAGRAMS 5-85 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (MAIN) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S203 (MAIN)

  • Page 105: Tccu-Part Time

    5-86 ELECTRICAL WIRING DIAGRAMS 13. TCCU-PART TIME a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION CIRCUIT C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block : M/T C102 (2Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block...
  • Page 106 ELECTRICAL WIRING DIAGRAMS 5-87 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (GSL) • W/H ENGINE (DSL) • W/H MAIN (I/P)

  • Page 107: 4Wd Switch, T/C Speed Sensor, T/C Motor Circuit

    5-88 ELECTRICAL WIRING DIAGRAMS 2) 4WD SWITCH , T/C SPEED SENSOR, T/C MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C104 (15Pin, Black) Engine - Main Under The Engine Room Fuse Block C205 (3Pin, Black) Main - T/M Upper The T/C Motor Main S203 (Gray)
  • Page 108 ELECTRICAL WIRING DIAGRAMS 5-89 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H T/M S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Front Cigar Lighter '2'...

  • Page 109: Tccu-Full Time

    5-90 ELECTRICAL WIRING DIAGRAMS 14. TCCU-FULL TIME a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, INDICATION LAMP, PNP RELAY, CLUTCH SWITCH CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION CIRCUIT C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block : M/T C102 (2Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block...
  • Page 110 ELECTRICAL WIRING DIAGRAMS 5-91 c. POSITION OF CONNECTORS AND GROUNDS • W/H T/M • W/H ENGINE (GSL) • W/H ENGINE (DSL) • W/H MAIN (I/P)

  • Page 111: 4Wd Switch, T/C Speed Sensor, T/C Motor Circuit

    5-92 ELECTRICAL WIRING DIAGRAMS 2) 4WD SWITCH , T/C SPEED SENSOR, T/C MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C205 (3Pin, Black) Main - T/M Upper The T/C Motor S203 (Gray) Main Under Right The Audio Main G203 Upper The ECM...
  • Page 112 ELECTRICAL WIRING DIAGRAMS 5-93 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H T/M S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Front Cigar Lighter '2'...

  • Page 113: Tod(Torque On Demand)-E32,Mse

    5-94 ELECTRICAL WIRING DIAGRAMS 15. TOD (TORQUE ON DEMAND) - E32, MSE a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, WARNING LAMP, 4WD SWITCH, T/C MOTOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ C103 (2Pin, White) Main - Engine...
  • Page 114 ELECTRICAL WIRING DIAGRAMS 5-95 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H T/M S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Front Cigar Lighter '2'...

  • Page 115: T/C Speed Sensor, Pnp Relay, Clutch Switch, Can Circuit

    5-96 ELECTRICAL WIRING DIAGRAMS 2) T/C SPEED SENSOR, PNP RELAY, CLUTCH SWITCH, CAN CIRCUIT a. CONNECTOR INFORMATION : M/T CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block C102 (2Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block T/C Front Speed Sensor...
  • Page 116 ELECTRICAL WIRING DIAGRAMS 5-97 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (DSL) d. SPLICE PACK S205 (COLORLESS) • W/H ENGINE (GSL) ECM '38' '37' ECM TCM 'A23' 'A24' TCM TOD 'A10' 'A11' TOD RESISTOR (M/T)

  • Page 117: Ecs

    5-98 ELECTRICAL WIRING DIAGRAMS 16. ECS a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, SENSOR (WHEEL'G, VERTICAL, LATERAL) CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C103 (21Pin, White) Main - Engine Inside The Engine Room Fuse Block BAT+ C109 (16Pin, Black) Engine - Main Under The Coolant Reservoir Tank IGN 1...
  • Page 118 ELECTRICAL WIRING DIAGRAMS 5-99 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (GSL) • W/H ENGINE (DSL) • W/H FLOOR G303 W/H Tail Connector Tail Lamp Tail Lamp G302 C305 C304 C301 C301~C303...

  • Page 119: Ecs Switch, Damper Circuit

    5-100 ELECTRICAL WIRING DIAGRAMS 2) ECS SWITCH, DAMPER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block C104 (15Pin, Black) Engine - Main Under The Engine Room Fuse Block Main - Floor C301 (20Pin, White) Beside The I/P Relay Block...
  • Page 120 ELECTRICAL WIRING DIAGRAMS 5-101 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4'...

  • Page 121: Cooling Fan, A/C Compressure Circuit

    5-102 ELECTRICAL WIRING DIAGRAMS 17. COOLING FAN, A/C COMPRESSURE CIRCUIT a. CONNECTOR INFORMATION 1) GASOLINE - HFM CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ C103 (21Pin, White) Main - Engine Inside The Engine Room Fuse Block IGN 2 Engine - Main...
  • Page 122 ELECTRICAL WIRING DIAGRAMS 5-103 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 123: Gasoline-Mse

    5-104 ELECTRICAL WIRING DIAGRAMS 2) GASOLINE - MSE a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ C103 (21Pin, White) Main - Engine Inside The Engine Room Fuse Block IGN 2 Enginex - Main C109 (16Pin, Black)
  • Page 124 ELECTRICAL WIRING DIAGRAMS 5-105 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 125: Diesel

    5-106 ELECTRICAL WIRING DIAGRAMS 3) DIESEL a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ C212 (17Pin, White) Main - Air Con Behind The Glove Box IGN 2 Main S204 (Black) Upper Right The Audio...
  • Page 126 ELECTRICAL WIRING DIAGRAMS 5-107 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 127: Manual Air Conditioner Circuit

    5-108 ELECTRICAL WIRING DIAGRAMS 18. MANUAL AIR CONDITIONER CIRCUIT a. CONNECTOR INFORMATION 1) BLOWER MOTOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block BAT+ Main - T/M C209 (8Pin, Black) Upper The T/C (DSL) IGN 2 Main - Air Con...
  • Page 128 ELECTRICAL WIRING DIAGRAMS 5-109 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 129: Intake Motor, Mode Motor Circuit

    5-110 ELECTRICAL WIRING DIAGRAMS 2) INTAKE MOTOR, MODE MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 2 Main - Air Con C212 (17Pin, White) Behind The Glove Box Main S203 (Gray)
  • Page 130 ELECTRICAL WIRING DIAGRAMS 5-111 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Hazard Switch '2'...

  • Page 131: Satc(Semi Auto Temperature Control) Circuit

    5-112 ELECTRICAL WIRING DIAGRAMS 19. SATC (SEMI AUTO TEMPERATURE CONTROL) CIRCUIT a. CONNECTOR INFORMATION 1) BLOWER MOTOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block IGN 2...
  • Page 132 ELECTRICAL WIRING DIAGRAMS 5-113 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 133: Sensor(Ambient, Sun, Water), Air Mix Door Motor Circuit

    5-114 ELECTRICAL WIRING DIAGRAMS 2) SENSOR (AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 2 Enginex - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank Main - Air Con...
  • Page 134 ELECTRICAL WIRING DIAGRAMS 5-115 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Hazard Switch '2'...

  • Page 135: Intake Motor, Mode Motor Circuit

    5-116 ELECTRICAL WIRING DIAGRAMS 3) INTAKE MOTOR, MODE MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 2 Main - Air Con C212 (17Pin, White) Behind The Glove Box Main S203 (Gray)
  • Page 136 ELECTRICAL WIRING DIAGRAMS 5-117 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S203 (GRAY) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4' Audio '3', 4WD Switch '7' Defroster Switch '4' Hazard Switch '2'...

  • Page 137: Fatc (Full Auto Temperature Control) Circuit

    5-118 ELECTRICAL WIRING DIAGRAMS 20. FATC (FULL AUTO TEMPERATURE CONTROL) CIRCUIT a. CONNECTOR INFORMATION 1) BLOWER MOTOR, MODE MOTOR, INTAKE MOTOR CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Enginex - Main C104 (15Pin, Black) Under The Engine Room Fuse Block BAT+ Main - Air Con C212 (17Pin, White)
  • Page 138 ELECTRICAL WIRING DIAGRAMS 5-119 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S204 (BLACK) Thermo AMP '3'(DSL) F19 (10A) Thermo AMP '4'(GSL) Rear Wiper/Washer Blower Relay 'S1' Switch '8' A/C Switch '3' C212 • W/H MAIN (I/P)

  • Page 139: Sensor(Ambient, Sun, Water), Air Mix Door Motor Circuit

    5-120 ELECTRICAL WIRING DIAGRAMS 2) SENSOR (AMBIENT, SUN, WATER), AIR MIX DOOR MOTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank Main - Air Con C212 (17Pin, White)
  • Page 140 ELECTRICAL WIRING DIAGRAMS 5-121 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S202 (GRAY) Stics '1' F17 (10A) Seat belt Switch '3' DLC '14' Chime Bell '2', Buzzer '3' Key Reminder Switch '3' Clock '1' Audio '5' C212 '10' S203 (GRAY) ECS Switch '4'...

  • Page 141: Head Lamp Circuit

    5-122 ELECTRICAL WIRING DIAGRAMS 21. HEAD LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block IGN 1 Engine S101 (Black)
  • Page 142 ELECTRICAL WIRING DIAGRAMS 5-123 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (DSL) d. SPLICE PACK S101 (BLACK) • W/H ENGINE (GSL) Fusible Link Box Head Lamp Relay (Low) '30' Fog Lamp Relay '30' Tail Lamp Relay '30'...

  • Page 143: Head Lamp Level'g Device Circuit

    5-124 ELECTRICAL WIRING DIAGRAMS 22. HEAD LAMP LEVEL'G DEVICE CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 1 Engine G103 Behind The Right Head Lamp Main G201 Right The I/P Fuse Block...

  • Page 144: Illumination Circuit

    5-126 ELECTRICAL WIRING DIAGRAMS 23. ILLUMINATION CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block Main - Air Con C212 (17Pin, White) Behind The Glove Box Main S101 (Black) Inside The Engine Room Fuse Block S203 (Gray)
  • Page 145 ELECTRICAL WIRING DIAGRAMS 5-127 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H A/C S101 (BLACK) Fusible Link Box Head Lamp Relay (Low) '30' Fog Lamp Relay '30' Tail Lamp Relay '30' S203 (BLACK) ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11'...

  • Page 146: Position Lamp, Tail Lamp, Licence Plate Lamp Circuit

    5-128 ELECTRICAL WIRING DIAGRAMS 24. POSITION LAMP, TAIL LAMP, LICENCE PLATE LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Beside The I/P Relay Block C301 (20Pin, White) Beside The I/P Relay Block 58 (ILL)
  • Page 147 ELECTRICAL WIRING DIAGRAMS 5-129 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H TAIL GATE S101 (BLACK) Fusible Link Box Head Lamp Relay (Low) '30' Def(-) Fog Lamp Relay '30' CHMSL Tail Lamp Relay '30' Left Right Licence Lamp Licence Lamp Wiper Motor...
  • Page 148 5-130 ELECTRICAL WIRING DIAGRAMS 25. TURN SIGNAL LAMP, HAZARD LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Engine C103 (21Pin, White) Inside The Engine Room Fuse Block IGN 1 Engine - Main C109 (16Pin, Black)
  • Page 149 ELECTRICAL WIRING DIAGRAMS 5-131 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR • W/H TAIL GATE d. SPLICE PACK S101 (BLACK) Def(-) CHMSL Fusible Link Box Left Right Licence Lamp Licence Lamp Wiper Motor Head Lamp Relay (Low) '30' Tail Lamp Fog Lamp Relay '30' Tail Lamp...

  • Page 150: Back Up Lamp Circuit

    5-132 ELECTRICAL WIRING DIAGRAMS 26. BACK UP LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - T/M C207 (16Pin, Black) Upper The T/C IGN 1 Main - T/M C208 (12Pin, Black) Upper The T/C (DSL) Main - T/M C208 (16Pin, Black) Upper The T/C (GSL) C208B (15Pin, Black)
  • Page 151 ELECTRICAL WIRING DIAGRAMS 5-133 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H TAIL GATE S401 (GRAY) License Lamp '2' Rear RH Combi Lamp '4' Rear LH Combi Lamp '4' License Lamp '2' Door lock Actuator '2' Rear Wiper Motor '3' High Maunted Stop Lamp '2' G302 C402...

  • Page 152: Frt Fog Lamp Circuit

    5-134 ELECTRICAL WIRING DIAGRAMS 27. FRT FOG LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ Main S101 (Black) Inside The Engine Room Fuse Block S204 (Black) Main Upper Right The Audio...
  • Page 153 ELECTRICAL WIRING DIAGRAMS 5-135 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (DSL) d. SPLICE PACK S101 (Black) Fusible Link Box • W/H ENGINE (GSL) Head Lamp Relay (Low) '30' Fog Lamp Relay '30' Tail Lamp Relay '30' S204 (Black) Thermo AMP '3'(DSL) F19 (10A)

  • Page 154: Rear Fog Lamp Circuit

    5-136 ELECTRICAL WIRING DIAGRAMS 28. REAR FOG LAMP CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ Main - Engine C103 (21Pin, White) Inside The Engine Room Fuse Block C301 (20Pin, White) Main - Floor Beside The I/P Relay Block...
  • Page 155 ELECTRICAL WIRING DIAGRAMS 5-137 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR d. SPLICE PACK S203 (Gray) • W/H TAIL GATE ECS Switch '4' Tail Lamp Relay '87' Rear Wiper/Washer Switch '6' C101 A/C Control Panel '11' Fog Lamp Switch '4' C212 Door unlock Switch '4'...

  • Page 156: Shift Lock Solenoid, Stop Lamp Circuit

    5-138 ELECTRICAL WIRING DIAGRAMS 29. SHIFT LOCK SOLENOID, STOP LAMP CIRCUIT a. CONNECTOR INFORMATION 1) M/T, MB A/T, DSL BTRE A/T CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C103 (2Pin, White) Main - Engine Inside The Engine Room Fuse Block BAT+ Main - Floor C301 (20Pin, White) Beside The I/P Relay Block...
  • Page 157 ELECTRICAL WIRING DIAGRAMS 5-139 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR • W/H TAIL GATE d. SPLICE PACK S401 (Gray) Rear RH Combi Lamp '4' License Lamp '2' Rear LH Combi Lamp '4' License Lamp '2' Door lock Actuator '2' Rear Wiper Motor '3' G302...

  • Page 158: Gsl Btre A/T

    5-140 ELECTRICAL WIRING DIAGRAMS 2) GSL BTRE A/T a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C103 (2Pin, White) Main - Engine Inside The Engine Room Fuse Block BAT+ Main - Floor C301 (20Pin, White) Beside The I/P Relay Block IGN1 C401 (6Pin, Colorless) Floor - Tail Gate...
  • Page 159 ELECTRICAL WIRING DIAGRAMS 5-141 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR d. SPLICE PACK S201 (Black) • W/H TAIL GATE F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204...

  • Page 160: Cluster

    5-142 ELECTRICAL WIRING DIAGRAMS 30. CLUSTER a. CONNECTOR INFORMATION 1) SPEED METER, TACHO METER, TEMP GAUGE, FUEL GAUGE CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C104 (15Pin, Black) Engine - Main Under The Engine Room Fuse Block [ ] : GSL(MSE) Engine - Engine C105 (1Pin, Black) Beside Pre-Heating Unit (DSL)
  • Page 161 ELECTRICAL WIRING DIAGRAMS 5-143 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR • W/H T/M d. SPLICE PACK S201 (Black) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204...
  • Page 162 5-144 ELECTRICAL WIRING DIAGRAMS 2) WARNING LAMP(BATTERY CHARGE, BRAKE, OIL PRESSURE, SEAT BELT, a. CONNECTOR INFORMATION ENGINE CHECK, AIR BAG) CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block C106 (4Pin, Black)
  • Page 163 ELECTRICAL WIRING DIAGRAMS 5-145 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H T/M • W/H MAIN (GSL)
  • Page 164 5-146 ELECTRICAL WIRING DIAGRAMS 3) WARNING LAMP(ABS, EBD, TCS, 4WD, ECS), INDICATOR LAMP(4H, 4L, POWER) a. CONNECTOR INFORMATION CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C211 (14Pin, Black) DLC Connector - Main Beside The Steering Column C303 (14Pin, White) Main - Floor Beside The I/P Relay Block b.
  • Page 165 ELECTRICAL WIRING DIAGRAMS 5-147 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR...
  • Page 166 5-148 ELECTRICAL WIRING DIAGRAMS 4) WARNING LAMP(PREHEAT'G, DOOR OPEN), INDICATOR LAMP(ECONOMIC, DE- a. CONNECTOR INFORMATION FROSTER, WINTER, T/SIGNAL, FOG, HIGH BEAM) CIRCUIT CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT + C104 (15Pin, Black) Engine - Main...
  • Page 167 ELECTRICAL WIRING DIAGRAMS 5-149 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (DSL) • W/H ENGINE (GSL)

  • Page 168: Illumination, Prnd Indicator Lamp Circuit(Btre A/T)

    5-150 ELECTRICAL WIRING DIAGRAMS 5) ILLULMINATION, PRND INDICATOR LAMP CIRCUIT (BTRE A/T) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block IGN 1 G201 Main Right The I/P Fuse Block b.
  • Page 169 ELECTRICAL WIRING DIAGRAMS 5-151 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)
  • Page 170 5-152 ELECTRICAL WIRING DIAGRAMS 6) ILLULMINATION, PRND INDICATOR LAMP CIRCUIT (E23 MB A/T) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block IGN 1 C208B (15Pin, Black) Main - T/M Upper The T/C (GSL) Main G202...
  • Page 171 ELECTRICAL WIRING DIAGRAMS 5-153 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (I/P)

  • Page 172: Illumination, Prnd Indicator Lamp Circuit(E32 Mb A/T)

    5-154 ELECTRICAL WIRING DIAGRAMS 7) ILLULMINATION, PRND INDICATOR LAMP CIRCUIT (E32 MB A/T) a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block IGN 1 C207 (16Pin, Black) Main - T/M Upper The T/C Main - T/M C208 (16Pin, Black)
  • Page 173 ELECTRICAL WIRING DIAGRAMS 5-155 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H MAIN (I/P)

  • Page 174: Stics

    5-156 ELECTRICAL WIRING DIAGRAMS 31. STICS a. CONNECTOR INFORMATION 1) POWER SUPPLY, GROUND, CHIME BELL, BUZZER, WARNING LAMP (PARK'G CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION BRAKE, SEAT BELT) CIRCUIT C101 (21Pin, Colorless) Main - Engine Inside The Engine Room Fuse Block BAT+ C103 (21Pin, White) Main - Engine...
  • Page 175 ELECTRICAL WIRING DIAGRAMS 5-157 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (MAIN) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S202 (MAIN)

  • Page 176: Front Wiper Circuit

    5-158 ELECTRICAL WIRING DIAGRAMS 2) FRONT WIPER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 2 Main G201 Right The I/P Fuse Block Main G202 Beside The STICS C101 b.
  • Page 177 ELECTRICAL WIRING DIAGRAMS 5-159 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)

  • Page 178: Lamp(Room, Map, Luggage), Door Switch Circuit

    5-160 ELECTRICAL WIRING DIAGRAMS 3) LAMP (ROOM, MAP, LUGGAGE), DOOR SWITCH CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Roof C201 (8Pin, White) Upper The I/P Fuse Block Main - Floor C301 (20Pin, White)
  • Page 179 ELECTRICAL WIRING DIAGRAMS 5-161 c. POSITION OF CONNECTORS AND GROUNDS • W/H ROOF • W/H DRIVER DOOR • W/H CO-DRIVER DOOR Sun-Roof Switch Sun-Roof Motor & MAP Lamp Room Lamp Power Window Motor Power Window Motor Door Lock Auto Dimming Actuator Room Mirror Door Lock...

  • Page 180: Central Door Lock Circuit

    5-162 ELECTRICAL WIRING DIAGRAMS 4) CENTRAL DOOR LOCK CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Floor C301 (20Pin, White) Beside The I/P Relay Block Main - Floor C304 (12Pin, Colorless) Inside Co-Driver Side Cowl Panel...
  • Page 181 ELECTRICAL WIRING DIAGRAMS 5-163 c. POSITION OF CONNECTORS AND GROUNDS • W/H FLOOR • W/H REAR DOOR Power Window Motor Power Window Motor G303 W/H Tail Door Lock Connector Actuator Tail Lamp Tail Lamp G302 C381 C371 Door Lock Actuator C305 C304 C301...

  • Page 182: Defroster,Dlc Circuit

    5-164 ELECTRICAL WIRING DIAGRAMS 5) DEFROSTER, DLC CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column Main - Floor C302 (16Pin, White) Beside The I/P Relay Block...
  • Page 183 ELECTRICAL WIRING DIAGRAMS 5-165 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR G303 W/H Tail Connector Tail Lamp Tail Lamp G302 C305 C304 C301 C301~C303...

  • Page 184: Power Window Circuit

    5-166 ELECTRICAL WIRING DIAGRAMS 6) POWER WINDOW CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block Main - Floor C301 (20Pin, White) Beside The I/P Relay Block...
  • Page 185 ELECTRICAL WIRING DIAGRAMS 5-167 c. POSITION OF CONNECTORS AND GROUNDS • W/H DRIVER DOOR • W/H REAR DOOR Power Window Motor Door Lock Actuator Power Window Motor Power Window Motor C381 Door Lock Actuator C371 Door Lock Actuator C351 • W/H CO-DRIVER DOOR Power Window Motor Door Lock Actuator...

  • Page 186: Rekes, Auto-Dimming Room Mirror Circuit

    5-168 ELECTRICAL WIRING DIAGRAMS 32. REKES, AUTO DIMMING ROOM MIRROR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Roof C201 (8Pin, White) Upper The I/P Fuse Block IGN 1 Main - T/M C207 (16Pin, Black)
  • Page 187 ELECTRICAL WIRING DIAGRAMS 5-169 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ROOF Sun-Roof Switch Sun-Roof Motor & MAP Lamp Room Lamp Auto Dimming Room Mirror C201 • W/H FLOOR d. SPLICE PACK S202 (MAIN) G303 W/H Tail Stics '1' F17 (10A)

  • Page 188: Sun Roof Circuit

    5-170 ELECTRICAL WIRING DIAGRAMS 33. SUN ROOF CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Roof C201 (8Pin, White) Upper The I/P Fuse Block BAT+ Main G201 Right The I/P Fuse Block IGN1 b. CONNECTOR IDENTIFICATION SYMBOL & PIN NUMBER POSITION 1 2 3 C201 C261...
  • Page 189 ELECTRICAL WIRING DIAGRAMS 5-171 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ROOF Sun-Roof Switch Sun-Roof Motor & MAP Lamp Room Lamp Auto Dimming Room Mirror C201...

  • Page 190: Rear Wiper Circuit

    5-172 ELECTRICAL WIRING DIAGRAMS 34. REAR WIPER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN2 Main - Floor C302 (16Pin, White) Beside The I/P Relay Block Main - Floor C304 (12Pin, Colorless) Inside Co-Driver Side Cowl Panel...
  • Page 191 ELECTRICAL WIRING DIAGRAMS 5-173 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H TAIL GATE Def(-) CHMSL Left Right Licence Lamp Licence Lamp Wiper Motor Tail Lamp Tail Lamp Tail Gate Door Lock Actuator d. SPLICE PACK S203 (MAIN) ECS Switch '4' Tail Lamp Relay '87'...

  • Page 192: Electric Osrv Mirror Circuit

    5-174 ELECTRICAL WIRING DIAGRAMS 35. ELECTRIC OSRV MIRROR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Driver C351 (22Pin, Blue) Upper The I/P Fuse Block ( ) : W/O Heating Mirror Main - Co-Driver Door C361 (22Pin, White) Inside Co-Driver Side Cowl Panel Main G201...
  • Page 193 ELECTRICAL WIRING DIAGRAMS 5-175 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H DRIVER DOOR Power Window Motor Door Lock Actuator C351 • W/H FLOOR • W/H CO-DRIVER DOOR G303 W/H Tail Connector Tail Lamp Power Window Motor Tail Lamp G302 Door Lock...

  • Page 194: Digital Clock, Seat Belt Tension Reducer Circuit

    5-176 ELECTRICAL WIRING DIAGRAMS 36. DIGITAL CLOCK, SEAT BELT TENSION REDUCER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Floor C301 (20Pin, White) Beside The I/P Relay Block IGN1 Main - Floor...
  • Page 195 ELECTRICAL WIRING DIAGRAMS 5-177 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S201 (MAIN) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S203 (MAIN)
  • Page 196 5-158 ELECTRICAL WIRING DIAGRAMS 2) FRONT WIPER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block IGN 2 Main G201 Right The I/P Fuse Block Main G202 Beside The STICS C101 b.
  • Page 197 ELECTRICAL WIRING DIAGRAMS 5-159 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)
  • Page 198 5-160 ELECTRICAL WIRING DIAGRAMS 3) LAMP (ROOM, MAP, LUGGAGE), DOOR SWITCH CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Main - Roof C201 (8Pin, White) Upper The I/P Fuse Block Main - Floor C301 (20Pin, White)
  • Page 199 ELECTRICAL WIRING DIAGRAMS 5-161 c. POSITION OF CONNECTORS AND GROUNDS • W/H ROOF • W/H DRIVER DOOR • W/H CO-DRIVER DOOR Sun-Roof Switch Sun-Roof Motor & MAP Lamp Room Lamp Power Window Motor Power Window Motor Door Lock Auto Dimming Actuator Room Mirror Door Lock...
  • Page 200 5-162 ELECTRICAL WIRING DIAGRAMS 4) CENTRAL DOOR LOCK CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Floor C301 (20Pin, White) Beside The I/P Relay Block Main - Floor C304 (12Pin, Colorless) Inside Co-Driver Side Cowl Panel...
  • Page 201 ELECTRICAL WIRING DIAGRAMS 5-163 c. POSITION OF CONNECTORS AND GROUNDS • W/H FLOOR • W/H REAR DOOR Power Window Motor Power Window Motor G303 W/H Tail Door Lock Connector Actuator Tail Lamp Tail Lamp G302 C381 C371 Door Lock Actuator C305 C304 C301...
  • Page 202 5-164 ELECTRICAL WIRING DIAGRAMS 5) DEFROSTER, DLC CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column Main - Floor C302 (16Pin, White) Beside The I/P Relay Block...
  • Page 203 ELECTRICAL WIRING DIAGRAMS 5-165 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FLOOR G303 W/H Tail Connector Tail Lamp Tail Lamp G302 C305 C304 C301 C301~C303...
  • Page 204 5-166 ELECTRICAL WIRING DIAGRAMS 6) POWER WINDOW CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block Main - Floor C301 (20Pin, White) Beside The I/P Relay Block...
  • Page 205 ELECTRICAL WIRING DIAGRAMS 5-167 c. POSITION OF CONNECTORS AND GROUNDS • W/H DRIVER DOOR • W/H REAR DOOR Power Window Motor Door Lock Actuator Power Window Motor Power Window Motor C381 Door Lock Actuator C371 Door Lock Actuator C351 • W/H CO-DRIVER DOOR Power Window Motor Door Lock Actuator...

  • Page 206: Horn, Cigar Lighter Circuit

    5-178 ELECTRICAL WIRING DIAGRAMS 37. HORN, CIGAR LIGHTER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Engine C103 (21Pin, White) Inside The Engine Room Fuse Block Main - Floor C302 (16Pin, White) Beside The I/P Relay Block...
  • Page 207 ELECTRICAL WIRING DIAGRAMS 5-179 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S203 (GRAY) S201 ECS Switch '4' Tail Lamp Relay '87' S202 Rear Wiper/Washer Switch '6' C201 C101 C351 S203 A/C Control Panel '11' Fog Lamp Switch '4' G201 C212...

  • Page 208: Power Seat Circuit

    5-180 ELECTRICAL WIRING DIAGRAMS 38. POWER SEAT CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block IGN1 Main - Driver Seat C204 (10Pin, White) Under The Driver Seat Driver Seat - Driver Seat, AUX C251 (3Pin, Black) Under The Driver Seat...
  • Page 209 ELECTRICAL WIRING DIAGRAMS 5-181 c. POSITION OF CONNECTORS AND GROUNDS • W/H DRIVER SEAT C251 C204 Seat Warming Unit • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 S204 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205...

  • Page 210: Seat Warmer Circuit

    5-182 ELECTRICAL WIRING DIAGRAMS 39. SEAT WARMER CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (15Pin, Black) Inside The Engine Room Fuse Block BAT+ Main - Driver Seat C204 (10Pin, White) Under The Driver Seat IGN1 Main S201 (Black)
  • Page 211 ELECTRICAL WIRING DIAGRAMS 5-183 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H DRIVER SEAT S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3' C204 S203 (GRAY)
  • Page 212 5-184 ELECTRICAL WIRING DIAGRAMS 40. AUDIO CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block Main - Floor C301 (20Pin, White) Beside The I/P Relay Block...
  • Page 213 ELECTRICAL WIRING DIAGRAMS 5-185 c. POSITION OF CONNECTORS AND GROUNDS • W/H CO-DRIVER DOOR • W/H FLOOR G303 W/H Tail Connector Tail Lamp Power Window Motor Tail Lamp Door Lock Actuator G302 C305 C304 C361 C301 C301~C303 d. SPLICE PACK S202 (GRAY) Stics '1' F17 (10A)

  • Page 214: Abs 5.3 Circuit

    5-186 ELECTRICAL WIRING DIAGRAMS 41. ABS 5.3 CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block BAT+ Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank IGN 1 DLC Connector - Main C211 (14Pin, Black)
  • Page 215 ELECTRICAL WIRING DIAGRAMS 5-187 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (DSL) • W/H MAIN (I/P) S201 S202 C201 C351 S203 G201 C101,C102 S204 S101, C103 C104 C109 C301~C303 G202 S205 C212 C203 C110 C361 C213 C204 G204 G207 G203 G205...
  • Page 216 5-188 ELECTRICAL WIRING DIAGRAMS a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C103 (2Pin, White) Inside The Engine Room Fuse Block BAT+ Engine - Main C109 (16Pin, Black) Under The Coolant Reservoir Tank IGN 1 Main - Floor C305 (6Pin, White) Beside Center Console Valve Relay...
  • Page 217 ELECTRICAL WIRING DIAGRAMS 5-189 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S202 (GRAY) Stics '1' F17 (10A) Seat belt Switch '3' DLC '14' Chime Bell '2', Buzzer '3' Key Reminder Switch '3' Clock '1' C212 '10' Audio '5' •...

  • Page 218: Modulator Circuit

    5-190 ELECTRICAL WIRING DIAGRAMS 2) MODULATOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C102 (2Pin, Colorless) Inside The Engine Room Fuse Block BAT+ DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column Main G206 Beside The ABS Module...
  • Page 219 ELECTRICAL WIRING DIAGRAMS 5-191 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)

  • Page 220: Air Bag Circuit

    5-192 ELECTRICAL WIRING DIAGRAMS 43. AIR BAG CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block BAT+ Main Air Bag C203 (4Pin, Colorless) Left The Audio DLC Connector - Main C211 (14Pin, Black) Beside The Steering Column G102...
  • Page 221 ELECTRICAL WIRING DIAGRAMS 5-193 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P)
  • Page 222 5-194 ELECTRICAL WIRING DIAGRAMS 44. IMMOBILIZER (DSL-CRYPTO TYPE) CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Generator - Engine C106 (4Pin, Black) Under The Air Cleaner Housing (DSL, Turbo) IGN 1 Main S201 (Black) Behind The Cluster Main G201 Right The I/P Fuse Block G202...
  • Page 223 ELECTRICAL WIRING DIAGRAMS 5-195 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H ENGINE (DSL) d. SPLICE PACK • W/H ENGINE (GSL) S201 (BLACK) F24 (10A) DLC '2' Stics '29' VSS '3' Stop Lamp Switch '3' (GSL) EGR Control unit '3' (DLC) Seat Warmer Control unit '9' Clock '3'...
  • Page 224 5-196 ELECTRICAL WIRING DIAGRAMS 45. IMMOBILIZER (GSL HFM-ROLLING CODE TYPE) CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block : E32 Engine - Main C104 (15Pin, Black) Under The Engine Room Fuse Block BAT+ Main - Engine Main...
  • Page 225 ELECTRICAL WIRING DIAGRAMS 5-197 c. POSITION OF CONNECTORS AND GROUNDS d. SPLICE PACK • W/H MAIN (I/P) S202 (MAIN) Stics '1' F17 (10A) Seat belt Switch '3' DLC '14' Chime Bell '2', Buzzer '3' Key Reminder Switch '3' Clock '1' Audio '5' C212 '10' •...

  • Page 226: Trailer Connector Circuit

    5-198 ELECTRICAL WIRING DIAGRAMS 46. TRAILER CONNECTOR CIRCUIT a. CONNECTOR INFORMATION CONNECTOR(NUMBER) CONNECTING. WIRING HARNESS CONNECTOR POSITION Main - Engine C101 (21Pin, Colorless) Inside The Engine Room Fuse Block Main - Floor C301 (20Pin, White) Beside The I/P Relay Block Main - Floor C303 (14Pin, White) Beside The I/P Relay Block...
  • Page 227 ELECTRICAL WIRING DIAGRAMS 5-199 c. POSITION OF CONNECTORS AND GROUNDS • W/H MAIN (I/P) • W/H FIOOR...
  • Page 228 SECTION 0B GENERAL INFORMATION TABLE OF CONTENTS Specifications......0B-1 While Operating the Vehicle ... . . 0B-12 At Each Fuel Fill .
  • Page 229 0B-2 GENERAL INFORMATION Engine Application 661LA 662NA 662LA 2.0L DOCH 2.3L DOCH 3.2L DOCH Engine Type 4Cylinder 5Cylinder 5Cylinder 4Cylinder 4Cylinder 6Cylinder DIESEL DIESEL DIESEL GASOLINE GASOLINE GASOLINE Bore (mm) 89.9 90.9 89.9 Stroke (mm) 92.4 92.4 92.4 78.7 88.4 Total Displacement (cc) 2299 2874...

  • Page 230: Specifications

    GENERAL INFORMATION 0B-3 Auto Transmission (MB) Application 662LA 2.3L DOHC 3.2L DOHC Maker Type or Model W4A040 W4A040 W4A040 Gear Ratio : 1st 3.871 3.871 3.871 2.247 2.247 2.247 1.436 1.436 1.436 1.000 1.000 1.000 Reverse 5.586 5.586 5.586 Final Drive Ratio 5.38 4.27 3.73...
  • Page 231 0B-4 GENERAL INFORMATION Steering System Application Specifications Gear Type RACK & PINION Wheel Alignment: Front Toe-in 0 - 4 mm Front Caster 2°3 0 ’± 30’ Front Camber 0° ± 30’ Oil Capacity Suspension Application Specifications Front Type Double Wishbone Rear Type 5 - Link Fuel System...

  • Page 232: Vehicle Dimensions And Weights

    GENERAL INFORMATION 0B-5 VEHICLE DIMENSIONS AND WEIGHTS Vehicle Dimensions Application Application Overall Length (mm) 4656 Overall Width (mm) 1864 Overall Height (mm) 1735 Wheel Base (mm) 2630 Tread : Front (mm) 1510 Rear (mm) 1520 Vehicle Weights Application 661LA 662NA 662LA 2.0L DOHC 2.3L DOHC...
  • Page 233 0B-6 GENERAL INFORMATION STANDARD BOLTS SPECIFICATIONS Torque (N•m / Ib-in) Standard Limit Bolt* M3 × 0.5 0.5 N• • • • • m 0.9 N• • • • • m 1.2 N• • • • • m 17 N• • • • • m 1.3 N•...

  • Page 234: Maintenance And Repair

    GENERAL INFORMATION 0B-7 MAINTENANCE AND REPAIR MAINTENANCE AND LUBRICATION Fuel Filter Replacement NORMAL VEHICLE USE Replace the engine fuel filter every. The maintenance instructions contained in the maintenance schedule are based on the assumption l Gasoline Engine : 60,000km (36,000 miles) that the vehicle will be used for the following reasons: l Diesel Engine : 45,000km (24,000 miles) l To carry passengers and cargo within the limitation...

  • Page 235: Scheduled Maintenance Charts (Gasoline Engine)

    0B-8 GENERAL INFORMATION SCHEDULED MAINTENANCE CHARTS (GASOLINE ENGINE) Engine Kilometers or time in months, whichever comes first MAINTENANCE INTERVAL x1,000 km MAINTENANCE ITEM Months Drive belt Engine oil & filter (1) (3) Cooling system hose & connections Engine coolant Fuel filter Fuel line &...
  • Page 236 GENERAL INFORMATION 0B-9 Chassis and Body Kilometers or time in months, whichever comes first MAINTENANCE INTERVAL x1,000 km MAINTENANCE ITEM Months Exhaust pipes & mountings Brake/Clutch fluid (3)(4) Parking brake/Brake pads F & R Brake line & connections (including booster) Manual transmission oil Clutch &...

  • Page 237: Scheduled Maintenance Charts (Diesel Engine)

    0B-10 GENERAL INFORMATION SCHEDULED MAINTENANCE CHARTS (DIESEL ENGINE) Engine MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first x1,000 km MAINTENANCE Months ITEM Drive belt Engine oil & fillter (1) (3) Cooling system hose & connections Engine coolant Fuel filter Fuel line &...
  • Page 238 GENERAL INFORMATION 0B-11 Chassis and Body MAINTENANCE INTERVAL Kilometers or time in months, whichever comes first x1,000 km MAINTENANCE Months ITEM Exhaust pipes & mountings Brake/clutch fluid (3) (4) Parking brake/Brake pads (F & R) Brake line & connections (including booster) Manual transmission fluid Clutch &...

  • Page 239: Owner Inspections And Services

    0B-12 GENERAL INFORMATION 5. Add oil, if needed, to keep the oil level above the OWNER INSPECTIONS lower mark. Avoid overfilling the engine, since this AND SERVICES may cause engine damage. 6. Push the indicator all the way back down into the engine after taking the reading.

  • Page 240: Each Time The Oil Is Changed

    GENERAL INFORMATION 0B-13 Weather-Strip Lubrication AT LEAST ANNUALLY Apply a thin film silicone grease using a clean cloth. Lap and Shoulder Belts Condition and EACH TIME THE OIL IS CHANGED Operation Inspect the belt system including: the webbing, the Brake System Inspection buckles, the latch plates, the retractor, the guide loops This inspection should be done when the wheels are and the anchors.

  • Page 241: Recommended Fluids And Lubricants

    0B-14 GENERAL INFORMATION RECOMMENDED FLUIDS AND LUBRICANTS Usage Capacity Fluid/Lubricant Engine Oil 8.2 L Quality class - API ; SH grade or above 3.2L DOHC (Change with filter) ACEA ; A2 or A3 7.5 L MB sheet ; 229.1 2.3L DOHC Viscosity - MB sheet ;...

  • Page 242: General Description And System Operation

    GENERAL INFORMATION 0B-15 l Use genuine DAEWOO parts. GENERAL DESCRIPTION l Discard used cotter pins, gaskets, O-rings, oil seals, AND SYSTEM OPERATION lock washers and self-locking nuts. Prepare new ones for installation. Normal function of these parts cannot be maintained if these parts are reused. GENERAL REPAIR INSTRUCTIONS l Keep the disassembled parts neatly in groups to l If a floor jack is used, the following precautions are...

  • Page 243: Vehicle Identification Number System

    0B-16 GENERAL INFORMATION VEHICLE IDENTIFICATION NUMBER SYSTEM K P T P 0 A 1 9 S W P 122357 12~17.Production Serial Number : 000001- 999999 11.Plant Code P : PyongTaek Plant 10.Model Year M : 1991 N : 1992 P : 1993 R : 1994 S : 1995 T : 1996...
  • Page 244 GENERAL INFORMATION 0B-17 Manufacturer’ s Plate 1.Type Approval No. 2.Vehicle Identification Number. Manufacturer’ s Plate Location Gasoline Engine Diesel Engine...
  • Page 245 0B-18 GENERAL INFORMATION Gasolind Engine Number Diesel Engine Number 162 990 1 0 012345 662 920 1 0 012345 Serial Number Serial Number 0 : Manual T/M 0 : Manual T/M 1 : Hydr - Auto Coupling 1 : Hydr - Auto Coupling 2 : Automatic T/M 2 : Automatic T/M 0 : Common...

  • Page 246: Vehicle Lifting Procedures

    GENERAL INFORMATION 0B-19 VEHICLE LIFTING PROCEDURES To raise the vehicle, place the lifting equipment only at the points indicated. Failure to use these precise positions may result in permanent vehicle body deformation. Many dealer service facilities and service stations are equipped with automative hoists that bear upon some parts of the frame in order to lift the vehicle.
  • Page 247 SECTION 1 ENGINE SECTION 1A1(M162 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Specifications..... . . 1A1-1 Diagnosis ......1A1-7 Engine Specifications .

  • Page 248: Engine Specifications

    1A1-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application E32 Engine Idle Speed (rpm) 700 ± 50 Fuel Injection Pressure (kg/cm²) 3 - 4 Oil Capacity (liter) Lubrication Type Forced by Gear Pump Oil Filter Type Full Flow with Paper Filter Fuel Unleaded Gasoline MSE 3.62S/3.53S (Motorsteuer Elektronik : German)

  • Page 249: Component Locator

    GENERAL ENGINE INFORMATION 1A1-3 COMPONENT LOCATOR FRONT VIEW 1 HFM Sensor 12 Intake Manifold 2 Intake Air Duct 13 Connecting Rod 3 Resonance Flap 14 Exhaust Manifold 4 Cylinder Head Cover 15 Crankshaft 5 Exhaust Camshaft 16 Engine Mounting Bracket 6 Intake Camshaft 17 Starter 7 Cylinder Head...

  • Page 250: Side View

    1A1-4 GENERAL ENGINE INFORMATION SIDE VIEW 23 Camshaft Adjuster 27 Oil Pump Drive Chain 24 Cooling Fan and Viscous Clutch 28 Oil Return Pipe 25 Piston 29 Timing Chain 26 Flywheel of Drive Plate 30 Oil Pump...

  • Page 251: Performance Curve

    GENERAL ENGINE INFORMATION 1A1-5 PERFORMANCE CURVE E32 ENGINE...

  • Page 252: Special Tools

    1A1-6 GENERAL ENGINE INFORMATION SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 001 589 65 09 00 Torque Wrench Socket 001 589 76 21 00 119 589 01 09 00 Compression Pressure Spark Plug Wrench Tester...

  • Page 253: Diagnosis

    GENERAL ENGINE INFORMATION 1A1-7 DIAGNOSIS 2. Operate the vehicle normal operating conditions as OIL LEAK DIAGNOSIS directed in the kit. Most fluid oil leaks are easily located and repaired by 3. Direct the light toward the suspected area. The dyed visually finding the leak and replacing or repairing the fluid will appear as a yellow path leading to the necessary parts.

  • Page 254: Engine Cranking At The Front Of Crankshaft

    1A1-8 GENERAL ENGINE INFORMATION ENGINE CRANKING AT THE FRONT OF CRANKSHAFT Preceding Work : Removal of cooling fan 1 Vibration Damper Assembly 3 Bolt ..........8.6 ± 0.9 Nm 2 Crankshaft Pulley Notice Remove the negative ground cable before proceeding the work. Rotate the pulley in normal engine rotating direction when cranking.

  • Page 255: Compression Pressure Test

    GENERAL ENGINE INFORMATION 1A1-9 COMPRESSION PRESSURE TEST 1 Compression Pressure Tester 3 Adaptor 2 Diagram Sheet 4 Sealing Cone Tools Required 001 589 76 21 00 Compression Pressure Tester 119 589 01 09 00 Spark Plug Wrench Standard Service Data Compression Ratio 10 : 1 Normal Engine Temperature...
  • Page 256 1A1-10 GENERAL ENGINE INFORMATION Measuring Procedure 1. Warm the engine up to normal operating temperature. 2. Remove the spark plugs. 3. Place the diagram sheet to compression pressure tester. 4. Connect the adaptor to compression pressure tester and install it into the spark plug hole. 5.

  • Page 257: Cylinder Pressure Leakage Test

    GENERAL ENGINE INFORMATION 1A1-11 CYLINDER PRESSURE LEAKAGE TEST 3 Engine Oil Filler Cap 6 Cylinder Pressure Leakage Tester with 4 Vibration Damper Connecting Hose Permissible Pressure Leakage At Whole Engine Max. 25 % At Valve and Cylinder Head Gasket Max. 10 % At Piston and Piston Ring Max.
  • Page 258 1A1-12 GENERAL ENGINE INFORMATION Leakage Test 1. Warm the engine up to normal operating temperature. 2. Disconnect the negative battery cable. 3. Remove the spark plugs. 4. Check the coolant level by opening the coolant surge tank cap and replenish if insufficient. 5.

  • Page 259: General Information

    GENERAL ENGINE INFORMATION 1A1-13 GENERAL INFORMATION Battery cables should be disconnected before any major CLEANLINESS AND CARE work is performed on the engine. Failure to disconnect An automobile engine is a combination of many cables may result in damage to wire harness or other machined, honed, polished and lapped surfaces with electrical parts.
  • Page 260 SECTION 1 ENGINE SECTION 1A2(M161 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Specifications..... . . 1A2-1 Diagnosis ......1A2-8 Engine Specifications .
  • Page 261 1A2-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application E23 Engine E20 Engine Idle Speed (rpm) 750 ± 50 ← Fuel Injection Pressure (kg/cm²) 3.2 - 4.2 ← Oil Capacity (liter) ← Lubrication Type Forced by Gear Pump ← Oil Filter Type Full Flow with Paper Filter ←...
  • Page 262 SECTION 1 ENGINE SECTION 1A3(OM600 ENGINE) GENERAL ENGINE INFORMATION TABLE OF CONTENTS Specifications..... . . 1A3-1 Special Tools Table ....1A3-9 Diagnosis .
  • Page 263 1A3-2 GENERAL ENGINE INFORMATION ENGINE SPECIFICATIONS (Cont'd) Application OM 662 LA OM661LA Idle Speed (rpm) 720 - 820 750 - 850 Fuel Injection Pressure (bar) 135 - 143 135 - 143 Oil Capacity (liter) 8.0 - 9.5 6.5 - 8.0 Lubrication Type Forced by Gear Pump Forced by Gear Pump...
  • Page 264 SECTION 1B1 M162 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 265 1B1-2 M162 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N• • • • • m Power Steering Hydraulic Lines 35 - 40 A/C High Pressure and Liquid Hose 10 - 15 Radiator Support Menber Bolt 5 - 10 Fuel Supply and Return Hose to Fuel Distributor 21 - 25 Exhaust Manifold and Pipe Propeller Shaft to Transmission...
  • Page 266 M162 ENGINE MECHANICAL 1B1-3 FASTENER TIGHTENING SPECIFICATIONS (Cont’d) Application N• • • • • m Exhaust Camshaft Sproket Bolt 20 / +90° Chain Tensioner Screw Plug Chain Tensioner Assembly 72 - 88 Exhaust Camshaft Sprocket to Camshaft 20 / +90° Oil Pump Sprocket Bolt 25 - 35 Tensioning Device Bolt...
  • Page 267 1B1-4 M162 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 000 589 40 37 00 Torque Wrench Hose Clamp 112 589 00 72 00 000 589 72 21 00 Oil Extractor Torque Wrench 001 589 66 21 00 124 589 15 21 00 Torque Wrench Radiator Cap...

  • Page 268: Special Tools Table

    M162 ENGINE MECHANICAL 1B1-5 SPECIAL TOOLS TABLE (Cont’d) 104 589 01 01 00 111 589 01 59 00 Spanner Supporting Bar 111 589 18 61 00 111 589 25 63 00 Lever Pusher Thrust Piece 116 589 06 63 00 104 589 00 37 00 Magnetic Finger Pliers...
  • Page 269 1B1-6 M162 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 116 589 20 33 00 601 589 03 43 00 Sliding Hammer Sleeve 602 589 00 40 00 103 589 00 33 00 Engine Lock Puller 001 589 65 09 00 000 589 88 33 00 Socket Wrench Insert Puller 001 589 74 21 00...
  • Page 270 M162 ENGINE MECHANICAL 1B1-7 SPECIAL TOOLS TABLE (Cont’d) 103 589 01 63 00 615 589 01 33 00 Rivet Set Caulking Bolt 103 589 02 09 00 102 589 12 15 00 Oil Filter Drift Socket Wrench 102 589 00 15 00 601 589 03 14 00 Drift Sleeve...

  • Page 271: Maintenance And Repair

    1B1-8 M162 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor...
  • Page 272 M162 ENGINE MECHANICAL 1B1-9 Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the under cover. Installation Notice Tightening Torque 28 - 47 Nm 4. Disconnect the coupling of HFM sensor and remove the air cleaner cross pipe.
  • Page 273 1B1-10 M162 ENGINE MECHANICAL 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug. 8. Remove the cooling fan shroud. 9. Disconnect the each hose from radiator. 10.
  • Page 274 M162 ENGINE MECHANICAL 1B1-11 11. Remove the hydraulic pipe of power steering. Notice Completely drain the oil. 12. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor. 13. Remove the acceleration control cable and automatic transmission pressure cable.
  • Page 275 1B1-12 M162 ENGINE MECHANICAL 15. Remove the automatic transmission dipstick guide tube. 16. Disconnect the wire of alternator. 17. Disconnect the wire of starter motor and remove the starter motor. 18. Disconnect the engine main harness ground. 19. Disconnect the engine ground wire.
  • Page 276 M162 ENGINE MECHANICAL 1B1-13 20. Disconnect following sensors connector. HFM sensor. Coolant temperature sensor. 2 knock sensors. Camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect the 6 injection valve connectors.
  • Page 277 1B1-14 M162 ENGINE MECHANICAL 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation Notice Tightening Torque 81 - 89 Nm 28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
  • Page 278 M162 ENGINE MECHANICAL 1B1-15 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 65 Nm 31. Remove the bolts for engine mounting bracket. Installation Notice Tightening Torque 50 - 75 Nm 32. Hook the chain to the bracket of engine and by using a hoist or crane, carefully separate the engine assembly from the vehicle.

  • Page 279: Crankcase Ventilation System

    1B1-16 M162 ENGINE MECHANICAL CRANKCASE VENTILATION SYSTEM 1 Crankcase 13 Intake Air Duct (Cross Pipe) 2 Air Admission Port in Crankcase 14 Cylinder Head Cover 3 Oil Drain Port 15 Oil Separator 4 Filter 16 Oil Separator 5 Gasket 17 Air Admission and Vent Connection 6 A/C Bracket 18 Air Admission and Vent Connection 7 Oil Drain Pipe...
  • Page 280 M162 ENGINE MECHANICAL 1B1-17 Operation at Idling and Mid-Load It show that the throttle valve (19) is closed or very partially opened and the vacuum pressure in intake manifold is high. The blowby gas in the crankcase in partial load flows into the intake manifold through the vent line (20) after passing the air conditioner bracket (6) and the filter (4).

  • Page 281: Alternator

    1B1-18 M162 ENGINE MECHANICAL ALTERNATOR 1 Nut (M8) ......... 22.5-27.5 Nm 4 Bolt (M8 x 70, 1 piece) ....22.5-27.5 Nm 2 Bolt (M8 x 30, 3 pieces) ....22.5-27.5 Nm 5 Bolt (M8 x 75, 1 piece) ....22.5-27.5 Nm 3 Bolt (M8 x 40, 1 piece) ....

  • Page 282: Power Steering Pump And A/C Bracket

    M162 ENGINE MECHANICAL 1B1-19 POWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud 1 Vent Hose 8 A/C Bracket 2 Bolt (M8 x 91, 2 pieces) ....22.5-27.5 Nm 9 Gasket ........... Replace 3 Power Steering Pump 10 Bracket 4 Bolt (M8 x 105, 4 pieces) ....
  • Page 283 1B1-20 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the belt pulley. Installation Notice Tightening Torque 40.5 - 49.5 Nm Notice Pull the tensioning pulley clockwise as shown in the figure. 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
  • Page 284 M162 ENGINE MECHANICAL 1B1-21 5. Disconnect the vent hose from the A/C bracket. 6. Unscrew all the mounting bolts (arrows) and remove the A/C bracket and the gasket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 7. Clean the sealing surface. 8.

  • Page 285: Hydraulic Engine Mounting Insulator

    1B1-22 M162 ENGINE MECHANICAL HYDRAULIC ENGINE MOUNTING INSULATOR Service Data...
  • Page 286 M162 ENGINE MECHANICAL 1B1-23 Sectional View 1 Rubber Body 9 Lower Orifice 2 Brackek 10 Upper Orifice 3 Core 11 Diaphram 4 Lower Bolt 12 Cover Plate 5 Rubber Plunger 13 Upper Bolt 6 Plunger Plate 14 Flange Bolt 7 Rubber 15 Rivet 8 Plate 16 Fluid...
  • Page 287 1B1-24 M162 ENGINE MECHANICAL 1 Upper Nut 2 Hydraulic Installor....62-93 Nm 3 Lower Nut......28-47 Nm Removal and Installation Procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation Notice Tightening Torque 62 - 93 Nm 2.

  • Page 288: Poly V-Belt

    M162 ENGINE MECHANICAL 1B1-25 POLY V - BELT Preceding Work : Removal of cooling fan 1 Poly V-belt 2 Belt Tensioning Pulley Removal & Installation Procedure 1. Release the belt tension by turning the belt tensioning pulley nut clockwise. 2. Remove the poly v-belt. Notice Check the belt for damage and tensioning pulley bearing point for wear and replace them if necessary.
  • Page 289 1B1-26 M162 ENGINE MECHANICAL Poly V-Belt Arrangement 1 Belt Tensioning Pulley 5 Alternator Pulley 2 Crankshaft Belt Pulley 6 Idler 3 A/C Compressor Pulley 7 Power Steering Pump Pulley 4 Cooling Fan Pulley 8 Cooling Fan and Water Pump Pulley...

  • Page 290: Tensioning Device

    M162 ENGINE MECHANICAL 1B1-27 TENSIONING DEVICE Preceding Work : Removal of poly v-belt 1 Belt (L = 2245) 3 Water Pump Pulley 2 Bolt Combi(M8 x 14, 3 pieces) + Washer 4 Nut ............22.5-27.5Nm 5 Tensioning Pulley Removal & Installation Procedure 1.
  • Page 291 1B1-28 M162 ENGINE MECHANICAL 3. Remove the 3 bolts (2) and remove the water pump pulley (arrow). Installation Notice Tightening Torque 22.5 - 27.5 Nm 4. Remove the mounting bolts(M8 x 30, 3 pieces) at the tensioning device, and remove the tensioning device (arrow). Installation Notice Tightening Torque 26 - 32 Nm...

  • Page 292: Poly V-Belt Inspection

    M162 ENGINE MECHANICAL 1B1-29 POLY V - BELT INSPECTION Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt. 1. Rubber lumps in the base of rib. 2.
  • Page 293 1B1-30 M162 ENGINE MECHANICAL 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs. 11. Splits across the back of the belt.

  • Page 294: Cylinder Head Cover

    M162 ENGINE MECHANICAL 1B1-31 CYLINDER HEAD COVER 1 Ignition Cable Dust Cover 6 Cylinder Head Cover 2 Bolt (M6 x 65, 8 pieces) ......9-11 Nm 7 Gasket ........... Replace 3 Bolt (M6 x 50, 4 pieces) ......9-11 Nm 8 Spart Plug Hole Seal ......
  • Page 295 1B1-32 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the intake air duct. Installation Notice Tightening Torque 8 - 9 Nm 2. Remove the ignition cable cover. Installation Notice Tightening Torque 9 - 10 Nm Notice Unscrew the seven (M6 x 60) bolts and remove the ignition cable cover.
  • Page 296 M162 ENGINE MECHANICAL 1B1-33 CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head cover Removal of coolant connection fitting 1 Camshaft Position Sensor 5 Bolt (M8 x 80, 3 pieces) ....22.5-27.5 Nm 2 Magnet Assembly 6 Front Cover 3 Upper Guide Rail 7 Rubber Gasket ........
  • Page 297 1B1-34 M162 ENGINE MECHANICAL 2. Remove the cylinder head front cover (6). Installation Notice Tightening Torque 22.5 - 27.5 Nm Apply the sealant at the mating surface of the cylinder head and the front cover. 3. Remove the upper guide rail pin and the guide rail (3). Installation Notice Install it while the chain tensioner is loose.

  • Page 298: Cylinder Head

    M162 ENGINE MECHANICAL 1B1-35 CYLINDER HEAD Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of upper intake manifold 1 Cylinder Head Bolt (14 pieces) 4 Exhaust Camshaft Sprocket ............ 1st step 55 Nm 5 Cylinder Head 2nd step 90°...
  • Page 299 1B1-36 M162 ENGINE MECHANICAL Tools Required 000 589 01 10 00 Box Wrench Insert 116 589 02 34 00 Screw-fixed Pin 116 589 20 33 00 Sliding Hammer Removal & Installation Procedure 1. Rotate the crankshaft so that the piston of number 1 cylinder is at TDC.
  • Page 300 M162 ENGINE MECHANICAL 1B1-37 6. Remove the guide rail fixing pin from the cylinder head using the sliding hammer (01) and the threaded pin (02). Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 7. Remove the cylinder head bolts in numerical order. Installation Notice 1st step 55 Nm 2nd step 90°...

  • Page 301: Timing Gear Case Cover

    1B1-38 M162 ENGINE MECHANICAL TIMING GEAR CASE COVER Preceding Work : Removal of cylinder head front cover Removal of alternator bracket Removal of tensioning device Removal of belt pulley and vibration damper 1 Bolt (M8 x 60, 3 pieces) ....22.5-27.5 Nm 6 Seal 2 A/C Bracket 7 Timing Gear Case Cover...
  • Page 302 M162 ENGINE MECHANICAL 1B1-39 3. Remove the cooling fan and the viscous clutch. Unscrew the three bolts from the cooling fan bracket and remove the bracket (arrows). Installation Notice Tightening Torque 22.5 - 27.5 Nm 4. Remove the timing gear case cover after unscrewing the bolts (3) and (4) from the timing gear case cover and the bolt (9) from the oil pan.

  • Page 303: Crankshaft Sealing Rear Cover

    1B1-40 M162 ENGINE MECHANICAL CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate 1 Bolt (M6 x 20, 6 pieces) ......9-11 Nm 4 Sleeve 2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......9-11 Nm 3 Rear Cover 6 Washer...
  • Page 304 M162 ENGINE MECHANICAL 1B1-41 Tools Required 601 589 03 43 00 Sleeve Removal & Installation Procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket. 2.

  • Page 305: Belt Pulley And Vibration Damper

    1B1-42 M162 ENGINE MECHANICAL BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Center Bolt (M18 x 50) ..1st step 200- 220 Nm 4 Vibration Damper Assembly 2nd step 90°+10°...
  • Page 306 M162 ENGINE MECHANICAL 1B1-43 Components 1 Center Bolt (M18 x 50) 2 Center Bolt Washer 3 Vibration Damper and Pulley Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket (Camshaft Driven) 8 Crankshaft Sprocket (Oil pump Driven) 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket...
  • Page 307 1B1-44 M162 ENGINE MECHANICAL 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation Notice 1st step 200 - 220 Nm Tightening Torque 2nd step 90° +10° Engine Lock 602 589 00 40 00 4.

  • Page 308: Crankshaft Front Radial Seal

    M162 ENGINE MECHANICAL 1B1-45 CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper 1 Center Bolt (M18 x 50) ........ 1st step 200-220 Nm 2nd step 90° +10° 2 Center Bolt Washer 3 Sleeve (Special Tool) 4 Crankshaft Front Seal 5 Key Tools Required...

  • Page 309: Crankshaft Rear Radial Seal

    1B1-46 M162 ENGINE MECHANICAL CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate 1 Special Tool 3 Crankshaft Rear Seal 2 Special Tool Tools Required 601 589 03 43 00 Sleeve Replacement Proceudre 1. Remove the radial seal with a screw driver. Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.

  • Page 310: Crankshaft

    M162 ENGINE MECHANICAL 1B1-47 CRANKSHAFT Preceding Work : Removal of engine assembly Removal of timing gear case cover Removal of cylinder head Removal of oil pump Removal of oil shield 1 12-sided Stretch Bolt ..55 Nm x 90°, Iubricate 4 Lower Thrust Bearing 2 Crank Shaft Bearing Cap 5 Crank Shaft...
  • Page 311 1B1-48 M162 ENGINE MECHANICAL Arrangement of the Thrust Bearing and the Main Bearing 1 Upper Main Bearing A Crankcase Side 2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side) 3 Crankshaft C Axial Fit Bearing (Number 5 Bearing Point) 4 Lower Main Bearing D Radial Bearing 5 Lower Thrust Bearing...
  • Page 312 M162 ENGINE MECHANICAL 1B1-49 Color Dot Marking Crankshaft Journal Diameter (mm) Blue 57.960 - 57.965 Yellow 57.955 - 57.960 57.950 - 57.955 White 57.945 - 57.950 Violet 57.940 - 57.945 Selection of Crankshaft Main Bearing 1. Crankcase Side There are seven punching marks on the mating surface to oil pan.
  • Page 313 1B1-50 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 40 Nm + 90° Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil.
  • Page 314 M162 ENGINE MECHANICAL 1B1-51 Inspection 1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing.
  • Page 315 1B1-52 M162 ENGINE MECHANICAL Service Data Standard (Crankshaft Main Bearing Gap) Item Measuring Position Gap (mm) Main Bearing Journal Static condition :0.015 - 0.039 ( NO. 1, 5, 7) Radial Dynamic condition: 0.031 - 0.051 (Consider the expansion 0.011 - 0.016) Axial 0.010 - 0.254 Main Bearing Journal...

  • Page 316: Flywheel / Driven Plate

    M162 ENGINE MECHANICAL 1B1-53 FLYWHEEL / DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission 1 Flywheel Mounting Bolt (M10 x 22, 8 pieces) 3 Driven Plate (A/T) ..........1st step 45+5 Nm 4 Dowel Pin 2nd step +90° +10° 2 Plate Service Data Standard (Stretch Bolt) Nominal Size...

  • Page 317: Bolt (M6 X 65, 8 Pieces)

    1B1-54 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Unscrew the stretch bolt. Installation Notice 1st step 45+5 Nm Tightening Torque 2nd step 90° + 10° Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm. For the stretch bolt tightening, keep the socket wrench and Tommy-bar to be 90°...

  • Page 318: Camshaft Adjuster

    M162 ENGINE MECHANICAL 1B1-55 CAMSHAFT ADJUSTER 1 Bolt (M6 x 16, 3 pieces) ......9-11 Nm 13 Camshaft Sprocket and Position Indicator (b) 2 Electromagnetic Actuator (2 Pin Connector) 14 Adjuster piston 3 Bolt ............35 Nm 15 Flange bolt (M7 x 13, 3 pieces) 4 Armature ..........
  • Page 319 1B1-56 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Turn the crankshaft to the direction of engine rotation and position the no.1 cylinder piston at TDC which the camshaft is positioned at OT. 2. Remove the cylinder head front cover. 3.
  • Page 320 M162 ENGINE MECHANICAL 1B1-57 7. Remove the camshaft sprocket (13) and adjust piston (14), and remove the flange shaft (16) from the intake camshaft (22) after removing the bolt (15). Installation Notice 1st step 18 - 22 Nm Tightening Torque 2nd step 90°...

  • Page 321: Camshaft Sprocket Bolt

    1B1-58 M162 ENGINE MECHANICAL CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt 1st step 18 - 22 Nm Tightening Torque 2nd step 90° ± 5° Notice The sprocket bolts are designed to be used only once, so always replace with new one. C.

  • Page 322: Camshaft

    M162 ENGINE MECHANICAL 1B1-59 CAMSHAFT Preceding Work : Removal of cylinder head cover, removal of coolant connection fitting 1 Chain Tensioner Assembly ....72-88 Nm 5 Intake Camshaft Sprocket 2 Exhaust Camshaft Sprocket 6 Chain 3 Upper Guide Rail 7 Wrench (Special Tool) 4 Cylinder Head Front Cover...
  • Page 323 1B1-60 M162 ENGINE MECHANICAL Tools Required 000 589 01 10 00 Box Wrench Insert 104 589 01 01 00 Spanner Removal Procedure 1. Turn the crankshaft and position the No. 1 cylinder piston at BTDC 30° . 2. Remove the alternator. 3.
  • Page 324 M162 ENGINE MECHANICAL 1B1-61 8. Unscrew the intake side bolts (8, 11, 13, 14) and the exhaust side bolts (1, 4, 6, 7). 9. Loosen the remaining bolts and unscrew the intake and exhaust side camshaft bearing cap bolts. Notice Number the camshaft bearing cap bolts when removing them, so that they don’t get mixed up.
  • Page 325 1B1-62 M162 ENGINE MECHANICAL 4. Turn the intake camshaft adjuster to the direction of camshaft rotation by hard until it stops and then install the chain. Notice l Make sure that the camshaft sprocket and timing chain are aligned with marks. l Intake camshaft adjuster should be in retarded position.
  • Page 326 M162 ENGINE MECHANICAL 1B1-63 8. Install the upper guide rail and cylinder head front cover. 9. Install the alternator.

  • Page 327: Camshaft Timing Position

    1B1-64 M162 ENGINE MECHANICAL CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover 1 Chain Tensioner Assembly 4 Cylinder Head Front Cover 2 Exhaust Camshaft Sprocket 5 Wrench (Special Tool) 6 Adjustment Hole Fitting Pin ( φ 4.0 mm) 3 Upper Guide Rail...
  • Page 328 M162 ENGINE MECHANICAL 1B1-65 Tools Required 104 589 01 01 00 Spanner Inspection 1. Position the No.1 cylinder piston to TDC (OT) by turning the crankshaft. Notice When the OT mark on vibration damper is aligned with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
  • Page 329 1B1-66 M162 ENGINE MECHANICAL 9. Install the chain to the exhaust camshaft sprocket and install it to the camshaft. Installation Notice (Sprocket Bolt) 1st step 18 - 22 Nm Tightening Torque 2nd step 90° ± 5° The sprocket bolt is designed to be used only once, so replace with new one.

  • Page 330: Valve Spring

    M162 ENGINE MECHANICAL 1B1-67 VALVE SPRING Preceding Work : Removal of camshaft Removal of spark plug 1 Valve Tappet Assembly 7 Connecting Hose 2 Valve Cotter 8 Thrust Piece 3 Upper Retainer 9 Slide 4 Valve Spring ..Check, Replace if necessary 10 Adjust Bolt 5 Valve Stem Seal 11 Lever Pusher...
  • Page 331 1B1-68 M162 ENGINE MECHANICAL Tools Required 111 589 01 59 00 Supporting Bar 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 116 589 06 63 00 Magnetic Finger Removal & Installation Procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (Nos 1 &...
  • Page 332 M162 ENGINE MECHANICAL 1B1-69 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). Lever Pusher 111 589 18 61 00 9. Mount the thrust piece (8) vertically to the valve spring retainer (3). 10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
  • Page 333 1B1-70 M162 ENGINE MECHANICAL Test (Upper and Lower Valve Tappet and Valve Cotter) l Upper Valve Spring Retainer Size (mm) 12.3 l Lower Valve Spring Retainer Thickness (mm) 0.8 - 1.0 l Valve Cotter Size (mm) 9.2 - 9.8...

  • Page 334: Valve Stem Seal

    M162 ENGINE MECHANICAL 1B1-71 VALVE STEM SEAL Preceding Work : Removal of valve spring 1 Drift (Special Tool) 2 Valve Stem Seal 3 Protective Sleeve Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1.

  • Page 335: Chain Tensioner

    1B1-72 M162 ENGINE MECHANICAL CHAIN TENSIONER 1 Screw Plug ..........40 Nm 5 Snap Ring 2 Seal 6 Thrust Pin 3 Filler Pin 7 Chain Tensioner Housing ..... 72-88 Nm 4 Compression Spring 8 Seal Removal Procedure 1. Position the No.1 cylinder to TDC (OT). Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam’s lobe (arrow) stays in the...
  • Page 336 M162 ENGINE MECHANICAL 1B1-73 4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice l For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. l Remove the screw plug only when the seal and compression spring are damaged.
  • Page 337 1B1-74 M162 ENGINE MECHANICAL 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 Nm 5. Check for leaks by operating the engine. Sectional View 1 Screw Plug 13 Chain Tensioner Housing 2 Ball (Nonreturn Valve) 14 Seal 3 Compression Spring...

  • Page 338: Timing Chain

    M162 ENGINE MECHANICAL 1B1-75 TIMING CHAIN Preceding Work : Removal of cylinder head cover Removal of spark plug 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge...
  • Page 339 1B1-76 M162 ENGINE MECHANICAL Tools Required 000 589 58 43 00 Chain Assembly 103 589 01 63 00 Rivet Set 001 589 72 21 00 Torque Wrench Replacement Procedure 1. Position the No.1 cylinder to TDC (OT). 2. Insert the φ 4mm pin to the intake and exhaust camshaft flange not to rotate camshaft.
  • Page 340 M162 ENGINE MECHANICAL 1B1-77 6. Remove the outer plate (7) with the screw driver and remove the link (5). 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
  • Page 341 1B1-78 M162 ENGINE MECHANICAL 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 15.
  • Page 342 M162 ENGINE MECHANICAL 1B1-79 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 Nm Tightening Torque Tensioner Assembly 72 - 88 Nm 19. Check the camshaft timing position.

  • Page 343: Tensioning Rail

    1B1-80 M162 ENGINE MECHANICAL TENSIONING RAIL Preceding Work : Removal of timing gear case cover 1 Tensioning Rail 2 Plastic Guide 3 Tensioning Rail Pin 4 Guide Rail Removal & Installation Procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).

  • Page 344: Cylinder Head Guide Rail

    M162 ENGINE MECHANICAL 1B1-81 CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Chain Tensioner 2 Upper Guide Rail 3 Upper Guide Rail Pin 4 Wrench (Special Tool) Tools Required 104 589 01 01 00 Spanner Removal &...

  • Page 345: Crankcase Guide Rail

    1B1-82 M162 ENGINE MECHANICAL CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover 1 Guide Rail 2 Plastic Guide 3 Guide Rail Pin 4 Tensioning Rail Removal & Installation Procedure 1. Put the assembly mark at the camshaft sprocket and the timing chain with the paint (arrow).

  • Page 346: Crankshaft Sprocket

    M162 ENGINE MECHANICAL 1B1-83 CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of tensioning rail Removal of crank case guide rail 1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer ..29-35 Nm 2 Oil Pump Chain Bushing 7 Oil Pump Sprocket 3 Oil Pump Chain Spring...
  • Page 347 1B1-84 M162 ENGINE MECHANICAL Tools Required 615 589 01 33 00 Puller Removal & Installation Procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain.

  • Page 348: Piston

    M162 ENGINE MECHANICAL 1B1-85 PISTON Preceding Work : Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bolt (M9 x 52, 12 pieces) 6 Piston Pin ............
  • Page 349 1B1-86 M162 ENGINE MECHANICAL Tools Required 001 589 72 21 00 Torqued Wrench 000 589 04 14 00 Clamping Strap Removal Procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice Make sure that the bearing cap and shell are not changed each other.
  • Page 350 M162 ENGINE MECHANICAL 1B1-87 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3.

  • Page 351: Connecting Rod

    1B1-88 M162 ENGINE MECHANICAL CONNECTING ROD Preceding Work : Removal of piston 1 Connecting Rod Bushing 2 Oil Gallery 3 Balance Weight 4 Connecting Rod Bolt (M9 x 52, 12 m pieces) .. 1st step 40+5 Nm 2nd step 90°+10° 5 Fit Sleeve 6 Upper Connecting Rod Bearing 7 Lower Connecting Rod Bearing...
  • Page 352 M162 ENGINE MECHANICAL 1B1-89 Inspection 1. Measure the basic bore of the connecting rod bearing. Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. Length When New (L) 51.7 - 52 mm Max.

  • Page 353: Piston Ring

    1B1-90 M162 ENGINE MECHANICAL PISTON RING Preceding Work : Removal of piston 1 Piston Compression Ring 2 Piston Compression Ring 3 Piston Oil Ring 5 Coil Spring and Control Ring 6 Hook Spring Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1.
  • Page 354 M162 ENGINE MECHANICAL 1B1-91 2. Remove the piston ring with a pliers. Clamping Strap 000 589 51 37 00 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120°...

  • Page 355: Engine Oil Specification

    1B1-92 M162 ENGINE MECHANICAL ENGINE OIL SPECIFICATION 1 Drain Plug ..........25 Nm 3 Engine Oil Filler Cap 2 Oil Filter 4 Dipstick Gauge Specifications Application Descrition Capacity Min : 6.7L, Max : 8.2L Quality l API SH or above grade l ACEA : A2 or A3 l Approved oil by MB Sheet 229.1 Viscosity...

  • Page 356: Oil Pan

    M162 ENGINE MECHANICAL 1B1-93 OIL PAN 1 Gasket ........... Replace 5 Bolt (M6 x 85)..........10 Nm 2 Bolt (M6 x 22, 6 pieces) ......10 Nm 6 Bolt (M8 x 40)..........25 Nm 3 Drain Plug (M6 x 20) ......... 25 Nm 7 Bolt (M10) ..........
  • Page 357 1B1-94 M162 ENGINE MECHANICAL Oil Circulation 1 Oil Pump 19 Oil Supply (To Intake Camshaft) 2 Oil Gallery (to oil filter) 20 Oil Supply (To Exhaust Camshaft Bearing) 3 Oil Filter 21 Oil Supply (To Intake Camshaft Bearing) 4 Oil Pressure Switch 22 Oil Gallery (Oil Supply to Exhaust Valve Tappet) 5 Main Oil Gallery 23 Oil Gallery (Oil Supply to Exhaust Valve Tappet)

  • Page 358: Engine Oil And Oil Filter Element

    M162 ENGINE MECHANICAL 1B1-95 ENGINE OIL AND OIL FILTER ELEMENT Tools Required 103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure 1. Install the socket wrench”7” (special tool : 103 589 02 09 00) on the oil filter cover (2). Notice Make the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).
  • Page 359 1B1-96 M162 ENGINE MECHANICAL 9. Fill up engine oil through the engine oil filler opening (3). 10. Check for oil leaks at normal engine temperature after starting the engine. 11. Stop the engine and wait 5 minutes. Check the oil level and fill up as specified if necessary. 3 Oil Filler Cap 4 Dipstick Gauge...

  • Page 360: Oil Filter

    M162 ENGINE MECHANICAL 1B1-97 OIL FILTER Preceding Work : Removal of starter motor Removal of upper intake manifold 1 Coolant Line 5 Bolt ............23 Nm 2 O-ring ............ Replace 6 Oil Filter 3 Clip 7 Gasket ........... Replace 4 Hose...
  • Page 361 1B1-98 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Drain the coolant from the crank case. 2. Remove the each coolant line and hose. 3. Remove the oil filter bolt and then remove the oil filter. Installation Notice Tightening Torque 23 Nm Notice Replace the oil filter gasket.

  • Page 362: Oil Pump

    M162 ENGINE MECHANICAL 1B1-99 OIL PUMP Preceding Work : Removal of oil pan 1 Bolt (M8 x 20, 1 piece) ......29-35 Nm 4 Spring Pin 2 Sprocket (Oil Pump Drive) 5 Oil Pump 3 Bolt (M8 x 35, 3 pieces) ....22.5-27.5 Nm...
  • Page 363 1B1-100 M162 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the bolt (1) from the oil pump drive sprocket (2) and separate the gear and the oil pump drive chain. Installation Notice Tightening Torque 29 - 35 Nm 2. Unscrew the oil pump mounting bolts (3). Installation Notice Tightening Torque 22.5 - 27.5 Nm...

  • Page 364: Oil Pressure Relief Valve

    M162 ENGINE MECHANICAL 1B1-101 OIL PRESSURE RELIEF VALVE Preceding Work : Removal of oil pan 1 Screw Plug ..........50 Nm 3 Guide Pin 2 Compression Spring 4 Piston Removal & Installation Procedure 1. Remove the screw plug (1). Installation Notice Tightening Torque 50 Nm 2.

  • Page 365: Oil Non-Return Valve

    1B1-102 M162 ENGINE MECHANICAL OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover 1 Oil Non-return Valve Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tensioner from getting dry.

  • Page 366: Oil Dipstick Guide Tube

    M162 ENGINE MECHANICAL 1B1-103 OIL DIPSTICK GUIDE TUBE 1 Oil Dipstick Level Gauge 3 O-ring 2 Oil Dipstick Guide Tube 4 Bolt (M6 x 12, 1 piece) ......9-11 Nm Removal & Installation Procedure 1. Pull out the oil dipstick level gauge (1). 2.

  • Page 367: Unit Repair

    1B1-104 M162 ENGINE MECHANICAL UNIT REPAIR OIL GALLERY IN CRANKCASE Preceding Work : Removal of crankshaft, removal of oil spray nozzle 3 Round Bar ........φ 11 x 750 mm 1 Plug 2 Steel Ball Cleaning Procedure 1. Remove the plug (1) with a screwdriver. 2.
  • Page 368 M162 ENGINE MECHANICAL 1B1-105 1 Plug ............Replace 3 Screw Plug 2 Main Oil Gallery Tools Required 102 589 12 15 00 Drift Sealing Procedure 1. Enlarge the end of main oil gallery (4) to be diameter of 16mm, depth of 15mm. 2.

  • Page 369: Oil Gallery In Cylinder Head

    1B1-106 M162 ENGINE MECHANICAL OIL GALLERY IN CYLINDER HEAD Preceding Work : Removal of cylinder head Removal of camshaft Removal of tappet 3 Steel Ball ( φ 8mm) 1 Screw Plug ..........15 Nm 2 Seal Cleaning Procedure 1. Remove the screw plug (1) and the seal (2). Installation Notice Tightening Torque 15 Nm...
  • Page 370 M162 ENGINE MECHANICAL 1B1-107 Sealing Procedure 1. Remove the screw plug (1) and the seal. Installation Notice Tightening Torque 15 Nm 2. Remove the steel ball from the oil gallery (4), (5), (6) and (7) using the round bar (12, φ 6 x 700 mm). 3.
  • Page 371 1B1-108 M162 ENGINE MECHANICAL 8. Make a screw hole at the oil gallery using M10 x 1 thread. 9. All the oil gallery should be cleaned with the compressed air. 10. Apply the Loctite 270 to new plug and press in using a suitable drift (arrow).

  • Page 372: Core Plugs In Crankcase

    M162 ENGINE MECHANICAL 1B1-109 CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant 1 Core Plug..........Replace...
  • Page 373 1B1-110 M162 ENGINE MECHANICAL Tools Required 102 589 00 15 00 Drift Replacement Procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 4.

  • Page 374: Cylinder Bore

    M162 ENGINE MECHANICAL 1B1-111 CYLINDER BORE Group Code Letter and Cylinder Bore Size Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm) φ 89.900 - φ 90.906 A or X φ 89.906 - φ 89.912 A, X or B φ...
  • Page 375 1B1-112 M162 ENGINE MECHANICAL Service Data Standard Wear Limit in Longitudinal and Transverse Direction 0.1 mm Permissible Deviation of Cylinder Out-of-round When new 0.007 mm Wear limit 0.05 mm Permissible Deviation of Rectangular Cylinder Height (Except Chamfered Area) 0.05 mm Basic Peak-to-valley Height After Final Honing and Brushing 0.003 - 0.006 mm Chamfer Angle...

  • Page 376: Crankcase Mating Surface

    M162 ENGINE MECHANICAL 1B1-113 CRANKCASE MATING SURFACE Service Data Standard Height of The Crankcase “H” (When new) 282.25 - 282.35mm Minimum Height After Milling 281.95mm Flatness Crankcase Upper Mating Surface 0.03mm Crankcase Lower Mating Surface 0.04mm Permissible Deviation of Parallelism of The Axial Direction 0.1mm Upper to Lower Mating Surface...
  • Page 377 1B1-114 M162 ENGINE MECHANICAL Chamfering Procedure 1. Chamfer angle : 60° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

  • Page 378: Cylinder Head Mating Surface

    M162 ENGINE MECHANICAL 1B1-115 CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves Service Data Standard Overall Height of Cylinder Head 135.9 - 136.0 mm Minimum Height After Machining 135.5 mm Flatness Axial Direction 0.08 mm Transverse Direction 0.0 mm Distance ‘T’...
  • Page 379 1B1-116 M162 ENGINE MECHANICAL Measurement of Mating Surface 1. Measure the height (H) of the cylinder head (refer to Service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4.
  • Page 380 SECTION 1B2 M161 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 381: Specifications

    1B2-2 M161 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N• • • • • m Power Steering Hydraulic Lines 35 - 40 A/C High Pressure and Liquid Hose 10 - 15 Radiator Support Menber Bolt 5 - 10 Fuel Supply and Return Hose to Fuel Distributor 21 - 25 Exhaust Manifold and Pipe Propeller Shaft to Transmission...
  • Page 382 M161 ENGINE MECHANICAL 1B2-3 FASTENER TIGHTENING SPECIFICATIONS (Cont’d) Application N• • • • • m Exhaust Camshaft Sproket Bolt 20 / + 90° Chain Tensioner Screw Plug Chain Tensioner Assembly 72 - 88 Exhaust Camshaft Sprocket to Camshaft 20 / + 90° Oil Pump Sprocket Bolt 25 - 35 Tensioning Device Bolt...

  • Page 383: Special Tools

    1B2-4 M161 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 000 589 10 99 01 000 589 40 37 00 Torque Wrench Hose Clamp 112 589 00 72 00 000 589 72 21 00 Oil Extractor Torque Wrench 001 589 66 21 00 124 589 15 21 00 Torque Wrench Radiator Cap...
  • Page 384 M161 ENGINE MECHANICAL 1B2-5 SPECIAL TOOLS TABLE (Cont’d) 104 589 01 01 00 111 589 01 59 00 Spanner Supporting Bar 111 589 18 61 00 111 589 25 63 00 Lever Pusher Thrust Piece 116 589 06 63 00 104 589 00 37 00 Magnetic Finger Pliers...
  • Page 385 1B2-6 M161 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 116 589 20 33 00 601 589 03 43 00 Sliding Hammer Sleeve 602 589 00 40 00 103 589 00 33 00 Engine Lock Puller 001 589 65 09 00 000 589 88 33 00 Socket Wrench Insert Puller 001 589 74 21 00...
  • Page 386 M161 ENGINE MECHANICAL 1B2-7 SPECIAL TOOLS TABLE (Cont’d) 103 589 01 63 00 615 589 01 33 00 Rivet Set Caulking Bolt 103 589 02 09 00 102 589 12 15 00 Oil Filter Drift Socket Wrench 102 589 00 15 00 601 589 03 14 00 Drift Sleeve...
  • Page 387 1B2-8 M161 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 617 589 00 10 00 116 589 01 34 00 Wrench Socket Threaded Bolt 104 589 00 40 00 111 589 03 15 00 Holder Insert Pin...

  • Page 388: Maintenance And Repair

    M161 ENGINE MECHANICAL 1B2-9 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY Tools Required 000 589 10 99 01 Torque Wrench 000 589 40 37 00 Hose Clamp 112 589 00 72 00 Oil Extractor...
  • Page 389 1B2-10 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the under cover. Installation Notice Tightening Torque 28 - 47 Nm 4. Disconnect the coupling of HFM sensor and remove the air cleaner cross pipe.
  • Page 390 M161 ENGINE MECHANICAL 1B2-11 7. Loosen the cylinder block drain plug and then drain the coolant completely. Installation Notice Tightening Torque 30 Nm Notice Replace the seal before installation of the drain plug. 8. Remove the cooling fan shroud. 9. Disconnect the each hose from radiator. 10.
  • Page 391 1B2-12 M161 ENGINE MECHANICAL 11. Remove the hydraulic pipe of power steering. Notice Completely drain the oil. 12. Discharge the refrigerant from A/C system, and disconnect the discharge pipe and suction pipe from the compressor. 13. Remove the acceleration control cable and automatic transmission pressure cable.
  • Page 392 M161 ENGINE MECHANICAL 1B2-13 15. Remove the automatic transmission dipstick guide tube. 16. Disconnect the wire of alternator. 17. Disconnect the wire of starter motor and remove the starter motor. 18. Disconnect the engine main harness ground. 19. Disconnect the engine ground wire.
  • Page 393 1B2-14 M161 ENGINE MECHANICAL 20. Disconnect following sensors connector. HFM sensor. Coolant temperature sensor. 2 knock sensors. Camshaft and crankshaft sensors. 21. After removing the ignition coil cover, disconnect the ignition coil connector. 22. Remove the harness cover and disconnect the 6 injection valve connectors.
  • Page 394 M161 ENGINE MECHANICAL 1B2-15 25. Separate the vacuum hose for brake booster. 26. Separate the other vacuum hoses. 27. Remove the propeller shaft from the front axle. Installation Notice Tightening Torque 81 - 89 Nm 28. By rotating the crankshaft from the front of engine, remove the 6 torque converter mounting bolts from the engine ring gear plate.
  • Page 395 1B2-16 M161 ENGINE MECHANICAL 30. Remove the transmission mounting bolts and separate the transmission from the engine. Installation Notice Tightening Torque 65 Nm 31. Remove the bolts for engine mounting bracket. Installation Notice Tightening Torque 50 - 75 Nm 32. Hook the chain to the bracket of engine and by using a hoist or crane, carefully separate the engine assembly from the vehicle.

  • Page 396: Crankcase Ventilation System

    M161 ENGINE MECHANICAL 1B2-17 CRANKCASE VENTILATION SYSTEM Operation at Idling and Mid-Load 1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling) 2 Cylinder Head Cover 12 Crank Chamber 3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe Mid-Load) 14 Oil Pan 4 Intake Air Duct (Cross Pipe)
  • Page 397 1B2-18 M161 ENGINE MECHANICAL Operation at Idling and Mid-Load The throttle valve(6) is closed or very partially opened, and the vacuum pressure in intake manifold is high. The blow-by gas and the fresh air that is additionally supplied through the vent connection(D) in the crankcase in partial load gets supplied to the combustion chamber from the crank chamber(12) through the oil separation chamber(11), air- conditioner bracket(10), vent line(9), and restrictor(7)
  • Page 398 M161 ENGINE MECHANICAL 1B2-19 Operation When Full-Load at Partial Load 1 HFM Sensor 11 Oil Separation Chamber (Mid-Load at Idling) 2 Cylinder Head Cover 12 Crank Chamber 3 Oil Spearation Chamber (Full-Load or Over 13 Oil Return Pipe Mid-Load) 14 Oil Pan 4 Intake Air Duct (Cross Pipe) 15 Timing Gear Case Cover 5 Vent Line (Full-Load or Over Mid-Load)
  • Page 399 1B2-20 M161 ENGINE MECHANICAL Operation When Full-Load at Partial Load The throttle valve (6) is partially opened or fully opened. The air flows very rapidly through the vent line(5)s connection(D) and the intake air duct when full-load at partial load. Consequently, most of the low-by gases are supplied to the combustion chamber through the timing gear case cover(15), chain housing(17), oil separation chamber(3),...

  • Page 400: Alternator

    M161 ENGINE MECHANICAL 1B2-21 ALTERNATOR 1 Bolt (M8 X 40, 3 pieces) ....22.5-27.5 Nm 3 Bolt (M8 X 85, 1 piece)....22.5-27.5 Nm 2 Bolt (M8 X 70, 2 pieces) ....22.5-27.5 Nm 4 Alternator Bracket Removal & Installation Procedure 1.

  • Page 401: Power Steering Pump And A/C Bracket

    1B2-22 M161 ENGINE MECHANICAL POWER STEERING PUMP AND A/C BRACKET Preceding Work : Removal of cooling fan and shroud Removal of drive belt 1 Nut ..........35.2-28.8 Nm 9 Washer 2 Washer 10 Bolt (M8 X 105,4 pieces) ....22.5-27.5 Nm 3 Belt Pulley 11 A/C Compressor 4 Bolt (M8 X 91, 2 pieces) ....22.5-27.5 Nm...
  • Page 402 M161 ENGINE MECHANICAL 1B2-23 Removal & Installation Procedure 1. Remove the belt pulley after removal of poly v-belt. Installation Notice Tightening Torque 40.5 - 49.5 Nm Notice Pull the tensioning pulley counterclockwise as shown in the figure. 2. Disconnect the hydraulic pipe of the power steering pump and drain the oil.
  • Page 403 1B2-24 M161 ENGINE MECHANICAL 5. Disconnect the vent hose from the A/C bracket. 6. Unscrew all the mounting bolts (arrows) and remove the A/C bracket and the gasket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 7. Clean the sealing surface. 8.

  • Page 404: Hydraulic Engine Mounting Insulator

    M161 ENGINE MECHANICAL 1B2-25 HYDRAULIC ENGINE MOUNTING INSULATOR Service Data...
  • Page 405 1B2-26 M161 ENGINE MECHANICAL Sectional View 1 Rubber Body 9 Lower Orifice 2 Brackek 10 Upper Orifice 3 Core 11 Diaphram 4 Lower Bolt 12 Cover Plate 5 Rubber Plunger 13 Upper Bolt 6 Plunger Plate 14 Flange Bolt 7 Rubber 15 Rivet 8 Plate 16 Fluid...
  • Page 406 M161 ENGINE MECHANICAL 1B2-27 1 Upper Nut 2 Hydraulic Installer ....62~93 Nm 3 Lower Nut......28~47 Nm Removal and Installation Procedure 1. Unscrew the upper nut(1) on engine mounting and remove the engine. Installation Notice Tightening Torque 62 - 93 Nm 2.

  • Page 407: Poly V-Belt

    1B2-28 M161 ENGINE MECHANICAL POLY V-BELT Preceding Work : Removal of cooling fan 3 Belt Tensioner 1 Poly V-belt (2,155 mm) 2 Belt Tensioning Pulley Removal & Installation Procedure 1. Release the belt tension by turning the stud on the cap with 12 sided wrench or spanner counterclockwise.
  • Page 408 M161 ENGINE MECHANICAL 1B2-29 Poly V-belt Arrangement 1 Belt Tensioning Pulley 5 Alternator Pulley 2 Crankshaft Belt Pulley 7 Power Steering Pump Pulley 3 A/C Compressor Pulley 8 Water Pump Pulley...

  • Page 409: Tensioning Deivce

    1B2-30 M161 ENGINE MECHANICAL TENSIONING DEVICE Preceding Work : Removal of tensioning device shock absorber 1 Bolt (M8 x 75, 2 pieces) + 3 Tensioning Device 4 Stud bolt Washer ..........22.5-27.5 Nm 2 Bolt (M8 x 25, 1 pieces) + 5 Tensioning Arm Washer ..........22.5-27.5 Nm Removal &...

  • Page 410: Tensioning Device Shock Absorber

    M161 ENGINE MECHANICAL 1B2-31 TENSIONING DEVICE SHOCK ABSORBER 1 End Cover 5 Tensioning Device 2 Nut ..........40.5-49.5 Nm 6 Bolt (M8 X 35) + Washer ....22.5-27.5 Nm 3 Tensioning Pulley 7 Shock Absorber 4 Bolt (M8 X 25) + Washer ....22.5-27.5 Nm Removal &...

  • Page 411: Poly V-Belt Inspection

    1B2-32 M161 ENGINE MECHANICAL POLY V-BELT INSPECTION Make marks on the belt with chalk. Rotate the engine and check the belt for damage. Notice If one of the following types of damages is found, replace the belt. 1. Rubber lumps in the base of rib. 2.
  • Page 412 M161 ENGINE MECHANICAL 1B2-33 5. Cord torn out at the side. 6. Outer cords frayed. 7. Rib detached from the base of belt. 8. Splits across the rib. 9. Sections of rib torn out. 10. Splits across several ribs.
  • Page 413 1B2-34 M161 ENGINE MECHANICAL 11. Splits across the back of the belt.

  • Page 414: Cylinder Head Cover

    M161 ENGINE MECHANICAL 1B2-35 CYLINDER HEAD COVER 1 Ignition Coil Cover 4 Cylinder Head Cover 2 Spark Plug Connector 5 Gasket ........... Replace 3 Bolt (M6 X 45 : 4 pieces, M6 X 60 : 6 pieces) ..........10 ± 1 Nm...
  • Page 415 1B2-36 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the intake air duct. Installation Notice Tightening Torque 9 - 11 Nm 2. Remove the ignition coil cover. Installation Notice Tightening Torque 9 - 10 Nm Notice Release 3 screws from the ignition cover and remove the cover for M161 Engine coil.
  • Page 416 M161 ENGINE MECHANICAL 1B2-37 CYLINDER HEAD FRONT COVER Preceding Work : Removal of cylinder head cover Removal of thermostat housing assembly Removal of engine hanger bracket 1 Bolt (M6 X 16, 3 pieces) ......9-11 Nm 6 Front Cover (E20 : M161.943) 2 Camshaft Adjuster 7 Sleeve 3 Bolt (M8 X 35, 2 pieces) ....
  • Page 417 1B2-38 M161 ENGINE MECHANICAL 2. Remove the cylinder head front cover. Installation Notice Tightening Torque (3) 22.5 - 27.5 Nm Tightening Torque (4) 9 - 11 Nm Apply the sealant at the mating surface of the cylinder head and the front cover. 3.

  • Page 418: Cylinder Head

    M161 ENGINE MECHANICAL 1B2-39 CYLINDER HEAD Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover Removal of intake manifold Removal of cylinder head lower line (intake manifold side) 4 Camshaft Bearing cap ....22.5-27.5 Nm 1 Cylinder Head Bolt (M12 X 100, 10 pieces) ............
  • Page 419 1B2-40 M161 ENGINE MECHANICAL Tools Required 617 589 00 10 00 Wrench Socket 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Bolt 001 589 66 21 00 Torque Wrence 104 589 00 40 00 Holder Removal &...
  • Page 420 M161 ENGINE MECHANICAL 1B2-41 6. Remove the in take camshaft sprocket (E20 engine). 7. Remove the camshaft adjuster (E23, M161.970 engine). Installation Notice (Flange Bolt) 1st step 18 - 22 Nm Tightening Torque 2nd step 85° - 95° Notice The flange bolt is designed to be used only once, so always replace with new one.

  • Page 421: Gasket

    1B2-42 M161 ENGINE MECHANICAL 10. Remove the cylinder head bolts in the reverse order of the numerics (No.10 → No.1). Installation Notice Tighten the bolts as numerical order with specified torque (No.1 → No.10). 1st step 55 ± 5 Nm 2nd step + 90°...
  • Page 422 M161 ENGINE MECHANICAL 1B2-43 15. Check the length of the cylinder head bolt. When New 100 mm Tightening Torque Max. Length 105 mm Notice Replace the bolt if the measured length exceed the max. length. 16. Installation should follow the removal procedure in the reverse order.

  • Page 423: Timing Gear Case Cover

    1B2-44 M161 ENGINE MECHANICAL TIMING GEAR CASE COVER Preceding Work : Removal of viscous clutch Removal of cylinder head front cover Removal of tensioning device Removal of water pump Removal of oil filter element Removal of oil pan Removal of alternator bracker 1 Bolt (M8 X 60, 3 pieces) ....22.5-27.5 Nm 4 Timing gear case cover 2 Bolt (M8 X 75, 1 piece) ....
  • Page 424 M161 ENGINE MECHANICAL 1B2-45 Tools Required 001 589 72 21 00 Torque Wrench 116 589 20 33 00 Sliding Hammer 116 589 01 34 00 Threaded Bolt Removal & Installation Procedure 1. Remove the power steering belt pulley and A/C compressor bracket.
  • Page 425 1B2-46 M161 ENGINE MECHANICAL 8. Unscrew the bolts (A). Installation Notice Tightening Torque 22.5 - 27.5 Nm 9. Remove the belt pulley and vibration damper. Installation Notice (Center Bolt) 1st step 180 - 220 Nm Tightening Torque 2nd step 80° - 100° 10.

  • Page 426: Crankshaft Sealing Rear Cover

    M161 ENGINE MECHANICAL 1B2-47 CRANKSHAFT SEALING REAR COVER Preceding Work : Removal of the automatic transmission drive plate or flywheel 1 Bolt (M6 x 20, 6 pieces) ......9-11 Nm 4 Sleeve 2 Radial Shaft Seal 5 Bolt (M6 x 85, 2 pieces) ......9-11 Nm 3 Rear Cover 6 Washer...
  • Page 427 1B2-48 M161 ENGINE MECHANICAL Tools Required 601 589 03 43 00 Sleeve Removal & Installation Procedure 1. Unscrew the bolts (1) and (5) and remove the closing cover by pulling the rear cover lug (arrows). Notice Be careful not to damage the oil pan gasket. 2.

  • Page 428: Belt Pulley And Vibration Damper

    M161 ENGINE MECHANICAL 1B2-49 BELT PULLEY AND VIBRATION DAMPER Preceding Work : Removal of cooling fan and viscous clutch Removal of fan shroud Removal of drive belt 1 Center Bolt 5 Vibration Damper Assembly (M18 X 55) ....... 1st step 200-220 Nm 6 Key 2nd step 90°...
  • Page 429 1B2-50 M161 ENGINE MECHANICAL Components 1 Center Bolt (M18 x 50) 2 Center Bolt Washer 3 Vibration Damper and Pulley Assembly 4 Key 5 Crankshaft Front Seal 6 Timing Gear Case Cover 7 Crankshaft Sprocket (Camshaft Driven) 8 Crankshaft Sprocket (Oil pump Driven) 9 Crankshaft 10 Oil Pan 11 Oil Pan Gasket...
  • Page 430 M161 ENGINE MECHANICAL 1B2-51 2. Remove the start motor and install the engine lock to the flywheel ring gear. 3. Remove the center bolt. Installation Notice 1st step 180 - 220 Nm Tightening Torque 2nd step + 90° Engine Lock 602 589 00 40 00 4.

  • Page 431: Crankshaft Front Radial Seal

    1B2-52 M161 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL Preceding Work : Removal of belt pulley and vibration damper 1 Center Bolt (M18 x 50) ....... 1st step 200-220 Nm 2nd step 90° +10° 2 Center Bolt Washer 3 Sleeve (Special Tool) 4 Crankshaft Front Seal 5 Key Tools Required...

  • Page 432: Crankshaft Rear Radial Seal

    M161 ENGINE MECHANICAL 1B2-53 CRANKSHAFT REAR RADIAL SEAL Preceding Work : Removal of flywheel or drive plate 1 Special Tool 3 Crankshaft Rear Seal 2 Special Tool Tools Required 601 589 03 43 00 Sleeve Replacement Proceudre 1. Remove the radial seal with a screw driver. Notice Use a clean cloth not to damage the radial seal mounting hole and the crankshaft.

  • Page 433: Crankshaft

    1B2-54 M161 ENGINE MECHANICAL CRANKSHAFT Preceding Work : Removal of engine Removal of cylinder head Removal of timing gear case cover Removal of crankcase sealing rear cover Removal of oil pan Removal of baffle plate Removal of oil pump 1 Bearing Cap Bolt (M8 X 55-10 pieces) ....
  • Page 434 M161 ENGINE MECHANICAL 1B2-55 Arrangement of the Thrust Bearing and the Main Bearing 1 Upper Main Bearing A Crankcase Side 2 Upper Thrust Bearing B Bearing Cap Side (Oil Pan Side) 3 Crankshaft 4 Lower Main Bearing 5 Lower Thrust Bearing Weight Balance/Color Marking Point j1 - j5 Journal Main Bearing #1 - #5...
  • Page 435 1B2-56 M161 ENGINE MECHANICAL Color Dot Marking Crankshaft Journal Diameter (mm) Blue 57.960 - 57.965 Yellow 57.955 - 57.960 57.950 - 57.955 White 57.945 - 57.950 Violet 57.940 - 57.945 Selection of Crankshaft Main Bearing 1. Crankcase Side There are seven punching marks on the mating surface to oil pan.
  • Page 436 M161 ENGINE MECHANICAL 1B2-57 Removal & Installation Procedure 1. Unscrew the connecting rod bearing cap bolt and remove the bearing cap. Installation Notice Tightening Torque 40 Nm + 90° Make sure that the upper and lower bearing shells do not change each other. Coat the bearing shell with engine oil.
  • Page 437 1B2-58 M161 ENGINE MECHANICAL Inspection 1. If the length ‘L’ of the crankshaft bearing cap bolt exceeds 63.8mm, replace it. 2. Make sure the crankshaft bearing cap is properly seated on the cylinder block (arrows). 3. Measure and record the inner diameter of the crankshaft bearing.
  • Page 438 M161 ENGINE MECHANICAL 1B2-59 Service Data Standard (Crankshaft Main Bearing Gap) Item Measuring Position Gap (mm) Main Bearing Journal Static condition :0.015-0.039 ( NO. 1, 5, 7) Radial Dynamic condition: 0.031-0.051 (Consider the expansion 0.011-0.016) Axial 0.010 - 0.254 (Connecting Rod Bearing Gap) Item Measuring Position Gap (mm)

  • Page 439: Flywheel/Driven Plate

    1B2-60 M161 ENGINE MECHANICAL FLYWHEEL/DRIVEN PLATE Preceding Work : Removal of manual or automatic transmission 1 Flywheel Mounting Bolt 3 Driven Plate (A/T) (M10 x 22, 8 pieces) ....1st Step 45 Nm 4 Dowel Pin 2nd Step 90°+10° 5 Flywheel (M/T) 2 Plate Service Data Standard (Stretch Bolt) Nominal Size...
  • Page 440 M161 ENGINE MECHANICAL 1B2-61 Removal & Installation Procedure 1. Unscrew the stretch bolt. Installation Notice 1st step 45 Nm Tightening Torque 2nd step 90°+5° Replace the bolt when the stretch side diameter (d) of the flywheel mounting bolt is less than 8.0mm. For the stretch bolt tightening, keep the socket wrench and Tommy-bar to be 90°...

  • Page 441: Camshaft Adjuster

    1B2-62 M161 ENGINE MECHANICAL CAMSHAFT ADJUSTER 1 Bolt (M6 X 16, 3 pieces) ......9-11 Nm 11 Flange Bolt 2 Cylinder Head Front Cover (M7 X 13, 3 pieces) ....1st Step 20±2 Nm 3 Bolt ............35 Nm 2nd Step 90° ± 5° Rotation Added 4 Armature 12 Flange Shaft 5 Roll Pin...
  • Page 442 M161 ENGINE MECHANICAL 1B2-63 Removal & Installation Procedure 1. Turn the crankshaft and position the n0.1 cylinder piston at ATDC 20° . Notice Turn the crankshaft in the direction of engine rotation. 2. Remove the cylinder head front cover. 3. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
  • Page 443 1B2-64 M161 ENGINE MECHANICAL 7. Unscrew the bolt (3) from the armature (4) and remove the roll pin, and remove the armature. Installation Notice Tightening Torque 35 Nm 8. Unscrew the nut (6) and remove the seal cover (7). Installation Notice Tightening Torque 60 - 70 Nm Notice...

  • Page 444: Camshaft Sprocket Bolt

    M161 ENGINE MECHANICAL 1B2-65 CAMSHAFT SPROCKET BOLT Intake Flange Shaft Bolt 1st step 20 Nm Tightening Torque 2nd step + 90° Notice The sprocket bolts are designed to be used only once, so always replace with new one. C. M7 x 13 Collar Bolt Torx-T30 e.

  • Page 445: Camshaft

    1B2-66 M161 ENGINE MECHANICAL CAMSHAFT Preceding Work : Removal of cylinder head cover Removal of camshaft adjust actuator and cylinder head front cover 1 Bolt (M7 X 13, 3 pieces) ..1st Step 18-22 Nm 4b Camshaft Adjuster and Camshaft Sprocket (E23) 2nd Step 90°+ 5°...
  • Page 446 M161 ENGINE MECHANICAL 1B2-67 Tools Required 000 589 01 10 00 Box Wrench Insert 104 589 01 01 00 Spanner Removal & Installation Procedure 1. Turn the crankshaft and position the no.1 cylinder piston at ATDC20° . 2. Put the alignment marks (arrows) on the camshaft sprocket and the timing chain.
  • Page 447 1B2-68 M161 ENGINE MECHANICAL 7. Remove the bearing cap, and remove the intake and the exhaust camshaft. Installation Notice Tightening Torque 22.5 - 27.5 Nm Notice Check the numbers on the bearing cap not to be miked 8. Apply the engine oil on the valve tappet and camshaft bearing.

  • Page 448: Camshaft Timing Position

    M161 ENGINE MECHANICAL 1-1B-69 CAMSHAFT TIMING POSITION Preceding Work : Removal of cylinder head cover Removal of cylinder head front cover 1 Insert Pin ( φ 6.5mm, Special Tool) 5 Exhaust Camshaft Sprocket 2 Intake Camshaft Sprocket 6 Bolt (M7 X 13, 3 pieces) ..1st step 20 ± 2 Nm 3 Camshaft Bearing Cap 2nd step 90°...
  • Page 449 1B2-70 M161 ENGINE MECHANICAL Tools Required 104 589 01 01 00 Spanner 111 589 03 15 00 Insert Pin Inspection Procedure 1. Position the NO.1 cylinder piston to ATDC 20° by turning the crankshaft Notice When the ATDC 20° mark on vibration damper is aligned with timing gear case cover, the intake and exhaust cam of cylinder will make the slope to the center and will face up.
  • Page 450 M161 ENGINE MECHANICAL 1B2-71 Adjustment Procedure 1. Position the NO.1 cylinder to ATDC 20° . 2. Remove the chain tensioner. 3. Remove the exhaust camshaft sprocket. 4. Adjust the timing position with inserting the insert pin (f6.5mm, 111 589 03 15 00) into the NO.1 and NO.4 camshaft bearing cap hole and flange hole while rotating the camshaft by using wrench (104 589 01 01 00).

  • Page 451: Valve Spring

    1B2-72 M161 ENGINE MECHANICAL VALVE SPRING Preceding Work : Removal of camshaft Removal of spark plug 1 Valve Tappet Assembly 7 Connecting Hose 2 Valve Cotter 8 Thrust Piece 3 Upper Retainer 9 Slide 4 Valve Spring ..Check, Replace if necessary 10 Adjust Bolt 5 Valve Stem Seal 11 Lever Pusher...
  • Page 452 M161 ENGINE MECHANICAL 1B2-73 Tools Required 111 589 01 59 00 Supporting Bar 111 589 18 61 00 Lever Pusher 111 589 25 63 00 Thrust Piece 116 589 06 63 00 Magnetic Finger Removal & Installation Procedure 1. Place the supporting bar (12) and the slide (9) at the camshaft bearing cap (Nos 1 &...
  • Page 453 1B2-74 M161 ENGINE MECHANICAL 8. Install the lever pusher (11) and the thrust piece (8) to the slide (9). Lever Pusher 111 589 18 61 00 9. Mount the thrust piece (8) vertically to the valve spring retainer (3). 10. Make the thrust piece (8) and the slide (9) perpendicular to each other.
  • Page 454 M161 ENGINE MECHANICAL 1B2-75 Test (Upper and Lower Valve Tappet and Valve Cotter) l Upper Valve Spring Retainer Size (mm) 12.3 l Lower Valve Spring Retainer Thickness (mm) 0.8 - 1.0 l Valve Cotter Size (mm) 9.2 - 9.8...

  • Page 455: Valve Stem Seal

    1B2-76 M161 ENGINE MECHANICAL VALVE STEM SEAL Preceding Work : Removal of valve spring 1 Drift (Special Tool) 2 Valve Stem Seal 3 Protective Sleeve Tools Required 104 589 00 37 00 Pliers 119 589 00 43 00 Drift Replacement Procedure 1.

  • Page 456: Chain Tensioner

    M161 ENGINE MECHANICAL 1B2-77 CHAIN TENSIONER 1 Screw Plug ..........40 Nm 5 Snap Ring 2 Seal 6 Thrust Pin 3 Filler Pin 7 Chain Tensioner Housing ..... 72-88 Nm 4 Compression Spring 8 Seal Removal Procedure 1. Position the number 1 cylinder to ATDC 20° . Notice Remove the oil filler cap at adjustment position, and check whether the intake camshaft cam’s lobe (arrow) stays in the...
  • Page 457 1B2-78 M161 ENGINE MECHANICAL 4. Carefully unscrew the screw plug (1), and remove the seal (2). Notice l For the removal of screw plug, be careful that it can be jumped out due to the force of compression spring. l Remove the screw plug only when the seal and compression spring are damaged.
  • Page 458 M161 ENGINE MECHANICAL 1B2-79 4. Lightly apply the grease to the seal (2) and install the screw plug (1). Installation Notice Tightening Torque 40 Nm 5. Check for leaks by operating the engine. Sectional View 1 Screw Plug 13 Chain Tensioner Housing 2 Ball (Nonreturn Valve) 14 Seal 3 Compression Spring...

  • Page 459: Timing Chain

    1B2-80 M161 ENGINE MECHANICAL TIMING CHAIN Preceding Work : Removal of cylinder head cover Removal of spark plug 1 Pin 5 Link 2 New Timing Chain 6 Center Plate 3 Timing Chain (Used) 7 Outer Plate 4 Wedge...
  • Page 460 M161 ENGINE MECHANICAL 1B2-81 Tools Required 000 589 58 43 00 Chain Assembly 103 589 01 63 00 Rivet Set 001 589 72 21 00 Torque Wrench Replacement Procedure 1. Position the NO.1 cylinder to ATDC 20° . 2. Insert the pin to the intake and exhaust camshaft flange. 3.
  • Page 461 1B2-82 M161 ENGINE MECHANICAL 6. Remove the outer plate (7) with the screw driver and remove the link (5). 7. Connect the new timing chain (2) to the used timing chain (3) with the link (5), center plate (6, thickness 1.6mm), and the outer plate (7).
  • Page 462 M161 ENGINE MECHANICAL 1B2-83 12. Place the outer plate (7, thickness 1.2mm) inside the thrust piece (b). 13. Install the assembly tool above the link and tighten the spindle (c) until a block is felt. 14. Place the assembly tool. 15.
  • Page 463 1B2-84 M161 ENGINE MECHANICAL 17. Rivet the link pin. Check the condition and it again if necessary. 18. Install the chain tensioner. Installation Notice Screw Plug 40 Nm Tightening Torque Tensioner Assembly 72 - 88 Nm 19. Check the camshaft timing position.

  • Page 464: Tensioning Rail

    M161 ENGINE MECHANICAL 1B2-85 TENSIONING RAIL Preceding Work : Removal of cylinder head 1 Sliding Rail Pin 3 Timing Gear Case Cover 2 Sliding Rail Removal & Installation Procedure 1. Remove the timing gear case cover (3). Notice Be careful not to damage the gasket. 2.

  • Page 465: Cylinder Head Guide Rail

    1B2-86 M161 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Bolt (M6 X 45, 2 pieces) ....9-11 Nm 2 Guide Rail Removal & Installation Procedure 1. Position the number 1 cylinder to ATDC20° guide rail. 2.

  • Page 466: Crankcase Guide Rail

    M161 ENGINE MECHANICAL 1B2-87 CRANKCASE GUIDE RAIL Preceding Work : Removal of timing gear case cover 1 Guide Rail Pin 3 Timing Gear Case Cover 2 Guide Rail Removal & Installation Procedure 1. Remove the timing gear case cover (3). Notice Be careful not to damage the gasket when removing/ installing the timing gear case cover.

  • Page 467: Crankshaft Sprocket

    1B2-88 M161 ENGINE MECHANICAL CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of tensioning rail Removal of crank case guide rail Removal of cylinder head 1 Oil Pump Chain Tensioner 6 Bolt (M8 x 20, 1 piece) / Washer ..29-35 Nm 2 Oil Pump Chain Spring 7 Oil Pump Sprocket 3 Oil Pump Chain Bushing (Pin)
  • Page 468 M161 ENGINE MECHANICAL 1B2-89 Tools Required 615 589 01 33 00 Caulking Bolt Removal & Installation Procedure 1. Put the assembly mark at the crankshaft sprocket (4) and the timing chain (10) with the paint (arrow). Installation Notice Align the assembly marks on cranshaft sprocket and timing chain.

  • Page 469: Piston

    1B2-90 M161 ENGINE MECHANICAL PISTON Preceding Work : Removal of engine Removal of cylinder head Removal of oil pan Removal of oil pump Removal of baffle plate 1 Connecting Rod Bearing Cap 4 Piston 2 Connecting Rod 5 Snap Ring 3 Connecting Rod Bolt 6 Piston Pin (M9 x 52, 8 pieces) ......1st step 40 Nm...
  • Page 470 M161 ENGINE MECHANICAL 1B2-91 Tools Required 001 589 72 21 00 Torqued Wrench 000 589 04 14 00 Clamping Strap Removal Procedure 1. Unscrew the connecting rod bolt (3) and remove the cap. 2. Remove the connecting rod and the piston upward. Notice Make sure that the bearing cap and shell are not changed each other.
  • Page 471 1B2-92 M161 ENGINE MECHANICAL 1. Check the piston ring gap and apply the engine oil to the piston pin and the connecting rod bushing. 2. Connect the piston and the connecting rod by pressing in the piston pin (6) and install the snap ring to the groove. 3.

  • Page 472: Connecting Rod

    M161 ENGINE MECHANICAL 1B2-93 CONNECTING ROD Preceding Work : Removal of piston 1 Connecting Rod Bushing 2 Oil Gallery 3 Balance Weight 4 Connecting Rod Bolt (M9 x 52, 8 pieces) ....1st step 40 Nm 2nd step 90° 5 Fit Sleeve 6 Upper Connecting Rod Bearing 7 Lower Connecting Rod Bearing 8 BearingShell Lug...
  • Page 473 1B2-94 M161 ENGINE MECHANICAL Inspection 1. Measure the basic bore of the connecting rod bearing. Notice If the basic bore exceeds the value of 51.614mm, replace the bearing or check the connecting rod. 2. Check connecting rod bolts. Length When New (L) 51.7 - 52 mm Max.

  • Page 474: Piston Ring

    M161 ENGINE MECHANICAL 1B2-95 PISTON RING Preceding Work : Removal of piston 1 Piston Compression Ring (Top Ring) 2 Piston Compression Ring (2nd Ring) 3 Piston Oil Ring 5 Spacer 6 Side Rail Tools Required 000 589 51 37 00 Clamping Strap Replacement Procedure 1.
  • Page 475 1B2-96 M161 ENGINE MECHANICAL 2. Remove the piston ring with a pliers. Clamping Strap 000 589 51 37 00 3. For installation, position the piston ring to be the ‘TOP’ mark on the piston ring upward and arrange the piston ring ends to be 120°...

  • Page 476: Oil Pan

    M161 ENGINE MECHANICAL 1B2-97 OIL PAN 1 Bolt 5 Bolt 2 Bolt 6 Oil Pan 3 Bolt 7 Gasket 4 Bolt 1. Remove the drain plug and drain the oil completely. 2. Unscrew the bolts and remove the oil pan and gasket. Notice Arrange the bolts according to each size.
  • Page 477 1B2-98 M161 ENGINE MECHANICAL Oil Circulation 1 Oil Strainer 16 Oil Supply (To Chain Tensioner) 2 Oil Pump 17 Camshaft 3 Oil Pan 18 Cam Bearing 4 Oil Non-Return Valve 19 Valve 5 Oil Filter 20 Oil Gallery (Supply Oil to Intake Tappet) 6 Oil Filter Bypass Valve 21 Oil Gallery (Supply Oil to Exhaust Tappet) 7 Main Oil Gallery...

  • Page 478: Engine Oil And Oil Filter Element

    M161 ENGINE MECHANICAL 1B2-99 ENGINE OIL AND OIL FILTER ELEMENT 1 Oil Filter Cover .......... 25 Nm 4 Oil Drain Plug 2 O-ring ............ Replace 5 Oil Filter Bypass Valve 3 Oil Filter Element 6 Oil Filter Cap...
  • Page 479 1B2-100 M161 ENGINE MECHANICAL Tools Required 103 589 02 09 00 Oil Filter Socket Wrench Replacement Procedure 1. Install the socket wrench”7” (special tool : 103 589 02 09 00) on the oil filter cover (2). Notice Make the screw cover removable by tightening the bolt at the side of the socket wrench (special tool).

  • Page 480: Oil Pump

    M161 ENGINE MECHANICAL 1B2-101 OIL PUMP Preceding Work : Removal of oil pan 1 Bolt (M8 X 35, 3 piece) ....22.5-27.5 Nm 6 Washer 2 Oil Pump 7 Sprocket (Oil Pump Drive) 3 Oil Strainer Assembly 8 Chain (Oil Pump Drive) 4 Bolt (M6 X 12, 2 pieces) ......
  • Page 481 1B2-102 M161 ENGINE MECHANICAL Removal & Installation Procedure 1. Unscrew the bolt (6) from the oil pump drive sprocket and separate the oil pump drive chain. Installation Notice Tightening Torque 29 - 35 Nm 2. Unscrew the bolts (4,5) and remove the oil strainer assembly (3).

  • Page 482: Oil Pressure Relief Valve

    M161 ENGINE MECHANICAL 1B2-103 OIL PRESSURE RELIEF VALVE Preceding Work : Removal of oil pan 1 Screw Plug ..........50 Nm 3 Guide Pin 2 Compression Spring 4 Piston Removal & Installation Procedure 1. Remove the screw plug (1). Installation Notice Tightening Torque 50 Nm 2.

  • Page 483: Oil Non-Return Valve

    1B2-104 M161 ENGINE MECHANICAL OIL NON-RETURN VALVE Preceding Work : Removal of timing gear case cover 1 Oil Non-Return Valve Functions The non-return valve prevents the oil in the chain tensioner from drying up. In other words, it stops oil-returning in order to prevent the oil in the chain tensioner from getting dry.

  • Page 484: Oil Dipstick Guide Tube

    M161 ENGINE MECHANICAL 1B2-105 OIL DIPSTICK GUIDE TUBE 1 Oil Dipstick Level Gauge 4 Bolt (M6 X 16, 1 piece)......9-11 Nm 2 Oil Dipstick Guide Tube 5 Clamp 3 O-ring Removal & Installation Procedure 1. Pull out the oil dipstick level gauge (1). 2.

  • Page 485: Unit Repair

    1B2-106 M161 ENGINE MECHANICAL UNIT REPAIR CORE PLUGS IN CRANKCASE Preceding Work : Draining of the coolant 1 Core Plug..........Replace...
  • Page 486 M161 ENGINE MECHANICAL 1B2-107 Tools Required 102 589 00 15 00 Drift Replacement Procedure 1. Remove the intake and exhaust manifolds. 2. Pull back the core plug until the end of one side comes out using the screw driver. 3. Pull out the plug carefully using a pliers. 4.

  • Page 487: Cylinder Bore

    1B2-108 M161 ENGINE MECHANICAL CYLINDER BORE Group Code Letter and Cylinder Bore Size Engine Group Code Letter of Cylinder Piston Type to be Used Cylinder Bore Size (mm) A or X φ 90.906 - φ 90.912 A, X or B φ...
  • Page 488 M161 ENGINE MECHANICAL 1B2-109 Type Group Code Letter Cylinder Bore Size (mm) φ 89.900 - φ 90.906 Standard Size φ 89.906 - φ 89.912 E20 : φ 89.9 E23 : φ 90.9 φ 89.912 - φ 89.918 1st Repair Size φ...

  • Page 489: Crankcase Mating Surface

    1B2-110 M161 ENGINE MECHANICAL CRANKCASE MATING SURFACE Service Data Standard Height of the Crankcase “H” (When New) 289.35 - 289.45mm Minimum Height After Milling 289.05mm Flatness Crankcase Upper Mating Surface 0.03mm Crankcase Lower Mating Surface 0.04mm Permissible Deviation of Parallelism of the Axial Direction 0.1mm Upper to Lower Mating Surface...
  • Page 490 M161 ENGINE MECHANICAL 1B2-111 Chamfering Procedure 1. Chamfer angle : 75° 2. Polish the lower chamfered area evenly with a grinder after finishing the chamfering with a suitable tool (e.g., hand milling cutter).

  • Page 491: Cylinder Head Mating Surface

    1B2-112 M161 ENGINE MECHANICAL CYLINDER HEAD MATING SURFACE Preceding Work : Removal of valves Service Data Standard Overall Height of Cylinder Head 135.9 - 136.0 mm Minimum Height After Machining 135.5 mm Flatness Axial Direction 0.08 mm Transverse Direction 0.0 mm Distance ‘T’...
  • Page 492 M161 ENGINE MECHANICAL 1B2-113 Measurement of Mating Surface 1. Measure the height (H) of the cylinder head (refer to Service data standard). 2. Check the mating surface of the cylinder head. 3. Mill the sharp edge of the combustion chamber. 4.
  • Page 493 SECTION 1B3 OM600 ENGINE MECHANICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 494: Specifications

    1B3-2 OM600 ENGINE MECHANICAL SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Engine Assembly N• • • • • m Application 28 - 47 Skid Plate Bolt Drain Plug Bolt Coolong Fan Shroud Bolt 3 - 7 8 - 18 Control Linkage Nut 20 - 34 Clutch Linkage Cylinder Nut Exhaust Manifold Bolt 70 - 80...
  • Page 495 OM600 ENGINE MECHANICAL 1B3-3 Cylinder Head N• • • • • m Application Camshaft Bearing Cap Bolt Camshaft Sprocket Bolt 25 / 90° Exhaust Pipe Bolt& Nut Chain Tensioner Injection Nozzle Intake Manifold Not Injection Nozzle Pipe Not Oil Dipstick Tube Bolt Screw Plug M18 x 15 Cam Support &...

  • Page 496: Special Tools

    1B3-4 OM600 ENGINE MECHANICAL SPECIAL TOOLS SPECIAL TOOLS TABLE 603 589 00 09 00 603 589 00 40 00 Serration Wrench Counter Holder 657 589 03 63 00 000 589 77 03 00 Sliding Hammer Box Wrench Insert 601 589 00 66 00 602 589 00 40 00 Counter Sink Engine Lock...
  • Page 497 OM600 ENGINE MECHANICAL 1B3-5 SPECIAL TOOLS TABLE (Cont’d) 116 589 03 07 00 115 589 34 63 00 T Type Socket Wrench 601 589 00 10 00 Cylinder Head Bolt 102 601 589 00 25 00 102 589 12 15 00 φ...
  • Page 498 1B3-6 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 08 15 00 103 589 00 33 00 Drift Puller 001 589 53 21 00 601 589 03 14 00 Dial Gauge Sleeve 601 589 07 21 00 601 589 03 43 00 Depth Gauge Oil Seal Assembler 667 589 01 21 00...
  • Page 499 OM600 ENGINE MECHANICAL 1B3-7 SPECIAL TOOLS TABLE (Cont’d) 363 589 02 21 00 116 589 07 15 00 Dial Gauge Holder Drift 000 589 33 33 00 000 589 04 14 00 Counter Support Tensioning Strap 000 589 25 33 00 102 589 03 40 00 Internal Extractor Magnetic Bar...
  • Page 500 1B3-8 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 601 589 02 59 00 667 584 02 63 00 Supporting Bridge Supporting Bar 667 589 00 31 00 104 589 00 37 00 Press Lever Pliers 116 589 06 63 00 601 589 02 43 00 Magnetic Finger Drift...
  • Page 501 OM600 ENGINE MECHANICAL 1B3-9 SPECIAL TOOLS TABLE (Cont’d) 601 589 02 23 00 601 589 05 15 00 Go/No Go Gauge Drift (for Intake) 105 589 03 15 00 601 589 06 15 00 Drift (for Intake) Drift (for Exhaust) 103 589 02 15 00 000 589 10 53 00 Drift (for Exhaust)
  • Page 502 1B3-10 OM600 ENGINE MECHANICAL SPECIAL TOOLS TABLE (Cont’d) 001 589 32 21 00 124 589 15 21 00 Dial Gauge Tester 001 589 53 21 00 667 589 02 21 00 Dial Gauge TDC Pulse Generator 000 589 58 43 00 501 589 73 21 00 Chain Assembling Vacuum Pump...
  • Page 503 OM600 ENGINE MECHANICAL 1B3-11 SPECIAL TOOLS TABLE (Cont’d) 000 589 14 21 00 601 589 00 08 00 Tester Flange 001 589 65 09 00 116 589 02 34 00 Serration Wrench Thread Bolt 000 589 00 68 00 667 589 04 63 00 Cleaning Set Retaining Plate 601 589 05 21 00...

  • Page 504: Maintenance And Repair

    1B3-12 OM600 ENGINE MECHANICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ENGINE ASSEMBLY...
  • Page 505 OM600 ENGINE MECHANICAL 1B3-13 Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the hood. 3. Remove the skid plate. Installation Notice Tightening Torque 28 - 47 Nm 4. Remove the radiator drain cock and drain the coolant. Notice Open the coolant reservoir tank cap.
  • Page 506 1B3-14 OM600 ENGINE MECHANICAL 8. Disconnect the upper coolant hose from the radiator. 9. Loosen the bolt and remove the coolant pipe and cooling fan shroud. Tightening Torque 3 -7 Nm 10. Remove the hoses (air intake to intercooler, intercooler to intake duct).
  • Page 507 OM600 ENGINE MECHANICAL 1B3-15 12. Remove the hose(air cleaner to turbocharger) with blow by hose. 13. Disconnect the air cleaner intake hose and remove the air cleaner cover and element. 14. Disconnect the coolant hose from the water inlet. 15. Remove the air-conditioner lines from the compressor. Notice Evacuate the refrigerant before removal.
  • Page 508 1B3-16 OM600 ENGINE MECHANICAL 16. Remove the power steering pump lines. Notice Completely drain the fluid. 17. Disconnect the fuel feed line with prefilter from the feed pump on injection pump. 18. Vehicle with automatic transmission. Remove the hydraulic lines (19, 20) from oil cooler (2). 19.
  • Page 509 OM600 ENGINE MECHANICAL 1B3-17 21. Remove the fuel lines from the fuel filter and cover the filter with plug. 22. Disconnect the brake booster hose from vacuum pump. 23. Disconnect the other vacuum lines. 24. Disconnect the ground cable. 25. Disconnect the alternator wires. 26.
  • Page 510 1B3-18 OM600 ENGINE MECHANICAL 27. Disconnect the preheating time relay sensor plug. 28. Disconnect the coolant temperature sensor plug. 29. Disconnect the accelerator cable from the control linkage. Installation Notice Tightening Torque 8 - 18 Nm 30. Loosen the connection of control pressure cable (an arrow) used in auto transmission.
  • Page 511 OM600 ENGINE MECHANICAL 1B3-19 31. Separate the exhaust pipe flange from the turbo charger. Installation Notice Tightening Torque 30 Nm 32. Loosen the installing bolt of clutch release cylinder and remove the clutch release cylinder. Installation Notice Tightening Torque 20 - 34 Nm 33.
  • Page 512 1B3-20 OM600 ENGINE MECHANICAL 37. Loosen the engine mounting bracket nut. Installation Notice Tightening Torque 50 - 75 Nm 38. Remove the engine assembly from the vehicle by using a hoist or crane. 39. Installation should follow the removal procedure in the reverse order.

  • Page 513: Poly V-Belt

    OM600 ENGINE MECHANICAL 1B3-21 POLY V-BELT 1 Nut ............. 23Nm 4 Spring 2 Tensioning Lever 5 Tensioning Lever 3 Bolt 6 Poly V-Belt...
  • Page 514 1B3-22 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. 2. Push the tensioning lever in direction of arrow with a rod (F12 ´ 180mm) and pull out the bolt to the rear. 3. Push back the tensioning lever (arrow direction) to release the spring tension and remove the belt.

  • Page 515: Tensioning Device

    OM600 ENGINE MECHANICAL 1B3-23 TENSIONING DEVICE Preceding Work : Removal of cooling fan 1 Bolt ............21Nm 10 Tensioning Pulley 2 Damper 11 Socket Bolt ..........29Nm 3 Nut ............. 21Nm 12 Closing Cover 4 Tensioning Lever 13 Washer 5 Guide Rail Pin 14 Tensioning Lever 6 Bolt 15 Fit Bolt .............
  • Page 516 1B3-24 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the nut. Installation Notice Tightening Torque 10 Nm 2. Push the tensioning lever in direction of arrow with a rod ( F12 ´ 180mm ) and push out the bolt to the rear. 3.
  • Page 517 OM600 ENGINE MECHANICAL 1B3-25 6. Pull off the tensioning lever (4) from guide rail pin. 7. Remove the spring (17). Installation Notice Insert spring (17) with color coding (blue/violet) facing up. 8. Pry off the closing cover (12) and remove the socket bolt (11) and then remove the tensioning pulley (10).

  • Page 518: Poly V-Belt Alignment & Inspection

    1B3-26 OM600 ENGINE MECHANICAL POLY V-BELT ALIGNMENT & INSPECTION Without Air Conditioner With Air Conditioner...
  • Page 519 OM600 ENGINE MECHANICAL 1B3-27 Inspection Procedure Mark poly V-belt at a clearly visible point with chalk. Rotate the engine and check the belt. Notice If one of the following types of damage is found, replace the belt. 1. Rubber lumps in the base of rips. 2.
  • Page 520 1B3-28 OM600 ENGINE MECHANICAL 7. Belt detached from the base of rip. 8. Splits across the rips. 9. Sections of rip torn out. 10. Splits across several rips. 11. Splits across the back.

  • Page 521: Prechamber

    OM600 ENGINE MECHANICAL 1B3-29 PRECHAMBER Preceding Work : Removal of glow plug Removal of fuel injection nozzle 1 Threaded Ring ........130 Nm 3 Cylinder Head 2 Prechamber...
  • Page 522 1B3-30 OM600 ENGINE MECHANICAL Tools Required 603 589 00 09 00 Serration Wrench 667 589 03 63 00 Sliding Hammer Removal & Installation Procedure 1. Using the serration wrench (4), remove the threaded ring (1). Serration Wrench 603 589 00 09 00 2.
  • Page 523 OM600 ENGINE MECHANICAL 1B3-31 Assembly Procedure Notice In case the prechambers are reused, inspect the prechambers thoroughly, if the ball pin by heat and fire is broken, it can not be used. 1. Clean the sealing surface of the prechamber. 2.

  • Page 524: Milling Of Prechamber Sealing Surface

    1B3-32 OM600 ENGINE MECHANICAL MILLING OF PRECHAMBER SEALING SURFACE 1 Drift 4 Counter Sink (Special Tool - 601 589 00 66) 2 Sleeve 5 Cylinder Head 3 Milling Cutter Tools Required 601 589 00 66 00 Counter Sink 667 589 00 23 00 Height Gauge Milling of the Prechamber Sealing Surface Notice The prechamber sealing surface may only be remachined...
  • Page 525 OM600 ENGINE MECHANICAL 1B3-33 1. Remove the injection nozzle. 2. Remove the prechamber. 3. Cover the prechamber bore to avoid any chips dropping into the combustion chamber. 4. Remove the protective sleeve from the countersink and rotate the countersink into the prechamber bore to be machined as far as the stop.
  • Page 526 1B3-34 OM600 ENGINE MECHANICAL 8. Remeasure size ‘X’ and compare it with the first measurement and determine the thickness of spacer ring. Size before machining 25.7 mm Size after machining 25.5 mm The spacer ring should be selected so that it is at least 0.1mm and not more than 0.3mm thicker than the measured on the sealing surface.

  • Page 527: Tdc (Tdc Sensor Bracket) Setting

    OM600 ENGINE MECHANICAL 1B3-35 TDC (TDC SENSOR BRACKET) SETTING Preceding Work : Removal of No.1 cylinder prechamber 1 Measuring Device 2 Dial Gauge 3 Cylinder Head 4 Piston ..........Set at TDC Tools Service 001 589 32 21 00 Dial Gauge 601 589 07 21 00 Deqth Gauge 667 589 01 21 00 Fixing Device Notice...
  • Page 528 1B3-36 OM600 ENGINE MECHANICAL Setting (with cylinder head installed) 1. Remove the prechamber of No. 1 cylinder. 2. Position the piston of No.1 cylinder at BTDC 10. 3. Install the measuring device into the prechamber bore and position the dial gauge with a preload of 5mm. Dial Gauge 001 589 53 21 00 Depth Gauge 601 589 07 21 00 4.

  • Page 529: Cylinder Head

    OM600 ENGINE MECHANICAL 1B3-37 CYLINDER HEAD 1 Fuel Injection Pipe ........18Nm 21 Camshaft Drive Sprocket ....... Replace 2 Cylinder Head 22 Washer 3 Gasket ........... Replace 23 Bolt(12-Sided)........25Nm + 90° 4 Bolt ............25Nm 24 Sliding Rail 5 Washer 25 Sliding Rail Pin 6 Clamp 26 Sliding Rail Pin...
  • Page 530 1B3-38 OM600 ENGINE MECHANICAL Tightening Torque stage1 10 Nm Cylinder Bolts (12-sided socket head) (Engine cold) stage2 35 Nm stage3 180° M8 Cylinder Head Bolts 25 Nm Tools Required 000 589 77 03 00 Box Wrench Insert 001 589 65 09 00 Socket Wrench Insert 102 589 03 40 00 Magnetic Bar 116 589 02 34 00 Threaded Pin 116 589 03 07 00 T Type Socket Wrench...
  • Page 531 OM600 ENGINE MECHANICAL 1B3-39 Notice The cylinder head may only be removed when the engine has cooled down. The cylinder head is removed together with the exhaust manifold. As the cylinder head bolts undergo a permanent tightening. They require to be replaced if they exceed the maximum lengthes indicated in the table.
  • Page 532 1B3-40 OM600 ENGINE MECHANICAL Disassembly Procedure 1. Completely drain the coolant from the radiator and cylinder block. 2. Remove the cooling fan shroud. 3. Hold the fan with counter holder and remove the bolt and then remove the cooling fan. Notice Keep the fan in vertical position.
  • Page 533 OM600 ENGINE MECHANICAL 1B3-41 8. Remove the air cleaner cover and element and then remove the air cleaner housing. 9. Remove the oil return hose and plug. Notice Cover them to prevent chips from coming into. 10. Unscrew the EGR pipe mounting bolts onto the exhaust manifold.
  • Page 534 1B3-42 OM600 ENGINE MECHANICAL 14. Pull out the accelerator control linkage. 15. Remove the fuel injection line(1) from the fuel injection nozzle(12). Box Wrench Inset 000 589 77 03 00 16. Remove the fuel injection line from the fuel injection pump. Box Wrench Insert 000 589 77 03 00 17.
  • Page 535 OM600 ENGINE MECHANICAL 1B3-43 18. Disconnect the booster hose connected to intake manifold. 19. Remove the intake manifold and gasket. 20. Remove the cylinder head cover and gasket with the blow- by gas hose. 21. Disconnect the glow plug cables.
  • Page 536 1B3-44 OM600 ENGINE MECHANICAL 22. Remove the cable channel. 23. Disconnect the cables from the glow plug sensor and coolant temperature sensor. 24. Remove the heater pipe bracket from the oil filter. 25. Pry off the clamp and push the heater feed pipe forward and then pull out the pipe.
  • Page 537 OM600 ENGINE MECHANICAL 1B3-45 26. Disconnect the fuel lines from the fuel filter. 27. Disconnect the fuel lines from the injection pump. 28. Remove the fuel filter(35). 29. Remove the fuel injection nozzle(12) and nozzle washer(11). Socket Wrench Insert 001 589 65 09 00...
  • Page 538 1B3-46 OM600 ENGINE MECHANICAL 30. Rotate the crankshaft and set the no.1 cylinder at TDC. Notice Do not rotate the crankshaft to the opposite direction of engine revolution. 31. Place alignment marks on the camshaft gear and timing chain. 32. Ensure that the camshaft and the bearing cap marking are aligned.
  • Page 539 OM600 ENGINE MECHANICAL 1B3-47 34. Remove the turbocharger. 35. Remove the exhaust manifold and gasket. 36. Remove the chain tensioner and seal. 37. Remove the bolt and separate the drive sprocket(21). Notice During removal, be careful not to drop the sprocket and chain into the timing case.
  • Page 540 1B3-48 OM600 ENGINE MECHANICAL 38. Remove the camshaft bearing cap bolts according to the numerical sequence. Notice Remove the No.1 bolts first and then remove the No. 2 bolts. Do not remove the bolts at a time completely but remove them step by step evenly or camshaft can be seriously damaged.
  • Page 541 OM600 ENGINE MECHANICAL 1B3-49 41. Remove the bolt(32). 42. Separate the spring and pull out the tensioning lever(31). 43. Pry off the closing cover. Remove the bolt and then remove the idle pulley. 44. Using the sliding hammer(36) and the threaded pin(37), pull out the sliding rail pins(25, 26) and remove the sliding rail(24).
  • Page 542 1B3-50 OM600 ENGINE MECHANICAL 45. Remove the vacuum line from the vacuum pump. 46. Disconnect the vacuum pipe from thermo valve. 47. Remove the socket bolts(13) of the chain box. T Type Socket Wrench 116 589 03 07 00 Magnetic Bar 102 589 03 40 00 48.
  • Page 543 OM600 ENGINE MECHANICAL 1B3-51 OM 661LA 49. Remove the cylinder head(2) and gasket(3).
  • Page 544 1B3-52 OM600 ENGINE MECHANICAL Assembly Procedure 1. Replace the cylinder head gasket. 2. Install the cylinder head onto the crankcase. Notice Align the cylinder head holes with the guide pins. 3. Measure the length(L) of cylinder head bolts. Notice If the max. length is exceeded, replace the bolts. Length(L) Thread Dia.
  • Page 545 OM600 ENGINE MECHANICAL 1B3-53 5. Tighten the cylinder head bolts to specified torque and torque angle. Stage 1 15 Nm Stage 2 35 Nm Torque angle 90° Wait for 10 minutes Torque angle 90° OM 662LA OM 661LA 6. Install the socket bolts in the chain box. Tightening Torque 25 Nm 7.
  • Page 546 1B3-54 OM600 ENGINE MECHANICAL 8. Connect the vacuum lines to the vacuum pump. 9. Install the fuel filter and connect the pipe. Tightening Torque 25 Nm Notice Be careful not to be confused the connections and hoses. 10. Connect the fuel pipe to the injection pump. 11.
  • Page 547 OM600 ENGINE MECHANICAL 1B3-55 12. Install the idle pulley and fit the closing cover. Tightening Torque 25 Nm 13. Insert the tensioning lever(31) and install the spring. 14. Install the damper. Tightening Torque 23 Nm Notice Insert the tensioning lever bolts onto the mounting hole. 15.
  • Page 548 1B3-56 OM600 ENGINE MECHANICAL 17. Coat the camshaft with oil and install the camshaft on the cylinder head to be TDC mark(arrow) upward. 18. Measure the axial end play of the camshaft. End Play 0.06 - 0.21mm Notice If out of standard, adjust it with the proper thickness of locking washer.
  • Page 549 OM600 ENGINE MECHANICAL 1B3-57 21. Position the camshaft on marking and install the camshaft sprocket. Notice Align the alignment marks on the chain and sprocket. 22. Check the TDC position of the crankshaft. 23. Install the camshaft sprocket bolt. Tightening Torque 25 Nm + 90°...
  • Page 550 1B3-58 OM600 ENGINE MECHANICAL Notice Measure the max. length ‘L’ and replace the bolt if it exceeds 53.6mm. 24. Install the exhaust manifold and gasket. 25. Install the turbocharger. 26. Install the exhaust pipe onto the turbocharger. Tightening Torque 25 Nm...
  • Page 551 OM600 ENGINE MECHANICAL 1B3-59 27. Replace the seal and then install the chain tensioner. Tightening Torque 80 Nm 28. Remove the engine lock. 29. Insert the nozzle washer into the hole to face round part downward. 30. Install the fuel injection nozzle. Tightening Torque 40 Nm 31.
  • Page 552 1B3-60 OM600 ENGINE MECHANICAL 33. Replace the gasket and install the cylinder head cover. Tightening Torque 10 Nm 34. Install the blow-by hose. 35. Connect the wires to the coolant temperature sensor and the glow plug sensor. 36. Replace the intake manifold gasket. 37.
  • Page 553 OM600 ENGINE MECHANICAL 1B3-61 38. Replace the O-ring of heater feed pipe and install it to the cylinder head. Notice For installation, clean the hole. 39. Install the bracket of heater feed pipe to the oil filter. 40. Install the fuel pipe and the accelerator control linkage. 41.
  • Page 554 1B3-62 OM600 ENGINE MECHANICAL 42. Install the poly V-belt. Notice Be careful not to contaminate the belt. 43. By inserting a rod into the tensioning lever upper hole and pulling the rod, install the bolt and then tighten the nut. Tightening Torque 23 Nm 44.

  • Page 555: Timing Case Cover

    OM600 ENGINE MECHANICAL 1B3-63 TIMING CASE COVER Preceding Work : Removal of the cooling fan Rmoval of the V-belt tensioning device Removal of the vibration damper and hub Removal of the alternator 1 Bolt ............10Nm 13 Bolt ............32Nm 2 Cylinder Head Cover 14 Timing Case Cover 3 Gasket ...........
  • Page 556 1B3-64 OM600 ENGINE MECHANICAL Tools Required 116 589 03 07 00 Socket Wrench Removal Procedure 1. Remove the fan clutch and cooling fan belt pulley. 2. Drain the engine oil completely. 3. Remove the oil dipstick tube bracket bolts. 4. Remove the crankshaft pulley. 5.
  • Page 557 OM600 ENGINE MECHANICAL 1B3-65 9. Disconnect the pipes of power steering pump and remove the belt pulley. Notice Be careful not to lose the key. 10. Remove the nut and pull out the bolt and then remove the power steering pump. 11.
  • Page 558 1B3-66 OM600 ENGINE MECHANICAL 13. Remove the camshaft. 14. Remove the socket bolts(4) in the chain box. Socket Wrench 115 589 03 07 00 15. Remove the injection pump. Notice See the ‘Removal of fuel injection pump’. 16. Remove the oil pan bolts (8, 9) in the area of the timing case cover (14).
  • Page 559 OM600 ENGINE MECHANICAL 1B3-67 Installation Procedure 1. Thoroughly clean the sealing surface and apply sealant. 2. Install the timing case cover. Tightening Torque 10 Nm Notice Bolts arrangement 1.M6 x 60 2.M6 x 70 3.M6 x 40 3. Tighten the socket bolts in the chain box. Tightening Torque 23 Nm 4.
  • Page 560 1B3-68 OM600 ENGINE MECHANICAL 5. Install the flange, vibration damper and crankshaft belt pulley. Notice Replace front radial seal if necessary. 6. Install the alternator bracket. 25 Nm Front Tightening Torque Side 25 Nm 7. Install the alternator Upper - 25 Nm Tightening Torque Low - 25 Nm 8.
  • Page 561 OM600 ENGINE MECHANICAL 1B3-69 10. Install the fuel filter. Tightening Torque 25 Nm 11. Install the vacuum pump. Tightening Torque 10 Nm 12. Install the power steering pump. Tightening Torque 23 Nm 13. Install the power steering pump pulley. Tightening Torque 32 Nm 14.
  • Page 562 1B3-70 OM600 ENGINE MECHANICAL 15. Install the guide pulley (22) and fit the closing cover (20). Tightening Torque 23 Nm 16. Replace the gasket (3) and install the cylinder head cover (2). Tightening Torque 10 Nm 17. Install the cooling fan belt pulley and fan clutch. 18.

  • Page 563: Crankshaft End Cover

    OM600 ENGINE MECHANICAL 1B3-71 CRANKSHAFT END COVER Preceding Work : Removal of flywheel and driven plate. 1 Crankshaft Flange 4 Radial Seal ..........Replace 2 End Cover......Clean, Loctite 573 5 Dowel Sleeve 3 Bolt ......... 10Nm, Loctite 573 6 Bolt ......... 10Nm, Loctite 573...
  • Page 564 1B3-72 OM600 ENGINE MECHANICAL Tools Required 601 589 03 43 00 Oil Seal Assmbler Removal Procedure 1. Remove the bolts (3, 6) from end cover, By pulling out the lugs (arrow), remove the cover. Notice Be careful not to damage the oil pan gasket. 2.
  • Page 565 OM600 ENGINE MECHANICAL 1B3-73 5. Coat a little oil on the sealing lip of new radial seal and contacting surface. Notice Don’t use grease. 6. Insert the new radial seal (4) onto the oil seal assembler (7). Notice The sealing lip of the repair radial seal is offset to the inside by 3mm to ensure that it does not run in any groove which the standard radial seal may have left on the crankshaft flange.

  • Page 566: Vibration Damper And Hub

    1B3-74 OM600 ENGINE MECHANICAL VIBRATION DAMPER AND HUB Preceding Work : Removal of the cooling fan Removal of poly V-belt 1 Bolt ............10Nm 6 Bolt ..........200Nm + 90° 2 Cooling Fan Belt Pulley 7 Washer 3 Socket Bolt ..........23Nm 8 Straight Pin 4 Crankshaft Belt Pulley 9 Hub...
  • Page 567 OM600 ENGINE MECHANICAL 1B3-75 Sectional View 3 Socket Bolt 9 Hub 4 Crankshaft Belt Pulley 11 Radial Seal 5 Vibration Damper 12 Timing Gear Case Cover 6 Bolt 13 Key 7 Washer 14 Crankshaft Sprocket 8 Straight Pin 16 Crankshaft Notice The mounting position of vibration damper is fixed by straight pin (8).
  • Page 568 1B3-76 OM600 ENGINE MECHANICAL Removal Procedure 1. Remove the starter motor and install the engine lock into the wheel ring gear. Engine Lock 602 589 00 40 00 2. Remove the poly V-belt. 3. Remove the cooling fan. Notice Keep the fan in vertical position. 4.
  • Page 569 OM600 ENGINE MECHANICAL 1B3-77 7. Remove the socket bolts (3) and then remove the belt pulley (4) and vibration damper (5). 8. Remove the washer and bolt. 9. Remove the hub by using a puller. Puller 103 589 00 33 00 10.
  • Page 570 1B3-78 OM600 ENGINE MECHANICAL Installation Procedure 1. Install the hub. Notice Exactly align the woodruff key and the groove of hub (arrow). 2. Install the washer (7) and tighten the bolt (6). Washer (new) : 1 EA 200 Nm + 90° 3.
  • Page 571 OM600 ENGINE MECHANICAL 1B3-79 5. Install the timing sensor bracket. Notice See the ‘TDC setting’. 6. Install the cooling fan pulley. Tightening Torque 10 Nm 7. Install the cooling fan. 8. Install the fan belt. 9. Remove the engine lock.

  • Page 572: Crankshaft Front Radial Seal

    1B3-80 OM600 ENGINE MECHANICAL CRANKSHAFT FRONT RADIAL SEAL 1 Radial Seal 3 Woodruff Key 2 Timing Case Cover Tools Required 601 589 03 14 00 Sleeve...
  • Page 573 OM600 ENGINE MECHANICAL 1B3-81 Notice The sealing lip of the repair radial seal is offset to the inside by 2mm to ensure that is does not run in any groove which the standard radial seal may have left on the crankshaft flange.

  • Page 574: Crankshaft Ball Bearing

    1B3-82 OM600 ENGINE MECHANICAL CRANKSHAFT BALL BEARING 1 Spacer 3 Ball Bearing 2 Cover ......... Replace 4 Bolt ........45Nm + 90° Notice Manual transmission only. Tools Required 000 589 33 33 00 Counter Support 000 589 25 33 00 Internal Extractor Removal &...

  • Page 575: Crankshaft

    OM600 ENGINE MECHANICAL 1B3-83 CRANKSHAFT Preceding Work : Removal of the end cover Removal of the piston Removal of the crankshaft sprocket 3 Crankshaft Main Bearing Shells (Upper) 7 Thrust Bearings (Lower) 4 Trust Bearings (Upper) 8 Crankshaft Bearing Cap 5 Crankshaft 9 Crankshaft Bearing Cap (Fit Bearing) 6 Crankshaft Main Bearing Shells (Lower)
  • Page 576 1B3-84 OM600 ENGINE MECHANICAL Thrust Washer and Bearing Arrangement OM662LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different...
  • Page 577 OM600 ENGINE MECHANICAL 1B3-85 OM661LA Engine 3 Crankshaft Main Bearing Shells (Upper) A Radial Bearings 4 Thrust Bearings (Upper) B Radial and Axial Bearings (Thrust Bearing) 5 Crankshaft 6 Crankshaft Main Bearing Shells (Lower) 7 Thrust Bearings (Lower) Notice The gaps between the bearing shell and bore and between the bearing shell and journal are different each other.
  • Page 578 1B3-86 OM600 ENGINE MECHANICAL Crankshaft Standard and Repair Sizes Crankshaft bearing Thrust bearing Thrust bearing journal diameter journal width journal diameter 24.500 - 24.533 Standard size 50.950 - 57.965 47.950 - 47.965 24.600 - 24.633 24.700 - 24.733 Repair size 1 57.500 - 57.715 47.700 - 47.715 24.900 - 24.933...
  • Page 579 OM600 ENGINE MECHANICAL 1B3-87 Matching Crankshaft Bearing Shells to Basic Bearing Bore in Crankshaft Marking of basic bearing bore in lower Color code of relevant crankshaft parting surface bearing shell Blue or white-blue 1 punch mark or blue Yellow or white-yellow 2 punch marks or yellow Red or white-red 3 punch marks or red...
  • Page 580 1B3-88 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the bearing cab bolt. 2. Remove the bearing caps (8). Notice The crankshaft bearing caps are marked with stamped numbers. Remove the bearing cap from the vibration damper side. 3. Remove the crankshaft bearing caps (9) and lower thrust bearings (7).
  • Page 581 OM600 ENGINE MECHANICAL 1B3-89 8. Thoroughly clean the oil gallery. 9. Select a proper new bearing shells with reference to table. 10. Coat the new bearing shells with oil and insert into the crankcase and into the crankshaft bearing caps. Notice Do not mix up upper and lower crankshaft bearing shells.
  • Page 582 1B3-90 OM600 ENGINE MECHANICAL 15. Measure radial clearance of crankshaft bearing (G). Clearance ‘G’ 0.027 - 0.051mm Notice If ‘G’ is out of standard, replace the bearing shells and adjust the radial clearance of crankshaft bearing. Example) Measured value ‘E’ = 57.700mm Measured value ‘F’...
  • Page 583 OM600 ENGINE MECHANICAL 1B3-91 Notice If the max. length of bolts(L) exceed 63.8mm, replace them. 19. Coat the new crankshaft with engine oil and place it on the crankcase. 20. Install the crankshaft bearing caps according to marking and tighten the bolts. Tightening Torque 55 Nm + 90°...
  • Page 584 1B3-92 OM600 ENGINE MECHANICAL 24. Insert the new connecting rod bearing shells into the connecting rod and connecting rod bearing cap and tighten the 12-sided stretch bolts (11). Tightening Torque 40 Nm + 90° 25. Measure inner diameter of connecting rod bearing. 26.

  • Page 585: Flywheel

    OM600 ENGINE MECHANICAL 1B3-93 FLYWHEEL Preceding Work : Removal of the transmission Removal of the clutch 1 Oil Pan 4 12-Sided Stretch Bolt ....Check, 45Nm + 90° 2 Straight Pin 5 Drive Plate (Automatic Transmission) 3 Flywheel 6 Flywheel (Automatic Transmission)
  • Page 586 1B3-94 OM600 ENGINE MECHANICAL Manual transmission flywheel OM662LA OM661LA Automatic transmission flywheel...
  • Page 587 OM600 ENGINE MECHANICAL 1B3-95 Tools Required 602 589 00 40 00 Engine Lock Removal & Installation Procedure 1. Install the engine lock. Engine Lock 602 589 02 40 00 2. Remove the 12-sided stretch bolts (4). Installation Notice Tightening Torque 45 Nm + 90°...
  • Page 588 1B3-96 OM600 ENGINE MECHANICAL 4. Remove the flywheel (6) and driven plate (5), if equipped with automatic transmission. Installation Notice Correctly align the position of dowel pin (2). 5. Installation should follow the removal procedure in the reverse order.

  • Page 589: Machining Of Flywheel

    OM600 ENGINE MECHANICAL 1B3-97 MACHINING OF FLYWHEEL 1 Flywheel OM662LA OM662LA Machining of Flywheel Notice Flywheels which have scorch marks, scoring or cracks in the clutch surface should be machined by grinding or precision-turning. If the scores or cracks are severe than permissible specifications, replace the flywheel.

  • Page 590: Flywheel Ring Gear

    1B3-98 OM600 ENGINE MECHANICAL FLYWHEEL RING GEAR Preceding Work : Removal of flywheel 1 Ring Gear 3 Centering Collar Diameter 2 Flywheel Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder...
  • Page 591 OM600 ENGINE MECHANICAL 1B3-99 Replacement Procedure 1. Drill a hole into the ring gear (1) (arrow) and snap with a chisel. 2. Thoroughly clean the collar surfaces of ring gear. 3. Measure diameter (a) of centering collar. Diameter ‘a’ 275 + 0.5mm Notice If out of standard, replace the flywheel.
  • Page 592 1B3-100 OM600 ENGINE MECHANICAL 6. Measure axial runout of ring gear (1) on a surface plate. Limit Max. 0.4mm Notice For correct measurement, put the flywheel on the flat measuring board. Dial Gauge 001 589 53 21 00 Dial Gauge Holder 363 589 02 21 00...

  • Page 593: Hydraulic Valve Clearance Compensation Element Check

    OM600 ENGINE MECHANICAL 1B3-101 HYDRAULIC VALVE CLEARANCE COMPENSATION ELEMENT CHECK 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace...
  • Page 594 1B3-102 OM600 ENGINE MECHANICAL Checking Notice The noise which continues short time during short travel (frequent starting of the engine) or engine starting after a long time storage is normal operating conditions. So, it does not need to be repaired. Determine the malfunctions in valve clearance compensation device with noise through following tests.
  • Page 595 OM600 ENGINE MECHANICAL 1B3-103 VALVE TAPPETS Preceding Work : Removal of camshaft 1 Valve Tappet 4 Seal ............Replace 2 Cylinder Head 5 Screw Plug 3 Oil Gallery Tools Required 102 589 03 40 00 Magnetic Bar...
  • Page 596 1B3-104 OM600 ENGINE MECHANICAL Replacement Procedure 1. Pull out the valve tappet (1). Magnetic Bar 102 589 03 40 00 2. Remove the plug (5) and blow compressed air into the oil gallery (3). At this time, check that the outlet bores(arrow) at the seat of the valve tappet are clear.
  • Page 597 OM600 ENGINE MECHANICAL 1B3-105 VALVE SPRINGS CHECK Preceding Work : Removal of valve spring 1 Valve Spring 2 Spring Scale Service Data At preloaded Outer diameter Wire diameter Free length Length Tension (new) Limit 33.1mm 4.20mm 50.0mm 27mm 680 - 740N 612N...

  • Page 598: Valve Tappets

    1B3-106 OM600 ENGINE MECHANICAL VALVE SPRINGS (CYLINDER HEAD REMOVED) Cylinder Head Removed 1 Valve Tappet 6 Stud Bolt ............ 12Nm 2 Valve Cotters 7 Washer 3 Spring Retainer 8 Nut ..........Replace, 25Nm 4 Valve Spring ... Check, replace if necessary 9 Exhaust Manifold 5 Cylinder Head...
  • Page 599 OM600 ENGINE MECHANICAL 1B3-107 Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger 601 589 01 59 00 Assembling Board 601 589 02 59 00 Supporting Bridge 667 589 00 31 00 Press Lever Removal &...
  • Page 600 1B3-108 OM600 ENGINE MECHANICAL 5. Using the press lever (14), press the spring retainer downward and remove the valve cotters (2) with magnetic finger (15). Notice Be careful not to damage guide bore of the valve tappet. Press Lever 667 589 00 31 00 Magnetic Finger 116 589 06 63 00 6.

  • Page 601: Valve Springs (Cylinder Head Installed)

    OM600 ENGINE MECHANICAL 1B3-109 VALVE SPRINGS (CYLINDER HEAD INSTALLED) Preceding Work : Removal of camshaft 1 Valve Tappet 4 Valve Spring ..Check, replace if necessary 2 Valve Cotters 5 Timing Chain 3 Spring Retainer 6 Cylinder Head Notice Remove the valve springs only when the piston is at TDC. Tools Required 102 589 03 40 00 Magnetic Bar 116 589 06 63 00 Magnetic Finger...
  • Page 602 1B3-110 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the valve tappet (1) with magentic lifter. Notice Place the valve tappets upside down (open end upward) Magentic Liter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain of camshaft sprocket piston.
  • Page 603 OM600 ENGINE MECHANICAL 1B3-111 6. Remove the spring retainer(3) and spring (4). 7. Check the valve spring and replace if necessary. 8. Insert valve spring (4) with the color coding (arrow) facing down and insert valve spring Retainer(3). 9. By press the spring retainer(3) with press lever (90), install the valve cotters with magnetic finger (10).

  • Page 604: Valve Stem Seals

    1B3-112 OM600 ENGINE MECHANICAL VALVE STEM SEALS Preceding Work : Removal of camshaft. 1 Valve Tappet 4 Valve Spring ... Check, replace if necessary 2 Valve Cotters 5 Valve Stem Seal 3 Spring Retainer 6 Valve Notice Remove the valve stem seals when the piston is positioned at TDC.
  • Page 605 OM600 ENGINE MECHANICAL 1B3-113 Tools Required 667 589 00 31 00 Press Lever 104 589 00 37 00 Pliers 102 589 03 40 00 Magnetic Lifter 603 589 01 40 00 Holding Wheel 601 589 02 43 00 Drift 116 589 06 63 00 Magnetic Finger 667 589 02 63 00 Supporting Bar B : Exhaust valve stem seal A : Intake valve stem seal...
  • Page 606 1B3-114 OM600 ENGINE MECHANICAL Replacement Procedure 1. Remove the valve tappet (1) with magnetic lifter. Notice Place the valve tappets upside down (open end upward). Magnetic Lifter 102 589 03 40 00 2. Install the holding wheel (7) into the timing chain (11). Holding Wheel 603 589 01 40 00 3.
  • Page 607 OM600 ENGINE MECHANICAL 1B3-115 6. Remove the spring retainer(3) and valve spring (4). 7. Remove the valve stem seal (5). Pliers 104 589 00 37 00 8. Insert the cap (12) onto the valve (6) and install the new valve stem seal (5) and then remover the cap. Drift 601 589 02 43 00 9.

  • Page 608: Check And Replacement Of Valve Guides

    1B3-116 OM600 ENGINE MECHANICAL CHECK AND REPLACEMENT OF VALVE GUIDES Preceding Work : Removal of cylinder head Removal of valve spring Removal of valve 1 Cylinder Head 3 Valve Seat Ring 2 Valve Guide a Basic Bore Diameter Service Data Overlap Valve Guide Basic Bore...
  • Page 609 OM600 ENGINE MECHANICAL 1B3-117 Notice Measure center (arrow) of the valve guide and if the inner diameter ‘A’ exceeds standard value, replace the guide. Tools Required 000 589 10 53 00 Reamer (for Exhaust) 000 589 10 68 00 Cylinder Brush 000 589 21 53 00 Reamer (for Intake) 102 589 00 23 00 GO / NO GO Gauge (for Intake) 103 589 02 15 00 Drift (for Exhaust)
  • Page 610 1B3-118 OM600 ENGINE MECHANICAL Checking 1. Thoroughly clean the valve guide bore using a cylinder brush. Cylinder Brush 000 589 10 68 00 2. Insert the GO/NO GO gauge into the valve guide bore. If the NO GO side is inserted fully, replace the valve guide (Intake 8mm, Exhaust 9mm).
  • Page 611 OM600 ENGINE MECHANICAL 1B3-119 4. Reaming basic bore in cylinder head (repair size). - Thoroughly remove carbon deposits in cylinder head. Notice Particularly remove the insides of the valve seat rings. - Remove the elevation (arrow) of intake valve seat rings. - Select correct broaching tool and guide sleeve (refer to the table).
  • Page 612 1B3-120 OM600 ENGINE MECHANICAL 5. Heat the cylinder head (1) in a wear tank to approx. 80°C. 6. Cool down the new valve guide (2) with liquid nitrogen. Notice Do not touch the cooled valve guide by hand. Super Cooling box 346 589 00 63 00 7.
  • Page 613 OM600 ENGINE MECHANICAL 1B3-121 9. If necessary, ream the valve guide bore evenly. Notice Never turn the reamer against the direction of rotation. Reamer (for Exhaust) 000 589 10 53 00 Reamer (for Intake) 000 589 21 53 00...

  • Page 614: Valve Seat Rings

    1B3-122 OM600 ENGINE MECHANICAL VALVE SEAT RINGS Preceding Work : Removal of valve Checking of valve guide, replace if necessary Removal of prechamber 1 Cylinder Head Valve Seat Ring Outer Diameter 2 Valve Seat Ring D1 Valve Seat Ring Inner Diameter 3 Valve Guide D2 Basic Bore Diameter A Height (Cylinder Head Upper / Lower Surface)
  • Page 615 OM600 ENGINE MECHANICAL 1B3-123 Commercial Tools Cylinder Head Clamping Device Hunger D-8000 München 70 Type Ventilknecht K2000 Order No. 221 00 100 Valve Seat Turning Tool Hunger D-8000 München 70 Type VDS 1A Order No. 236 03 308 Ring Seat Turning Tool Hunger D-8000 München 70 Type RDS 1...
  • Page 616 1B3-124 OM600 ENGINE MECHANICAL Removal Procedure 1. Measure dimension ‘A’ . Limit 142.5mm 2. Clamp the cylinder head with clamping device. 3. Cut groove into the valve seat ring so that dimension ‘C’ is approx. 2mm and dimension ‘E’ is approx. 6mm. 4.
  • Page 617 OM600 ENGINE MECHANICAL 1B3-125 8. Turn over the cylinder head. 9. Remove the tensioning head (4) and valve seat ring (2) with drift (14mm) and removal tool. 10. Clean the basic bore of valve seat ring. 11. Measure the basic bore diameter (D2) and outer diameter (D) of the new valve seat ring (standard size).
  • Page 618 1B3-126 OM600 ENGINE MECHANICAL 15. Hang the cylinder head (1) to the lifting device and heat in a water tank to approx. 80°C. 16. Cool down new valve seat ring (2) into the cooling box with liquid nitrogen. Notice Do not touch the cooled valve seat rings with hand. Super Cooling Box 345 589 00 63 00 17.

  • Page 619: Check And Machining Of Valves

    OM600 ENGINE MECHANICAL 1B3-127 CHECK AND MACHINING OF VALVES Preceding Works : Removal of cylinder head Removal of the vale spring Removal of the valve I Valve Length Y Half Camshaft Basic Bore Diameter W Camshaft Cam Basic Diameter Z Distance (Cylinder Head Cover Parting Surface - X Distance (Camshaft Basic Bore - Valve Stem) Valve Stem)
  • Page 620 1B3-128 OM600 ENGINE MECHANICAL Intake Valve Exhaust Valve Item Intake Valve Exhaust Valve Valve Disc Diameter ‘d’ 37.90 - 38.10 mm 34.90 - 35.10 mm Valve Disc Height ‘h’ 1.7 mm 1.7 mm Setting Angle “α” or Machining the Valve 45°...
  • Page 621 OM600 ENGINE MECHANICAL 1B3-129 Tools Required 001 589 32 21 00 Dial Gauge Commercial Tool Valve corn grinding machine Checking and Machining 1. Clean the valves and do visual check. Valves with wobbled valve disc, with worn or scored valve stem should be replaced.
  • Page 622 1B3-130 OM600 ENGINE MECHANICAL 5. Clean the vales, valve seats and valve guides. 6. Coat the valve stem with oil and insert it into valve guide. 7. Insert the valves (1) into the valve guides according to marking. 8. Measure amount by which the valve arrears ‘a’. Arrears ‘a’...
  • Page 623 OM600 ENGINE MECHANICAL 1B3-131 11. The distance ‘x’ (camshaft basic bore - valve stem). ‘x’ = ‘z’ - ‘y’. Determine the valve to use according to this measurement (See ‘matching valves’) Example) Measured value ‘w’ = 38.2 mm Measured value ‘z’ = 36.5 mm Value ‘y’...

  • Page 624: Machining Of Valve Seat

    1B3-132 OM600 ENGINE MECHANICAL MACHINING OF VALVE SEAT Preceding Work : Removal of prechamber Removal and inspection of valve, replace if necessary Inspection of valve guide, replace if necessary 1 Valve a Valve Seat Angle 2 Valve Seat Ring b Valve Seat Free Angle 3 Cylinder Head 4 Valve Guide...
  • Page 625 OM600 ENGINE MECHANICAL 1B3-133 Service Data Item Intake Exhaust Valve Arrears ‘a’ 0.1 - 0.7 mm 0.1 - 0.7 mm Valve Seat Width ‘b’ 1.2 - 1.7 mm 1.5 - 2.0 mm α Valve Seat Angle ‘ ’ 45° 45° β...
  • Page 626 1B3-134 OM600 ENGINE MECHANICAL Machining Procedure Valve machining is required : - When the valve is leaking. - When replacing the valve. - When replacing the valve guide. - When replacing the valve seat or valve seat ring. 1. Machine the valve seat (a=45° ). 2.
  • Page 627 OM600 ENGINE MECHANICAL 1B3-135 5. Insert the valve (1) into the valve guide according to marking and measure amount by which the valve arrears ‘a’. Arrears ‘a’ 0.1 - 0.7mm 6. Measure camshaft cam basic circle diameter (w). 38 ± 0.2mm Diameter ‘w’...
  • Page 628 1B3-136 OM600 ENGINE MECHANICAL I Length of Valve y Half Camshaft Basic Bore Diameter w Camshaft Cam Basic Circle Diameter z Distance (Cylinder head cover parting surface -. x Distance (Camshaft basic bore - valve stem) valve stem) 8. Measure ‘x’ (Camshaft basic bore - valve stem). ‘...

  • Page 629: Camshaft Timing Test

    OM600 ENGINE MECHANICAL 1B3-137 CAMSHAFT TIMING TEST Preceding Work : Removal of glow plug 1 Cylinder Head Cover 4 Valve Tappet 2 Bolt ............10Nm 5 Cylinder Head 3 Gasket ........... Replace Timing Intake valve Exhaust valve Condition of camshaft Open Close Open...
  • Page 630 1B3-138 OM600 ENGINE MECHANICAL Tools Required 001 589 53 21 00 Dial Gauge 363 589 02 21 00 Dial Gauge Holder 366 589 00 21 05 Extension Measurement Procedure 1. Remove the cylinder head cover. 2. Rotate the engine in the direction of engine rotation until the intake valve of NO.

  • Page 631: Camshaft

    OM600 ENGINE MECHANICAL 1B3-139 CAMSHAFT Preceding Work : Removal of cylinder head cover 1 Bolt ............25Nm 8 Cylinder Head 2 Washer 9 Oil Pan 3 Camshaft Bearing Cap 10 Camshaft Sprocket 4 Camshaft 11 Washer 5 Dowel Pin 12 12-Sided Bolt (M11) ..... Check, 25Nm + 90° 6 Locking Washer 13 Gasket ...........
  • Page 632 1B3-140 OM600 ENGINE MECHANICAL Tools Required 602 589 00 40 00 Engine Lock Removal Procedure 1. Rotate the crankshaft and position the piston of no.1 cylinder at TDC. Notice Do not rotate the crankshaft in the opposite direction of engine rotation. In this position, the markings of the camshaft/camshaft bearing cap (arrow) must be aligned.
  • Page 633 OM600 ENGINE MECHANICAL 1B3-141 4. Remove the bolt and then remove the camshaft sprocket. Notice During removal, be careful not to drop the sprocket with chain. Remove the chain carefully and then pull out the sprocket. 5. Remove the chain tensioner. 6.
  • Page 634 1B3-142 OM600 ENGINE MECHANICAL 7. Remove the camshaft bearing cap. 8. Pull off the camshaft. Notice Be careful not to miss front locking washer. 9. Pull out the locking washer. Notice Check the condition of locking washer and replace if necessary.
  • Page 635 OM600 ENGINE MECHANICAL 1B3-143 5. Tighten the camshaft bearing cap bolts acccording to installation order. Tightening Torque 25 Nm Notice Tighten the No. 1 bolts (light arrow) by one revolution in stages first and then tighten the No.2 bolts (dark arrow). OM 662LA OM 661LA 6.
  • Page 636 1B3-144 OM600 ENGINE MECHANICAL Notice If max. length ‘L’ of the 12-sided bolt exceeds 53.6mm, replace it. 8. Install the chain tensioner. Tightening Torque 80 Nm Notice Replace the seal. Before installation, by pumping in the oil approx. 10 times, fill the oil.

  • Page 637: Chain Tensioner

    OM600 ENGINE MECHANICAL 1B3-145 CHAIN TENSIONER 1 Chain Tensioner ........80Nm 2 Seal ............Replace...
  • Page 638 1B3-146 OM600 ENGINE MECHANICAL Notice Always install the chain tensioner to be filled with oil. Place the chain tensioner in engine oil up to over the collar on the hexagon head with the thrust pin facing up. Slowly push down the thrust pin as far as the stop 7~10 times with the aid of a press or a column drill Faulty chain tensioners should be replaced completely.

  • Page 639: Timing Chain

    OM600 ENGINE MECHANICAL 1B3-147 TIMING CHAIN Preceding Work : Removal of glow plug Removal of chain tensioner Removal of cooling fan Removal of cylinder head cover 1 Chain Link 2 Timing Chain 3 Camshaft Sprocket 4 Outer Plate...
  • Page 640 1B3-148 OM600 ENGINE MECHANICAL Tools Required 000 589 58 43 00 Chain Assembling Device Replacement Procedure 1. Cover over the chain box with cleaning rag and grind off both chain pins (arrow) at a chain link (1) of the timing chain. 2.
  • Page 641 OM600 ENGINE MECHANICAL 1B3-149 7. Insert the new chain link (1) to connect the chain. 8. Insert the new outer plate (4) into the fitting tool (8) and then the outer plate will be held by a magnet. Chain Assembling Device 000 589 58 43 00 9.
  • Page 642 1B3-150 OM600 ENGINE MECHANICAL 11. Place the fitting tool (8) onto the chain link and rivet the chain pins one by one. Tightening Torque 35 - 40 Nm 12. Check the riveting of chain pins and re-rivet if necessary. 13. Remove the wire. 14.

  • Page 643: Tensioning Rail

    OM600 ENGINE MECHANICAL 1B3-151 TENSIONING RAIL Preceding Work : Removal of cylinder head Removal of timing case cover 1 Tensioning Rail 2 Bearing Pin Notice The plastic coating of the tensioning rail can not be replaced.

  • Page 644: Cylinder Head Guide Rail

    1B3-152 OM600 ENGINE MECHANICAL CYLINDER HEAD GUIDE RAIL Preceding Work : Removal of the cooling fan Removal of poly V-belt Removal of chain tensioner 1 Cylinder Head Cover 9 Bearing Pin ......Sealing Compound 2 Bolt ............10Nm 10 Guide Rail 3 Gasket ...........
  • Page 645 OM600 ENGINE MECHANICAL 1B3-153 Tools Required 115 589 02 34 00 Sliding Hammer 116 589 20 33 00 Threaded Pin Removal Procedure 1. Removal the cylinder head cover. 2. Pull off the tensioning lever (7) and remove from the spring (15).
  • Page 646 1B3-154 OM600 ENGINE MECHANICAL 6. Pull out the bearing pins (9, 11) with sliding hammer and remove the guide rail 10. Sliding Hammer 116 589 20 33 00 Threaded Pin 116 589 02 34 00 Installation Procedure 1. Apply collar of both bearing pins with sealing compound. 2.
  • Page 647 OM600 ENGINE MECHANICAL 1B3-155 In this position, the marking on the camshaft / camshaft bearing cap (arrow) must also be aligned. 5. Install the guide pulley (12). Tightening Torque 23 Nm 6. Attach the tensioning lever (7) to the spring (15) and install. 7.

  • Page 648: Timing Case Cover Guide Rail

    1B3-156 OM600 ENGINE MECHANICAL TIMING CASE COVER GUIDE RAIL Preceding Work : Removal of cylinder head cover 1 Bearing Pin 5 Crankshaft 2 Bearing Pin 6 Spring 3 Guide Rail 7 Bushing 4 Oil Pump Chain 8 Tensioning Lever...

  • Page 649: Crankshaft Sprocket

    1B3-158 OM600 ENGINE MECHANICAL CRANKSHAFT SPROCKET Preceding Work : Removal of oil pan Removal of timing case cover 1 12-Sided Stretch Bolt (M11) .. Check, 25Nm + 90° 11 Bolt ............25Nm 2 Washer 12 Crankshaft Sprocket 3 Camshaft Sprocket 13 Crankshaft 4 Timing Chain 15 Key...
  • Page 650 OM600 ENGINE MECHANICAL 1B3-159 Special Tools 116 589 07 15 00 Drift 102 589 05 33 00 Puller Removal Procedure 1. Pull out the tensioning lever (19) together with the spring (17) and guide rail (16) far enough until the tensioning lever has passed the oil pump chain (9) and is resting against the crankshaft (13).
  • Page 651 1B3-160 OM600 ENGINE MECHANICAL 5. Place alignment marks (arrow) on the timing chain (4) and crankshaft sprocket (12). 6. Remove the woodruff key(15). 7. Place alignment marks (arrow) on the timing chain (4) and camshaft sprocket (3). 8. Remove the chain tensioner. 9.
  • Page 652 OM600 ENGINE MECHANICAL 1B3-161 Installation Procedure 1. Put the same alignment mark on the new crankshaft sprocket as in the old sprocket. Notice Check the timing chain, camshaft sprocket, injection pump timing sprocket, oil pump chain and oil pump sprocket for wear and replace if necessary.
  • Page 653 1B3-162 OM600 ENGINE MECHANICAL Notice If the max. length ‘L’ of the stretch bolt exceeds 53.6mm, replace it. 5. Fit the oil pump chain (9) on the crankshaft sprocket (12) and insert the oil pump sprocket (8) into the oil pump chain and then install it on the oil pump.

  • Page 654: Piston

    OM600 ENGINE MECHANICAL 1B3-163 PISTON Preceding Work : Removal of the cylinder head Removal of the oil pump 1 Oil Ring 8 Connecting Rod 2 2nd Ring 9 Connecting Rod Upper Bearing Shell 3 Top Ring 10 Connecting Rod Lower Bearing Shell 4 Snap Ring ..........
  • Page 655 1B3-164 OM600 ENGINE MECHANICAL Service Data Piston clearance Max. 0.12 mm Piston crown protrusion in TDC position 0.735 - 0.965 mm Connecting rod bushing diameter 26.012 - 26.018 mm Connecting Rod Bolt Dimensions Thread M9 x 1 Stretch shaft(C) diameter (new) -0.1 Minimum stretch shaft diameter (C) 7.1 mm...
  • Page 656 OM600 ENGINE MECHANICAL 1B3-165 Removal Procedure 1. Remove combustion residues from the cylinder bores. 2. Remove the connecting rod bolts (12) and then remove the connecting rod bearing caps(11). 3. Remove the connecting rod bearing shells (9, 10). Notice Be careful not mix the bearing caps and shells each other. 4.
  • Page 657 1B3-166 OM600 ENGINE MECHANICAL Installation Procedure 1. Fit the piston onto the connecting rod so that the arrow (15) and the locking slot (16) are facing in direction of the vehicle. 2. Coat the piston pin (15) with engine oil and insert it by hand. Notice Do not heat up the piston.
  • Page 658 OM600 ENGINE MECHANICAL 1B3-167 6. Coat the cylinder bore, connecting rod bearing journal, connecting rod bearing shell and piston with oil. 7. Compress the piston rings with a tensioning strap (7). Tensioning Strap 000 589 04 14 00 8. Insert the piston assembly into the cylinder with a wooden stick (18).
  • Page 659 1B3-168 OM600 ENGINE MECHANICAL 12. Coat the bolts (12) with oil and then tighten the bolts. Tightening Torque 40Nm + 90° 13. Rotate the crankshaft and check axial clearance between the connecting rod and crankshaft. 14. Measure clearance between the piston crown and cylinder Standard Max.

  • Page 660: Oil Filter

    OM600 ENGINE MECHANICAL 1B3-169 OIL FILTER 1 Nut ............25 Nm 6 Bolt (M8) ............ 10Nm 2 Oil Filter ............. Cover 7 Oil Pressure Switch 3 O-Ring ........... Replace 8 Gasket 4 Oil Filter ....Element Replace If necessary 9 Bolt ............25 Nm 5 Oil Filter Housing...
  • Page 661 1B3-170 OM600 ENGINE MECHANICAL Removal & Installation Procedure 1. Remove the oil filter cover and then drain the oil. 2. Remove the oil pressure switch line. 3. Remove the oil filter housing. 4. Clean the sealing surface. 5. Installation should follow the removal procedure in the reverse order.

  • Page 662: Oil Pan

    OM600 ENGINE MECHANICAL 1B3-171 OIL PAN OM662LA OM661LA 1 Gasket ........... Replace 6 Lower Oil Pan 2 Upper Oil Pan 7 Combination Bolt ........25 Nm 3 Combination Bolt ........10 Nm 8 Drain Plug ..........25 Nm 4 Combination Bolt ........10 Nm 9 Washer Seal ..........
  • Page 663 1B3-172 OM600 ENGINE MECHANICAL Oil Circulation...
  • Page 664 OM600 ENGINE MECHANICAL 1B3-173 Oil Filter a From Oil Pump b To Main Oil Gallery c To Oil Pan...

  • Page 665: Oil Spray Nozzle

    1B3-174 OM600 ENGINE MECHANICAL OIL SPRAY NOZZLE 1 Fitting Sleeve 3 Combination Bolt ........10 Nm 2 Oil Spray Nozzle A Oil Duct Disassembly Procedure 1. Remove oil pan or crankshaft. 2. Loose the bolt and then remove the nozzle.

  • Page 666: Oil Pump

    OM600 ENGINE MECHANICAL 1B3-175 OIL PUMP 1 Oil Pump 5 Screw Plug ..........50 Nm 2 Piston 6 Combination Bolt ........25 Nm 3 Pressure Spring 7 Oil Strainer 4 Guide Pin 8 Bracket Disassembly Procedure 1. Remove the oil pan. 2.
  • Page 667 1B3-176 OM600 ENGINE MECHANICAL 3. Unscrew the oil strainer bracket bolt. Tightening Torque 10 Nm 4. Remove the oil pump. 5. Unscrew the screw plug and remove the relief valve. 6. Installation should follow the removal procedure in the reverse order.

  • Page 668: Unit Repair

    OM600 ENGINE MECHANICAL 1B3-177 UNIT REPAIR CYLINDER HEAD PRESSURE LEAKAGE TEST Preceding Work : Removal of the cylinder head Removal of the exhaust manifold Removal of the valve 1 Feed Pipe 2 Bolt 3 Return Connection 4 Gasket ..............Replace 5 Coolant Gallery ...........

  • Page 669: Facing Cylinder Head Mating Surface

    1B3-178 OM600 ENGINE MECHANICAL FACING CYLINDER HEAD MATING SURFACE Preceding Work : Removal of prechamber Cylinder head pressure leakage test 1 Valve B Longitudinal Direction 2 Cylinder Head C Transverse Direction 3 Prechamber a Valve Arrears A Height of Cylinder Head b Prechamber Protrusion Service Data Height ‘A’...
  • Page 670 OM600 ENGINE MECHANICAL 1B3-179 Measurement Procedure 1. Measure height ‘A’ . Limit 142.5 mm Notice If the height is less than 142.5mm, replace the cylinder head. 2. Insert the valve (1) and measure valve arrears ‘a’. Valve Arrears ‘a’ 0.1 - 0.7 mm Notice If out of standard, machine the valve seat.

  • Page 671: Replacement Of Crankcase Core Plug

    1B3-180 OM600 ENGINE MECHANICAL REPLACEMENT OF CRANKCASE CORE PLUG Left Right φ φ Core plug ............34mm Core plug ............34mm OM661LA - 2EA OM661LA - 2EA OM662LA - 3EA OM662LA - 3EA Left Right φ φ Core plug ............17mm Core plug ............
  • Page 672 OM600 ENGINE MECHANICAL 1B3-181 Tools Required 102 589 00 15 00 Drift 102 589 12 15 00 Drift Replacement Procedure 1. Completely drain the coolant. 2. Remove any parts which impede access. (Example : transmission, injection pump) 3. Place the screwdriver to the deepdrawn edge of the core plug and pull forward and then rotate 90°...

  • Page 673: Facing Crankcase Contacting Surface

    1B3-182 OM600 ENGINE MECHANICAL FACING CRANKCASE CONTACTING SURFACE 1 Crankcase B Longitudinal Direction 2 Crankcase Contacting Surface C Transverse Direction H Chamfer Height Y Height (crankcase upper surface - crankcase b Chamfer Angle lower surface) Service Data Height ‘Y’ Min. 299.62 mm Permissible unevenness of contacting surface In longitudinal direction (B) 0.06 mm...

  • Page 674: Oil Gallery Steel Ball

    OM600 ENGINE MECHANICAL 1B3-183 OIL GALLERY STEEL BALL Preceding Work : Removal of cooling fan Removal of the coolant pump housing Removal of the flywheel and driven plate φ 1 Steel Ball..........15mm 2 Screw Plug .......Loctite 241,50Nm Notice The screw plug (2) has to be installed as a repair solution if the steel ball (1) is leaking.
  • Page 675 1B3-184 OM600 ENGINE MECHANICAL φ 3 Steel Ball..........17mm 5 Screw Plug ..........50Nm 4 Seal Notice The seal (4) and screw plug (5) have to be installed as a repair solution if the steel ball (3) is leaking. Tools Required 601 589 08 15 00 Drift...
  • Page 676 OM600 ENGINE MECHANICAL 1B3-185 Removal & Installation Procedure 1. Remove the timing case cover. 2. By inserting a round bar (6) approx. 0.7m from the back to the front side through the oil gallery, knock out the steel balls (1,3). Notice Be careful not to damage the bores of the steel balls.
  • Page 677 1B3-186 OM600 ENGINE MECHANICAL Installation of Screw Plug Notice If steel ball leaks again, install the screw plug. 1. Remove the steel ball. 2. Tap thread into the bores of the oil gallery. Notice Front bore : M18 ´ 1.5, depth 10mm Rear bore : M16 ´...

  • Page 678: Cylinder Bore Measurement

    OM600 ENGINE MECHANICAL 1B3-187 CYLINDER BORE MEASUREMENT Longitudinal Direction Transverse Direction c, d, e. Measuring Point Crankcase Contacting Surface TDC of 1st Piston Ring BDC of Ring Service Data Standard size Code letter ‘A’ 89.000 - 89.006mm Code letter ‘X’ 89.006 - 89.012mm Code letter ‘B’...
  • Page 679 SECTION 1D1 M162 ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 680: Fastener Tightening Specifications

    1D1-2 M162 ENGINE COOLING FASTENER TIGHTENING SPECIFICATIONS Application N• • • • • m Coolant Drain Plug Engine Hanger Bracket and Coolant Outlet 22.5 - 27.5 Port Bolt Thermostat Cover Bracket Bolt 9 - 11 Oil Cooler Pipe Line Bolt 9 - 11 Cooling Fan Bolt 9 - 11...

  • Page 681: Special Tools

    M162 ENGINE COOLING 1D1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 603 589 00 40 Tester Counter Holder...

  • Page 682: Diagnosis

    1D1-4 M162 ENGINE COOLING DIAGNOSIS SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, cap must not be opened unless the coolant temperature is below 90°C.

  • Page 683: Maintenance And Repair

    M162 ENGINE COOLING 1D1-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90 2.
  • Page 684 1D1-6 M162 ENGINE COOLING 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose. 7. Fill up the coolant through the coolant reservoir tank. Notice Match the anti-freeze and the water ratio to 50 : 50. Supplement the coolant until the coolant overflows to the deaeration hose.

  • Page 685: Coolant Connection Fitting

    M162 ENGINE COOLING 1D1-7 COOLANT CONNECTION FITTING Preceding Work : Removal of cooling fan shroud 1 Bolt (M8 X 100, 2 pieces) ....22.5-27.5 Nm 4 O-ring 2 Engine Hanger Bracket 5 Hose Mounting Clamp 3 Coolant Outlet Port 6 Hose Removal &...

  • Page 686: Water Pump

    1D1-8 M162 ENGINE COOLING WATER PUMP Preceding Work : Removal of V-belt Removal of air admission housing 1 Air Admission Housing 8 Coolant Hose 2 Oil Cooler Pipe Line 9 Inlet Coolant Hose 3 Seal ............Replace 10 Coolant Pump 4 Bolt ............
  • Page 687 M162 ENGINE COOLING 1D1-9 Removal & Installation Procedure 1. Drain the coolant. 2. Disconnect the coolant pump wire connector. 3. Loosen the hose clip and dsconnect all hoses from the coolant pump 4. Remove the coolant line bolts (4) and then remove the coolant line (2).

  • Page 688: Thermostat

    1D1-10 M162 ENGINE COOLING THERMOSTAT 1 Thermostat Cover 5 Bolt (M6 X 25, 3 pieces) ......9-11 Nm 2 Thermostat 6 Hose Mounting Clamp 3 O-ring 7 Heater Hose 4 Thermostat Cover Bracket Removal & Installation Procedure 1. Drain the coolant from the radiator. 2.

  • Page 689: Oil Cooler Pipe Line

    M162 ENGINE COOLING 1D1-11 OIL COOLER PIPE LINE Preceding Work : Removal of upper intake manifold 1 Upper Intake Manifold 4 Oil Cooler Pipe Line 2 Bolt (M6 X 35, 1 piece) ......9-11 Nm 5 O-ring ............ Replace 3 Bolt (M6 X 16, 2 pieces) ......9-11 Nm Removal &...

  • Page 690: Cooling Fan And Viscous Clutch

    1D1-12 M162 ENGINE COOLING COOLING FAN AND VISCOUS CLUTCH Preceding Work : Removal of cooling fan shroud 1 Cooling Fan Pulley 4 Bolt (M6 X 12, 4 pieces) ......9-11 Nm 2 Viscous Clutch 5 Bolt (M10 X 45, 1 piece) ....40.5-49.5 Nm 3 Cooling Fan...
  • Page 691 M162 ENGINE COOLING 1D1-13 Tools Required 603 589 00 40 00 Counter Holder Removal & Installation Procedure 1. Hold the cooling fan pulley using the counter holder (special tool : 603 589 00 40 00) and remove the cooling fan after unscrewing the four bolts (4).

  • Page 692: Cooling Fan Shroud

    1D1-14 M162 ENGINE COOLING COOLING FAN SHROUD 1 Clip 4 Fan Shroud Assembly 2 Lower Fan Shroud 5 Radiator 3 Bolt Removal & Installation Procedure 1. Pull out the 2 clips (1) from the fan shroud assembly. 2. Remove the lower fan shroud (2). Notice For installation, exactly align the lower fan shroud pin into the hole of the fan shroud assembly (4) and insert the...

  • Page 693: Radiator

    M162 ENGINE COOLING 1D1-15 RADIATOR Preceding Work : Removal of cooling fan shroud 1 Radiator Inlet Coolant Hose 6 Bolt 2 Radiator Outlet Coolant Hose 7 Insulator 3 Make Up Coolant Hose 8 Stopper 4 Automatic Transmission Oil Cooling Hose 9 Bolt .............
  • Page 694 1D1-16 M162 ENGINE COOLING Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. 4. Remove the automatic transmission oil cooling hose. Installation Notice Tightening Torque 14 Nm 5.
  • Page 695 SECTION 1D2 M161 ENGINE COOLING CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 696: Fastener Tightening Specifications

    1D2-2 M161 ENGINE COOLING FASTENER TIGHTENING SPECIFICATIONS N• • • • • m Application Coolant Drain Plug 22.5 - 27.5 Engine Hanger Bracket and Coolant Outlet Port Bolt Thermostat Cover Bracket Bolt 9 - 11 9 - 11 Oil Cooler Pipe Line Bolt 9 - 11 Cooling Fan Bolt 40.5 - 49.5...

  • Page 697: Special Tools

    M161 ENGINE COOLING 1D2-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 124 589 15 21 00 603 589 00 40 Tester Counter Holder 111 589 02 01 00 111 589 00 40 00 Open End Wrench Open End Wrench...

  • Page 698: Diagnosis

    1D2-4 M161 ENGINE COOLING DIAGNOSIS SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, cap must not be opened unless the coolant temperature is below 90°C.

  • Page 699: Maintenance And Repair

    M161 ENGINE COOLING 1D2-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE COOLANT DRAIN AND FILL UP Draning & Filling up Procedure 1. Loosen the cap a little and release pressure and remove the cap. Notice For the risk of scalding, the cap must not be opened unless the coolant temperature is below 90oC.
  • Page 700 1D2-6 M161 ENGINE COOLING 4. After complete draining of the coolant, remove the hose connector to drain plug and reinstall the drain plug. Installation Notice Tightening Torque 30 Nm 5. Tighten the radiator lower drain cock. 6. Remove the de-aeration hose clamp in the coolant pump and remove the de-aeration hose.

  • Page 701: Cooling Fan And Viscous Clutch

    M161 ENGINE COOLING 1D2-7 COOLING FAN AND VISCOUS CLUTCH 1 Bolt (M6 X 14, 3 piece) ......9-11 Nm 3 Viscous Clutch 2 Cooling Fan 4 Union Nut (Left Threaded Screw)... 40.5-49.5 Nm...
  • Page 702 1D2-8 M161 ENGINE COOLING Tools Required 111 589 02 01 00 Open End Wrench 111 589 00 40 00 Open End Wrench Removal & Installation Procedure 1. Install the holder (special tool : 111 589 00 40 00) to the bolt at the pulley as shown in the right figure to hold the pulley.

  • Page 703: Coolant Pump

    M161 ENGINE COOLING 1D2-9 COOLANT PUMP Preceding Work : Removal of viscous clutch 1 Bolt (M6 X 45, 1 piece) ......9-11 Nm 7 Coolant Pump Pulley 2 Bolt (M6 X 95, 1 piece) ......9-11 Nm 8 Coolant Inlet Hose 3 Bolt (M6 X 25, 4 piece) ......
  • Page 704 1D2-10 M161 ENGINE COOLING Tools Required 124 589 15 21 00 Tester Removal & Installation Procedure 1. Drain the coolant. 2. Disconnect the coolant hoses (8, 9, 10). 3. Tak off the drive belt. 4. Unscrew the four bolts (6) from coolant pump pulley and remove the pulley (7).

  • Page 705: Thermostat

    M161 ENGINE COOLING 1D2-11 THERMOSTAT 1 Bolt (M6 X 25, 3 pieces) ......9 -11 Nm 4 Coolant Outlet Hose 2 Thermostat Cover 5 Thermostat 3 De-aeration Hose 6 O-ring Removal & Installation Procedure 1. Drain the coolant from the radiator. 2.

  • Page 706: Thermostat Housing Assembly

    1D2-12 M161 ENGINE COOLING THERMOSTAT HOUSING ASSEMBLY Preceding Work : Removal of viscous clutch 1a Bolt (M6 X 95, 2 pieces) ......9-11 Nm 4 De-aeration Hose 1b Bolt (M8 X 75, 2 pieces) ....22.5-27.5 Nm 5 Coolant Outlet Hose 1c Bolt (M8 X 35, 1 piece) ....
  • Page 707 M161 ENGINE COOLING 1D2-13 Removal & Installation Procedure 1. Drain the coolant. 2. Remove the de-aeration hose (4), coolant outlet hose (5) and coolant bypass hose (6). 3. Disconnect the coolant temperature sensor connector. 4. Unscrew the bolt (1c) and pry off the tensioning device shock absorber (7).

  • Page 708: Removal And Installation Of Cooling Fan Shroud

    1D2-14 M161 ENGINE COOLING REMOVAL AND INSTALLATION OF COOLING FAN SHROUD 1 Fan Suroud Assembly 2 Bolt (M6 X 16, 2 pieces) ......3-7 Nm Removal & Installation Procedure 1. Unscrew two bolts from cooling fan shroud and remove the shrud. Installation Notice Tightening Torque 3 - 7 Nm...

  • Page 709: Removal And Installation Of Radiator

    M161 ENGINE COOLING 1D2-15 REMOVAL AND INSTALLATION OF RADIATOR Preceding Work : Removal of cooling fan shroud 1 Inlet Hose 7 Bolt (M6 X 20, 4 pieces) ......3-7 Nm 2 Hose (to Engine) 8 Insulator 3 Hose (to 3-way Connector) 9 Radiator Bracket 4 Make-up Hose (to Coolant Reservoir) 10 Radiator...
  • Page 710 1D2-16 M161 ENGINE COOLING Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermo connector from the radiator. 3. Remove the each coolant hoses. 4. Remove the automatic transmission oil cooling hose. Installation Notice Tightening Torque 14 Nm 5.
  • Page 711 SECTION 1D3 OM600 ENGINE COOLING Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 712: Diagnosis

    1D3-2 OM600 ENGINE COOLING DIAGNOSIS COOLING CIRCULATION A Thermostat G Deaeration Line B Radiator H Reservoir D From Heater E Hose...

  • Page 713: Thermostat Operation

    OM600 ENGINE COOLING 1D3-3 THERMOSTAT OPERATION Operation 1. At warming up Valve closes until temperature of coolant reaches to 85°C. B. From Radiator C. From Crankcase D. To Crankcase 2. At partial opening. Valve opens partially as temperature of coolant is maintained between 85-100°C.

  • Page 714: Cooling System Leakage Test

    1D3-4 OM600 ENGINE COOLING COOLING SYSTEM LEAKAGE TEST Tools Required 124 589 15 21 00 Tester Test 1. Loosen the pressure cap by 1 notch and remove the cap after. Notice Do not remove radiator cap when coolant is above 90°C. 2.

  • Page 715: Maintenance And Repair

    OM600 ENGINE COOLING 1D3-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE DRAIN AND FILLING OF COOLANT Preceding Work : Removal of skid plate Drain / Filling 1. Loosen the pressure cap of reservoir by 1 notch and remove pressure and then loosen the cap. Notice Do not remove radiator cap when coolant is above 90°C.

  • Page 716: Coolant Pump

    1D3-6 OM600 ENGINE COOLING COOLANT PUMP Preceding Work : Removal of cooling fan Removal of V-belt 1 Tensioning Lever 4 Belt Pulley 2 Gasket ........... Replace 5 Bolt ............10 Nm 3 Bolt ............10 Nm 6 Coolant Pump...
  • Page 717 OM600 ENGINE COOLING 1D3-7 Removal & Installation Procedure 1. Loose the bolts(5) and remove the pulley (4). Installation Notice Tightening Torque 10 Nm 2. Loose the bolts (3). Installation Notice Tightening Torque 10 Nm 3. Pull the tensioning lever(1) to the arrow direction. 4.

  • Page 718: Coolant Pump Housing

    1D3-8 OM600 ENGINE COOLING COOLANT PUMP HOUSING Preceding Work : Removal of coolant pump Removal of thermostat Removal of alternator 1 Gasket ........... Replace 5 Coolant Hose 2 Coolant Pump Housing 6 Return Pipe 3 Connector 7 O-Ring 4 Bolt ............10 Nm 8 Temperature Sensor Notice The bolt on the arrow should be installed last.
  • Page 719 OM600 ENGINE COOLING 1D3-9 Removal & Installation Procedure 1. Disconnect the connector(3). 2. Separate the coolant hose (5) and return pipe(6). 3. Remove the bolts(4) evenly. Installation Notice Tightening Torque 10 Nm Notice Clean gasket residues on the sealing surface of coolant pump and replace the gasket.

  • Page 720: Cooling Fan Clutch

    1D3-10 OM600 ENGINE COOLING COOLING FAN CLUTCH 1 Belt Pulley 4 Socket Bolt..........45 Nm 2 Cooling Fan Clutch 5 Socket Bolt..........10 Nm 3 Cooling Fan Tools Required 603 589 00 40 00 Counter Holder...
  • Page 721 OM600 ENGINE COOLING 1D3-11 Removal & Installation Procedure 1. Hold the bolt pulley with counter holder and remove the bolt(4). Counter Holder 603 589 00 40 00 Installation Notice Tightening Torque 45 Nm 2. Remove the socket bolt(5) and then remove the cooling fan(3) and fan clutch(2).

  • Page 722: Radiator

    1D3-12 OM600 ENGINE COOLING RADIATOR Preceding : Removal of cooling fan shroud 1 Radiator Inlet Hose ....OM662LA : 220mm 5 Spring Clamp ..........OM661LA : 321mm 6 Bolt ............3-7 Nm 2 Radiator outlet Hose 7 Radiator 3 Radiator Deaeration Tube & Hose 8 Spring Clamp 4 Clamp 9 Bolt ............
  • Page 723 OM600 ENGINE COOLING 1D3-13 Removal & Installation Procedure 1. Drain coolant from the radiator. 2. Remove the coolant thermoswich connector from radiator. 3. Remove the each coolant hose. 4. Remove the auto T/M oil cooling hose and cooling line. Installation Notice Hose : 29 - 40Nm Tightening Torque 5.

  • Page 724: Cooling Sub-System

    1D3-14 OM600 ENGINE COOLING COOLING SUB-SYSTEM 1 Radiator 7 Mounting Bracket 2 Cooling Fan Shroud 8 Make-up Cooling Hose 3 Bolt ............3-7Nm 9 Bolt ............3-7Nm 4 Cooling Fan Shroud 10 Cooling Reservoir-tank Cap 5 Radiator Deaieration Hose 11 Cooling Reservoir-tank...
  • Page 725 OM600 ENGINE COOLING 1D3-15 Removal & Installation Procedure Cooling Fan Shroud 1. Remove the radiator deaeration hose and tube. Installation Notice Tightening Torque 3 - 7 Nm Tightening torque 3-7Nm 2. Check the shroud. 3. Installation should follow the removal procedure in the reverse order.

  • Page 726: Thermostat

    1D3-16 OM600 ENGINE COOLING THERMOSTAT 1 Thermostat 4 Coolant Hose 2 Seal ............Replace 5 Bolt ............10Nm 3 Thermostat Housing Cover...
  • Page 727 OM600 ENGINE COOLING 1D3-17 Removal & Installation Procedure 1. Drain the coolant completely. 2. Disconnect the coolant hose(4) from the thermostat housing cover(3). 3. Remove the bolts(5) and then remove the thermostat(1) and housing cover(3) Installation Notice Align the groove on thermostat and the housing cover rib(arrow).
  • Page 728 SECTION 1E1 M162 ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 729: Battery Specifications

    1E1-2 M162 ENGINE ELECTRICAL STARTING MOTOR SPECIFICATIONS Application Description Voltage 12 V Output Power 1.7 KW BATTERY SPECIFICATIONS Application Description Capacity 75 AH Specific Gravity ≥ 1.24 Max. Tolerance Between Cells ≥ 0.04 FASTENER TIGHTENING SPECIFICATIONS Application N•m Alternator Terminal B+Nut 14 - 18 Alternator Terminal D+Nut 4 - 5...

  • Page 730: Special Tools

    M162 ENGINE ELECTRICAL 1E1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench...

  • Page 731: Maintenance And Repair

    1E1-4 M162 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation Notice Tightening Torque 14 - 18 Nm 3.

  • Page 732: Starting Motor

    M162 ENGINE ELECTRICAL 1E1-5 STARTING MOTOR Removal & Installation Procedure 1. Disconnect the ground cable. 2. Unscrew the nut and disconnect the battery cable(1). Installation Notice Tightening Torque 12 - 15 Nm 3. Unscrew the nut and disconnect the engine electric wire (2).

  • Page 733: Battery

    1E1-6 M162 ENGINE ELECTRICAL BATTERY 1 Cable Terminal (-) 7 Battery holddown Bracket 2 Cable Terminal Cap (-) 8 Battery Clamp Bolt 3 Cable Terminal Cap (+) 9 Battery 4 Nut 10 Sub Tray 5 Fuseblink Box 11 Battery Tray 6 Terminal (+) Removal &...

  • Page 734: Spark Plug

    M162 ENGINE ELECTRICAL 1E1-7 SPARK PLUG Preceding Work : Removal of intake air duct 1 Ignition Coil Cable Cover T1/1 Ignition Coil : Cylinder 2 and 5 2 Bolt (M6 X 60, 7 pieces) ......9-11 Nm T1/2 Ignition Coil : Cylinder 3 and 4 3 Spark Plug T1/3 Ignition Coil : Cylinder 1 and 6...
  • Page 735 1E1-8 M162 ENGINE ELECTRICAL Tools Required 120 589 09 00 Spark Plug Wrench Replacement Procedure 1. Remove the seven bolts (2) and remove the ignition cable cover. Installation Notice Tightening Torque 9 - 11 Nm 2. Remove the two bolts (M6 X 25) from each ignition cable and remove the ignition cable.

  • Page 736: Ignition Cable

    M162 ENGINE ELECTRICAL 1E1-9 IGNITION CABLE Preceding Work : Removal of intake air duct 1 Control Cable Connection 5a, 5b Secondary Voltage Connection 2 Ignition Cable Iron Core 3 Spark Plug Connector Secondary Ignition Coil 4 Coupling Plug Primary Ignition Coil...
  • Page 737 1E1-10 M162 ENGINE ELECTRICAL Functions 1. Firing order : 1-5-3-6-2-4 2. The ignition cables are located on the cylinder head cover. Each ignition coil provides the high voltage to two spark plugs simultaneously. T1/1 : cylinder 2 and 5 T1/2 : cylinder 3 and 4 T1/3 : cylinder 1 and 6 3.
  • Page 738 M162 ENGINE ELECTRICAL 1E1-11 Circuit Diagram Inspection & Maintenance Procedure (for MSE) 1. While the ignition switch is in 'OFF' position, remove the wiring connectors (1 and 15) from ignition coil and measure the primary resistance between terminal No.1 and No.15. Specified Value 0.9 - 1.6 Ω...

  • Page 739: Unit Repair

    1E1-12 M162 ENGINE ELECTRICAL UNIT REPAIR BATTERY Inspection Notice When charging the battery, do not leave the inflammable objects around it. When checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found on it.
  • Page 740 SECTION 1E2 M161 ENGINE ELECTRICAL CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 741: Starting Motor Specifications

    1E2-2 M161 ENGINE ELECTRICAL STARTING MOTOR SPECIFICATIONS Application Description Voltage 12 V Output Power 1.2 KW BATTERY SPECIFICATIONS Application Description Capacity 90 Ah Specific Gravity ≥ 1.24 Max. Tolerance Between Cells ≥ 0.04 FASTENER TIGHTENING SPECIFICATIONS Application N•m Alternator Terminal B+Nut 14 - 18 Alternator Terminal D+Nut 4 - 5...

  • Page 742: Special Tools

    M161 ENGINE ELECTRICAL 1E2-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 120 589 02 09 00 Spark Plug Wrench...

  • Page 743: Maintenance And Repair

    1E2-4 M161 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE ALTERNATOR Preceding Work : Removal of the drivebelt Removal & Installation Procedure 1. Disconnect the negative battery terminal. 2. Unscrew the nut and disconnect the terminal (1). Installation Notice Tightening Torque 14 - 18 Nm 3.

  • Page 744: Starting Motor

    M161 ENGINE ELECTRICAL 1E2-5 STARTING MOTOR Removal & Installation Procedure 1. Disconnect the ground cable. 2. Unscrew the nut and disconnect the battery cable(1). Installation Notice Tightening Torque 12 - 15 Nm 3. Unscrew the nut and disconnect the engine electric wire (2).

  • Page 745: Battery

    1E2-6 M161 ENGINE ELECTRICAL BATTERY 1 Cable Terminal (-) 7 Battery holddown Bracket 2 Cable Terminal Cap (-) 8 Battery Clamp Bolt 3 Cable Terminal Cap (+) 9 Battery 4 Nut 10 Sub Tray 5 Fuseblink Box 11 Battery Tray 6 Terminal (+) Removal &...

  • Page 746: Spark Plug

    M161 ENGINE ELECTRICAL 1E2-7 SPARK PLUG Preceding Work : Removal of intake air duct 1 Screw (3 pieces) ........9 - 11 Nm 6 Bolts (M6 X 25, 4 pieces) ..... 9 - 11 Nm 2 Adaptor (3 pieces) 7 Ignition Coil (T1/1) 3 Ignition Coil Cable Cover 8 Coupling Plug 4 Spark Plug Connector...
  • Page 747 1E2-8 M161 ENGINE ELECTRICAL Replacement Procedure 1. Unscrew the three screws(1) and remove the ignition coil cable cover Installation Notice Tightening Torque 9 - 11Nm 2. Disconnect the cable from ignition coil and spark plug. 3. Unscrew two bolts(M6 X 25) from each ignition coil and remove the ignition coil(arrow) .

  • Page 748: Ignition Cable

    M161 ENGINE ELECTRICAL 1E2-9 IGNITION CABLE Preceding Work : Removal of intake air duct 1 Control Cable Connection 5a, 5b Secondary Voltage Connection 2 Ignition Cable E Iron Core 3 Spark Plug Connector L1 Secondary Ignition Coil 4 Coupling Plug L2 Primary Ignition Coil...
  • Page 749 1E2-10 M161 ENGINE ELECTRICAL Removal & Installation Procedure 1. Disconnect the battery negative cable. 2. Unscrew the 3 screws and remove the ignition cable duct cover. Installation Notice Tightening Torque 9 - 11 Nm 3. Seperate the cable from the ignition cable and the spark plug.
  • Page 750 M161 ENGINE ELECTRICAL 1E2-11 Inspection & Maintenance (for E2.3 MSE) 1. Measure the primary resistance between the cable terminals 1 and 15 after removing the ignition cable wiring connector (1 and 15) with ignition switch OFF. Notice Replace the ignition coil if out of the specified resistance. Specified Value 0.9 - 1.6 Ω...

  • Page 751: Unit Repair

    1E2-12 M161 ENGINE ELECTRICAL UNIT REPAIR BATTERY Inspection Notice When charging the battery, do not leave the inflammable objects around it. When checking the electrolyte of battery, put on an eye protector and gloves. 1. Inspect the surface of the battery and replace if any defects were found on it.
  • Page 752 SECTION 1E3 OM600 ENGINE ELECTRICAL Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.
  • Page 753 1E3-2 OM600 ENGINE ELECTRICAL MAINTENANCE AND REPAIR ON-VEHICLE SERVICE GLOW PLUG 1 Wiring Harness 3 Wire Terminal 2 Nut .............. 4 Nm 4 Glow Plug Preheating System General information The preheating system consists of control, coolant temperature sensor and glow plugs. Control relay - preheating time.
  • Page 754 OM600 ENGINE ELECTRICAL 1E3-3 1. Preheating time - control relay. Control relay functions as followings : Switching of preheating current. Indication of preheating finish. Control of preheating sequence. Indication of fault. 2. Coolant temperature sensor. Coolant temperature sensor senses coolant’s temperature and signals it to the preheating relay continuously.
  • Page 755 1E3-4 OM600 ENGINE ELECTRICAL Preheating System Operation 1. Preheating before start. Preheating time is different by coolant temperature and it is on until the glow indicator light goes off. 2. Preheating after start. Preheating continues for max. 60 seconds to rise in characteristic of warming-up on engine after starting too.
  • Page 756 OM600 ENGINE ELECTRICAL 1E3-5 Removal & Installation Procedure 1. Disconnect the negative terminal of battery. 2. Remove the nut (2). 3. Remove the glow plug (4). 4. Install the glow plug (4). Tightening Torque 20 Nm 5. Tighten the nut (2). Tightening Torque 4 Nm...
  • Page 757 1E3-6 OM600 ENGINE ELECTRICAL ALTERNATOR Preceding Work : Removal of poly V-belt 1 Cooling Fan 4 Alternator 2 Bolt ............45Nm 5 Plug Connection 3 Bolt ............45Nm...
  • Page 758 OM600 ENGINE ELECTRICAL 1E3-7 Removal & Installation Procedure 1. Disconnect the negative terminal of the battery. 2. Disconnect the plug connection (5). 3. OM 662 Engine Align the groove of cooling fan with bolt (2) (arrow). 4. Remove the bolts (2, 3) and take out the alternator. Tightening Torque 45 Nm 5.
  • Page 759 1E3-8 OM600 ENGINE ELECTRICAL STARTER MOTOR 1 Starter Motor 3 Nut ............. 15Nm 2 Washer 4 Bolt ............48Nm Removal & Installation Procedure 1. Disconnect the battery terminals. 2. Disconnect the starter motor cable harnesses. 3. Remove the bolts and then remove the starter motor. 4.
  • Page 760 SECTION 1F1 M162 ENGINE CONTROLS CAUTION: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 761: Specifications

    1F1-2 M162 ENGINE CONTROLS SPECIFICATIONS FASTENER TIGHTENING SPECIFICATIONS Application N•m Fuel Return and Supply Line 25 - 30 Fuel Distributor Assembly Bolt 22.5 - 27.5 Pressure Test Connector 21.6 - 26.4 Fuel Inlet and Outlet Line 25 - 30 Fuel Filter Mounting Bracket Bolt 4 - 8 Crankshaft Position Sensor Bolt 9 - 11...

  • Page 762: Special Tools

    M162 ENGINE CONTROLS 1F1-3 SPECIAL TOOLS SPECIAL TOOLS TABLE 129 589 00 21 00 106 589 00 21 00 Test Box Pressure Tester 119 589 04 63 00 210201Adaptor line Pressure Hose 210 589 08 63 00 ECU Test Cable...
  • Page 763 M162 ENGINE CONTROLS 1F1-5...

  • Page 764: Schematic And Routing Diagrams

    1F1-4 M162 ENGINE CONTROLS SCHEMATIC AND ROUTING DIAGRAMS...

  • Page 765: Diagnosis

    1F1-6 M162 ENGINE CONTROLS DIAGNOSIS SELF DIAGNOSIS SOCKET PIN NUMBERS AND DESCRIPTIONS 1 Ground 11 Remote Engine Start Unit(PIN 10) 2 Ignition 1 12 - 3 Battery Power Supply (Fuse NO.17) 13 Brake System 4 REKES :PIN 6 (ABS 5.3:PIN 11, ABS/ABD 5.3:PIN 46) 5 Engine Speed Signal :MSE PIN 60 14 MSE 3.62S/3.53S(ECU Data Output:PIN 58) 6 TCCU(Part-time)

  • Page 766: Self Diagnosis Failure Code

    M162 ENGINE CONTROLS 1F1-7 SELF DIAGNOSIS FAILURE CODE Failure Fa ilure Description Description code code Coolant temperature sensor open Purge valve open/short Coolant temperature sensor short Condenser fan(HI) relay short(PWR) Coolant temperature sensor signal failure Condenser fan(HI) relay short(GND) Intake temperature sensor open No.1 knock sensor signal failure Intake temperature sensor short No.2 knock sensor signal failure...
  • Page 767 1F1-8 M162 ENGINE CONTROLS Failure Failure Description Description code code Short learning control failure Cruise control acceleration failure Lambda control failure (rich stop) Cruise control deceleration failure Lambda control failure (lean stop) ECU failure(RAM) Lambda idle adaptation failure(above rich ECU failure(EPROM) threshold) Servo motor control output inter-ruption Lambda idle adaptation failure(below lean...
  • Page 768 M162 ENGINE CONTROLS 1F1-9 Failure Failure Description Description code code No.5 injector open/short(GND) Control lever dual operation(CPU2) No.6 injector short(PWR) Control lever safety terminal failure(CPU2) No.6 injector open/short(GND) Unusual pedal position variation(CPU2) Variable intake air valve short(PWR) Unusal throttle position variation(CPU2) Variable intake air valve open/short(GND) Unusal throttle control data(CPU2) Cam actuator short(PWR)

  • Page 769: Test Box Connection

    1F1-10 M162 ENGINE CONTROLS TEST BOX CONNECTION 1 ECU 01 Test Box 2 Test Coupling(No.1 - 60) 02 ECU Test Cable 3 Test Coupling(No.61 - 120) 4 Multi-tester Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 ECU Test Cable...

  • Page 770: Fuel Injection System Test (Mse3.62)

    M162 ENGINE CONTROLS 1F1-11 FUEL INJECTION SYSTEM TEST (MSE3.62) Failure Test Specified Item Checking method Requirement Possible cause step code value ⇒ 1.1 ⇒ 1.0 • • • • • ECU:power • Ignition:ON 11 -14V • supply • ⇒ 1.2 - terminal 30(TM.30) •...
  • Page 771 1F1-12 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value • • • • • ⇒ 4.0 HFM sensor • Ignition:ON 0.9 - 1.1V • ⇒ 4.1 - 4.3 signal • Cable • Engine:in Idle 1.3 - 1.7V •...
  • Page 772 M162 ENGINE CONTROLS 1F1-13 Specified Failure Test Item Checking method Requirement Possible cause value step code • • • • • ⇒ 6.0 Fuel pump • Ignition:ON 11 - 14V • Cable relay: (Fuel pump relay will (approx.1- • Fuel pump relay - Operation operate for 1 - 2 2sec.)
  • Page 773 1F1-14 M162 ENGINE CONTROLS Test Failure Specified Item Checking method Requirement Possible cause step value code • • • • • ⇒ 8.0 ECU: • Engine:in cranking or refer to figure • Cable - RPM signal idle • output - Voltage Engine:in cranking 6.0 - 7.0 V •...
  • Page 774 M162 ENGINE CONTROLS 1F1-15 Failure Test Specified Item Checking method Requirement Possible cause code step value - Internal • Ignition:OFF(injector 14 - 17 Ω resistance temperature is 20°C) (No.1 injector) ⇒ 12.0 • • • • • No.2 • When the coolant •...
  • Page 775 1F1-16 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause step code value - Internal • Ignition:OFF(injector 14 - 17 Ω resistance temperature is 20°C) (No.3 injector) ⇒ 14.0 • • • • • No.4 • When the coolant •...
  • Page 776 M162 ENGINE CONTROLS 1F1-17 Failure Test Specified Item Checking method Requirement Possible cause code step value - Internal • Ignition:OFF(injector 14 - 17 Ω resistance temperature is 20°C) (No.5 injector) ⇒ 16.0 No.6 When the coolant • Cable 194, • • • • • •...
  • Page 777 1F1-18 M162 ENGINE CONTROLS Test Failure Specified Item Checking method Requirement Possible cause step code value ⇒ 18.1 • • • • • Camshaft • Ignition:OFF 8 - 12 Ω • Cable actuator: • Camshaft actuator Diagnosis Solenoid socket resistance 226, •...
  • Page 778 M162 ENGINE CONTROLS 1F1-19 Failure Test Specified Item Checking method Requirement Possible cause code step value ⇒ 22.1 • • • • • CAN module • Ignition:OFF 115 - 125 Ω • Cable resistance in - disconnect the • ABS, ABD, ASR ABS, ABD, coupling "No.1"...
  • Page 779 1F1-20 M162 ENGINE CONTROLS Reference Figures Figure 3. Injection Valve Wave(at idle speed) Figure2. RPM Sgnal Output Figure 4. Injection Valve Wave(at sharp Figure 5. Purge Control Valve Operationg Wave acceleration)

  • Page 780: Ignition System Test

    M162 ENGINE CONTROLS 1F1-21 IGNITION SYSTEM TEST Failure Test Specified Item Checking method Requirement Possible cause step value code ⇒ 1.1 • • • • • ECU:power • Ignition:ON 11 - 14V • supply • ⇒ 1.2 - terminal 30(TM.30) •...
  • Page 781 1F1-22 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value • • • • • Ignition • Ignition:ON 11 -14 V • Cable ⇒ 4.0 coil(T1/2) Ignition coil(T1/2) • - No.3,4 • Fuse No.17 Cylinder •...
  • Page 782 M162 ENGINE CONTROLS 1F1-23 Failure Test Specified Item Checking method Requirement Possible cause step value code - Voltage Engine:in cranking The value will • (alternating) be changed in 1.2 - 1.7 V • Ignition:ON • ⇒ 7.1 • • • • • Camshaft 11 -14 V Cable...
  • Page 783 1F1-24 M162 ENGINE CONTROLS Test Failure Specified Item Checking method Requirement Possible cause step code value • • • • • Ignition ⇒ 10.0 Engine:in cranking 200 - 350 V ⇒ 10.1 • • coil(T1/3) (starter operating) - primary coil - Measuring range: voltage 400 V...
  • Page 784 M162 ENGINE CONTROLS 1F1-25 Reference Figures Figure 6. Crankshaft Position Sensor Signal Figure 7. Camshaft Position Sensor Signal Voltage Identifying the No.1 - 2 Missing Teeth Figure 8. Signal Function Crank Angle Cylinder Crankshaft Position Sensor Signal Camshaft Position Sensor Signal RPM Signal...

  • Page 785: Idling Control And Electronic Pedal System Test

    1F1-26 M162 ENGINE CONTROLS IDLING CONTROL AND ELECTRONIC PEDAL SYSTEM TEST Specified Failure Test Item Checking method Requirement Possible cause code value step 160, ⇒ 1.1 ⇒ 1.0 • • • • • Pedal valve • Ignition:ON • 161, sensor: •...
  • Page 786 M162 ENGINE CONTROLS 1F1-27 Failure Test Specified Item Checking method Requirement Possible cause code step value Throttle valve • Position of potentiometer 2 accelerator pedal: 4.0 - 4.6 V - Closed throttle position - Full throttle with 0.3 - 0.9 V kick down 4.75 - 5.25 V Cable...

  • Page 787: Air Conditioner Control System Test

    1F1-28 M162 ENGINE CONTROLS AIR CONDITIONER CONTROL SYSTEM TEST Specified Failure Test Item Checking method Requirement Possible cause value step code ⇒ 5.1 ⇒ 1.0 • • • • • • Engine:In idling • conditioner • Air conditioner • Cable •...

  • Page 788: Fuel Pressure And Internal Leakage Test

    M162 ENGINE CONTROLS 1F1-29 FUEL PRESSURE AND INTERNAL LEAKAGE TEST Preparation 01 Pressure Tester 02 Pressure Hose 03 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2. Remove the air cleaner cross pipe. 3. Remove the cap on fuel pressure test plug and connect the pressure hose and pressure tester.
  • Page 789 1F1-30 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code step value • • • • • ⇒ 1.0 Fuel Connect the fuel • Engine:in idling 3.2 - 3.6 bar • ⇒ Fuel pump test pressure:in pressure test plug to - Close the valve •...

  • Page 790: Fuel Pump Test

    M162 ENGINE CONTROLS 1F1-31 FUEL PUMP TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Stop Watch 5 Measuring Beaker Connection of the Equipment 1. Turn the ignition switch to "OFF" position. 2.
  • Page 791 1F1-32 M162 ENGINE CONTROLS Test Failure Specified Item Checking method Requirement Possible cause step code value • • • • • ⇒ 1.0 Fuel pump: • Ignition:ON 1 liter of fuel • ⇒ 2.0 - Fuel supply - Disconnect the fuel supply for •...

  • Page 792: Injector Test

    M162 ENGINE CONTROLS 1F1-33 INJECTOR TEST Preparation 1 ECU 03 Test Box 2 Test Coupling(No.1-60) 04 ECU Test Cable 3 Test Coupling(No.61-120) 4 Measuring Beaker 5 Shop Made Cable Tools Required 129 589 00 21 00 Test Box 210 589 08 63 00 Ecu Test Cable Connection of the Equipment 1.
  • Page 793 1F1-34 M162 ENGINE CONTROLS Failure Test Specified Item Checking method Requirement Possible cause code value step • • • • • ⇒ 1.0 Injector: • Ignition:ON There should - Leakage test - Remove the fuel be no leaks distributor and fuel and later injector with a unit.

  • Page 794: Maintenance And Repair

    M162 ENGINE CONTROLS 1F1-35 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE Appearance 1 Cover 5 Pin 2 Plate Vehicle Side : No. 13 - 60 3 Connector Engine Side : No. 73 - 120 4 Flat Pin A Vehicle Side Connector : Black Vehicle Side : No.
  • Page 795 1F1-36 M162 ENGINE CONTROLS Location Engine ECU is located at the inside of cowl side trim in right bottom of instrument panel of passenger side. Removal & Installation Procedure 1. Turn the ignition switch to "OFF" position. 2. Disconnect the battery negative cable 3.
  • Page 796 M162 ENGINE CONTROLS 1F1-37 ECU Pin Numbers and Descriptions Vehicle Connector Pin No. Description Abbreciation Starter motor TM.50 TM.50 Electronic ground Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87 V-BATTERY TM.30 TM.30 Immobilizer crypto read WFS I/O Immobilizer crypto write WFS O Lambda probe 1 ground...
  • Page 797 1F1-38 M162 ENGINE CONTROLS Pin No. Decription Abbreciation Brake switch Air conditioning clutch relay KLIKU Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan (H1) CAN-Low CAN L CAN-High CAN H Clutch switch Air conditioning KLIMA Electronic traction signal...
  • Page 798 M162 ENGINE CONTROLS 1F1-39 Engine Connector Pin No. Abbreciation Decription Injector-cylinder 2 Injector-cylinder 4 Injector-cylinder 1 Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 Ignition coil cylinder 1+6 ZSC16 Ignition coil cylinder 2+5 ZSA25 Ignition coil cylinder 3+4 ZSB34...
  • Page 799 1F1-40 M162 ENGINE CONTROLS Pin No. Description Abbreciation Hot film air mass signal E-GAS potentiometer ground E-GAS potentiometer 2 signal IP2S E-GAS potentiometer 1 signal IP1S Intake manifold resonance flap Crankshaft sensor ground Crankshaft sensor signal Camshaft sensor ground NOWE- Hot film air mass ground Camshaft sensor signal NOWE+...
  • Page 800 M162 ENGINE CONTROLS 1F1-41 Application E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Starter motor TM.50 TM.50 Electronic ground Lambda probe 1 heating LSH1 Power ground TM.31 TM.31 V-BATTERY TM.87 TM.87 V-BATTERY TM.30 TM.30 Immobilizer crypto read WFS I/O Immobilizer crypto write...
  • Page 801 1F1-42 M162 ENGINE CONTROLS E32 ENG, E32 ENG, 4speed A/T Remarks Pin No. Description Abbreviation 5speed M/T (BTRA) Pedal potentiometer 1 ground Pedal potentiometer 1 supply SP1+5V Fuel pump relay Tank purge valve Engine fan CAN-Low CAN L CAN-High CAN H ¡...
  • Page 802 M162 ENGINE CONTROLS 1F1-43 E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Injector-cylinder 2 Injector-cylinder 4 Injector-cylinder 1 Injector-cylinder 6 Injector-cylinder 5 Injector-cylinder 3 E-GAS motor plus E-GAS motor minus Power ground TM.31 TM.31 Ignition coil cylinder 1+6 ZSC16 Ignition coil cylinder 2+5...
  • Page 803 1F1-44 M162 ENGINE CONTROLS E32 ENG, E32 ENG, 4speed A/T Pin No. Description Abbreviation Remarks 5speed M/T (BTRA) Intake manifold resonance flap Crankshaft sensor ground Crankshaft sensor signal Camshaft sensor ground NOWE- Hot film air mass ground Camshaft sensor signal NOWE+ Hot film air mass supply V-REF.HFM...
  • Page 804 M162 ENGINE CONTROLS 1F1-45 Removal & Installation Procedure l when removing the ECU only 1. Turn the ignition switch to "OFF" position. 2. Disconnect the negative battery cable. 3. Disconnect the couplings from ECU. 4. Unscrew the left and right bolt (3) on bolt (1) and auxiliarly bracket and remove the auxiliarly bracket from the bracket assembly (2).

  • Page 805: Fuel Pressure Regulator

    1F1-46 M162 ENGINE CONTROLS FUEL PRESSURE REGULATOR 1 Vacuum Hose 4 O-ring ............. replace 2 Circlip 5 O-ring ............. replace 3 Fuel Pressure Regulator...
  • Page 806 M162 ENGINE CONTROLS 1F1-47 Removal & Installation Procedure 1. Remove the fuel pressure test connector. 2. Discharge the pressure in fuel supply system by pressing the service valve. 3. Disconnect the vacuum hose. 4. Disconnect the circlip and remove the fuel pressure regulator.
  • Page 807 1F1-48 M162 ENGINE CONTROLS Function of the Fuel Pressure Regulator The fuel pressure regulator maintains the fuel pressure in the fuel line with the pressure of 3.2 bars to 3.8 bars according to the intake manifold pressure. This operating pressure cannot be changed, and the fuel injection volume will be only determined by the injection time.
  • Page 808 M162 ENGINE CONTROLS 1F1-49 The pressure difference between the fuel pressure and the intake manifold is approx. 3.2 bars during idling. 1. Fuel Pressure Regulator 2. Intake Manifold 3. Fuel Return(to fuel tank) 4. Fuel Supply(from fuel pump) 7. Fuel Pressure(approx. 3.2 bars) 8.

  • Page 809: Fuel Distributor

    1F1-50 M162 ENGINE CONTROLS FUEL DISTRIBUTOR Preceding Work : Removal of intake air duct 1 Vacuum Hose 5 Bolt (M8 X 50) ........ 22.5-27.5 Nm 2 Fuel Return Line ........25-30Nm 6 Fuel Distributor 3 Fuel Supply Line ........25-30Nm 7 O-ring ........
  • Page 810 M162 ENGINE CONTROLS 1F1-51 Removal & Installation Procedure 1. Discharge the fuel pressure from the fuel pressure test connector. 2. Disconnect the battery ground cable. 3. Disconnect the vacuum hose from the fuel pressure regulator. 4. Remove the cable guide. 5.
  • Page 811 1F1-52 M162 ENGINE CONTROLS 8. Remove the injectors and the fuel distributor carefully. 9. Installation should follow the removal procedure in the reverse order. 10. Check for fuel pressure and internal leakage by operating the engine. Fuel Pressure Test 1. Turn the ignition switch to "OFF" position. 2.
  • Page 812 M162 ENGINE CONTROLS 1F1-53 Internal Leakage Test 1. Connect the fuel pressure gauge to the fuel pressure test connector. 2. Stop the engine for approx. 30 minutes and then check the fuel pressure changes. Pressure Change Possible Cause Fuel leakage at the •...

  • Page 813: Injector

    1F1-54 M162 ENGINE CONTROLS INJECTOR Preceding Work : Removal of fuel distributor 1 O-ring ........rplace, if damaged 4 O-ring ........replace, if damaged 2 Injector Bracket 5 Fuel Distributor 3 Injector...
  • Page 814 M162 ENGINE CONTROLS 1F1-55 Removal & Installation Procedure 1. Remove the O-ring. Check for damage and replace it if necessary. 2. Remove the injector bracket from the injector. Installation Notice Exactly seat the anti-twist lock into the square groove in injector.
  • Page 815 1F1-56 M162 ENGINE CONTROLS The Injector Spray Pattern Check 1. Connect the test box (129 589 00 21 00) to the ECU. 2. Disconnect the connector from connector. 3. Disconnect the fuel distributor and injector with a unit from engine without removing the fuel supply and return line. Notice Prepare the beaker for taking the poping fuel.

  • Page 816: Fuel Filter

    M162 ENGINE CONTROLS 1F1-57 FUEL FILTER 1 Fuel Filter 3 Inlet 2 Outlet Removal & Installation Procedure 1. Open the fuel tank cap and remove the fuel tank pressure. 2. Remove the fuel at (2) and in (3). Installation Notice Tightening Torque 25 - 30 Nm 3.

  • Page 817: Fuel Pump

    1F1-58 M162 ENGINE CONTROLS FUEL PUMP 1 Reservoir Tank 2 Fuel Sensor (float/arm) 3 Resistance 4 Wiring Connector 5 Fuel Supply Pipe 7 Float 10 Flange and Harness Assembly 11 Fuel Pump 12 Spring 13 Thermister Housing 14 Thermister 15 Resistor Card and Wiper 16 Float Arm Requirements for Fuel Pump Item...
  • Page 818 M162 ENGINE CONTROLS 1F1-59 1 Fuel Pump Connector Wiring 5 Fuel Return Pipe 2 Fuel Return Pipe 6 Fuel Supply Pipe 3 Fuel Supply Pipe 7 Float 4 Bolts 8 Ground Stud (Sender "-") Harness Location & Connector COLOR Pump "+" 2.0 BR Thermister "+"...
  • Page 819 1F1-60 M162 ENGINE CONTROLS Tools Required 661 589 00 46 00 Cap Remover Removal & Installation Procedure 1. Disconnect the negative battery cable. 2. Disconnect the harness connector (1). 3. Disconnect the fuel supply (6) and return (5) pipes. 4. Using a special tool, Unscrew the eight fuel retaining bolts and remove the pump from fuel tank.
  • Page 820 M162 ENGINE CONTROLS 1F1-61 Measure the Fuel Delivery From the Fuel Pump 1. Disconnect the return pipe from fuel distributor and insert the appropriate hose into it. 2. Place the hose end into the beaker with the minimum capacity of 1Liter. 3.

  • Page 821: Purge Switchover Valve

    1F1-62 M162 ENGINE CONTROLS PURGE SWITCHOVER VALVE 1 Purge Switchover Valve 2 Line to Engine 3 Line to Canister 4 Canister Functions The fuel vaporization control system is installed to inhibit the fuel vaporized gas from discharging into the atmosphere. The fuel vaporized gas that is accumulated in the canister abstracts through the purge switchover valve purification during the engine combustion (except the decreasing mode) and coolant...
  • Page 822 M162 ENGINE CONTROLS 1F1-63 Test 1. Maintain the normal temperature and idling state by operating the engine. 2. Connect the ECU terminal No.11 and No.34 and check for normal operation through the output waves using the scanner. Notice Test during purge control switchover valve operation after the minimum of 1 minute after the engine turned on.

  • Page 823: Vacuum System

    1F1-64 M162 ENGINE CONTROLS VACUUM SYSTEM 1 Purge Control Valve 10 Vacuum Line Rubber Hose 2 Molded Hose 11 Vacuum Tube(Gray, 270mm) 12 Molded Hose 3 Insulator 13 Rubber Cap 4 Fuel Tube 18 Rubber Hose 5 Molded Hose 19 Vacuum Tube(Brown or Black, 770mm) 6 Idle Regulator 20 Rubber Hose 7 Resonance Flap...

  • Page 824: Crankshaft Position Sensor

    M162 ENGINE CONTROLS 1F1-65 CRANKSHAFT POSITION SENSOR 1 Crankshaft Position Sensor 3 Segment 2 Bolt (M6 X 14) ........9 -11Nm 4 Flywheel Removal & Installation Procedure 1. Disconnect the wiring connector at the crankshaft position sensor. 2. Unscrew the bolt and remove the crankshaft position sensor unit.
  • Page 825 1F1-66 M162 ENGINE CONTROLS Crankshaft Position Sensor Resistance Inspection 1. Disconnect the coupling "E" of ECU while the ignition switch is in "OFF" position. 2. Measure the resistance between the coupling terminal pin No.99 and No.100 using a multimeter. Specified Value 1050 - 1400 Ω...

  • Page 826: Camshaft Position Sensor

    M162 ENGINE CONTROLS 1F1-67 CAMSHAFT POSITION SENSOR 1 Bolt (M6 X 14) ......... 9-11Nm 3 Shim 2 Camshaft Position Sensor 5 O-ring Removal & Installation Procedure 1. Disconnect the wiring connector from the camshaft position sensor. 2. Unscrew the bolt (2) and remove the camshaft position sensor.
  • Page 827 1F1-68 M162 ENGINE CONTROLS Camshaft Position Sensor Signal Voltage Inspection 1. Connect the test box to the ECU. 2. Measure the voltage between the ECU terminal No.11 and No.106 while the engine speed is at idle. Specified Value 1.2 - 1.7 V Notice The signal voltage will be changed in the range of 1.2 - 1.7V.

  • Page 828: Hot Film Air Mass (Hfm) Sensor

    M162 ENGINE CONTROLS 1F1-69 HOT FILM AIR MASS (HFM) SENSOR 1 Housing 4 Connector 2 Protector Net 5 Hot film Sensor 3 Electronic Housing 6 Measuring Port Removal & Installation Procedure 1. Turn the HFM sensor coupling in the direction shown in the figure in the right so that it gets separated from the contact surface.
  • Page 829 1F1-70 M162 ENGINE CONTROLS Circuit Diagram 1 Housing 2 Electronic Housing 3 Connector : Heat Resistance : Temperature Resistance : Sensor Resistance...
  • Page 830 M162 ENGINE CONTROLS 1F1-71 HFM Sensor Input Voltage Inspection 1. Measure the HFM sensor signal voltage between the ECU terminal No.103 and No.104. Specified Value (coolant temperature is over 70°C) Iginition"ON” 0.9 - 1.1 V Engine at Idle 1.3 - 1.7 V If the measured value is not within the specified value, the possible cause may be in cable or HFM sensor in itself.

  • Page 831: Oxygen Sensor

    1F1-72 M162 ENGINE CONTROLS OXYGEN SENSOR 1 Electricity Wire 2 Oxygen Sensor Housing 3 Sensor Ceramic 4 Electrode (Internal) 5 Electrode (External) 6 Heating Coil 7 Open Space 8 Protector Tube Functions The oxygen sensor optimizes the combustion (Air-Fuel Ratio 14.7:1) and resets the Air-fuel ratio in the ECU after sensing the amount of oxygen from the exhaust gases to diminish the exhaust gases.
  • Page 832 M162 ENGINE CONTROLS 1F1-73 Oxygen Sensor Signal Voltage Inspection 1. Measure the oxygen sensor signal voltage between the ECU terminal No.11 and No.9. Maintain the engine speed ia at idle while the coolant temperature is over 80°C. Specified Value -0.2 - 1.0 V If the measured value is not within the specified value, the possible cause may be in cable, oxygen sensor or ECU.

  • Page 833: Knock Sensor

    1F1-74 M162 ENGINE CONTROLS KNOCK SENSOR Functions Vibration of the engine block is transmitted to the sensor and transferred to the ECU in the form of an alternating voltage signal via a shielded cable. The knock sensor is fastened to the engine block to recognize knocking in all cylinders.

  • Page 834: Coolant Temperature Sensor

    M162 ENGINE CONTROLS 1F1-75 COOLANT TEMPERATURE SENSOR 1 Artificial Resin Housing 4 Connector 2 Metal Housing 5 Coolant Temperature Sensor 3 NTC (negative temperature coefficient) Resistor Removal & Installation Procedure 1. Remove the pressure by opening the pressure cap in the coolant subtank.
  • Page 835 1F1-76 M162 ENGINE CONTROLS Inspection 1. Measure the coolant sensor input voltage between the ECU terminal No.79 and No.78 while the ignition switch in "ON" position. Temperature (°C) Voltage (V) 3.57 1.22 0.78 allowable error :±5% 2. Measure the resistance between the coolant temperature sensor terminal No.1 and No.4 with the coolant temperature sensor disconnected.
  • Page 836 M162 ENGINE CONTROLS 1F1-77 Service Data Temperature(°C) Resistance(W) Voltage(V) Temperature(°C) Resistance(W) Voltage(V) 48,550 4.8991 1.8632 27,000 4.8214 1.5132 15,670 4.7001 1.2179 9,450 4.5215 0.9775 5,890 4.4273 0.7806 3,790 3.9562 0.6255 2,500 3.5714 111.6 0.5020 1,692 3.1426 88.0 0.4044 1,170 2.6959 71.2 0.3323 2.2618...

  • Page 837: Accelerator Pedal Module

    1F1-78 M162 ENGINE CONTROLS ACCELERATOR PEDAL MODULE 1 Accelerator pedal 4 6-Pin Connector 2 Accelerator pedal Sensor 5 Kick down Switch 3 Bolts (2 Pieces) ........4-8 Nm 6 Nut (1 piece) ..........4-8 Nm Removal and Installation Procedure 1. Disconnect the 6-pin connector(arrow). 2.
  • Page 838 M162 ENGINE CONTROLS 1F1-79 Accelerator Pedal Sensor Connector(Sensor Side) Potentiometer 1. Pin no. 3 :Red Pin no. 1 :Yellow Pin no. 5 :Brown Potentiometer 2. Pin no. 6 :Violet Pin no. 4 :Green Pin no. 2 :White Accelerator Pedal Sensor Connector(Vehicle Side) Potentiometer 1.
  • Page 839 SECTION 1F3 OM600 ENGINE CONTROLS Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 840: Fuel System

    1F3-2 OM600 ENGINE CONTROLS MAINTENANCE AND REPAIR ON-VEHICLE SERVICE FUEL SYSTEM 1 Fuel Injection Pump 6 Fuel Return Hose 2 Fuel Feed Pump 7 Injection Line 3 Overflow Valve 8 Fuel Tank 4 Injection Nozzle 9 Fuel Filter 5 Pre-filter 10 Choke Orifice...

  • Page 841: Fuel Injection Pump Coding

    OM600 ENGINE CONTROLS 1F3-3 FUEL INJECTION PUMP CODING Model Code OM661 LA Engine PES 4M 55C 320 RS 167 OM662 LA Engine PES 5M 55C 320 RS 168 Fuel Injection Pump Code Example) PES 5M 55C 320 RS 168 Pump Self-Driven End Flange Mounting Number of Cylinders (5EA)

  • Page 842: Fuel Tank

    1F3-4 OM600 ENGINE CONTROLS FUEL TANK 1 Fuel Tank 8 Fuel Return Tube 2 The Sender of Fuel Tank 9 Filter Hose 3 2-way Check Valve 10 Fuel Tank Hose 4 Pre Filter 11 Fuel Filler Cap 5 Front Fuel Filler Neck 12 Clip 6 Rear Fuel Filler Neck 13 Clip...

  • Page 843: Vacuum Control System Test

    OM600 ENGINE CONTROLS 1F3-5 VACUUM CONTROL SYSTEM TEST 2 Engine Cut-Off Valve (Ignition Key Switch) 8 30° Thermovalve 3 Auto-locking Hub Solenoid Valve 9 Fuel Injection Pump 4 Engine Stop Valve Unit 10 Filter with Restriction 5 PLA Vacuum Unit (Idle Speed Adjustment) 11 Check Valve 6 Engine 12 Modulating Pressure Line (Automatic T/M)
  • Page 844 1F3-6 OM600 ENGINE CONTROLS Tools Required 001 589 73 21 00 Vacuum Pump 201 589 13 21 00 Vacuum Tester 667 589 00 21 00 TDC pulse generator Commercial Tools e.g. Bosch MOT 001.03 Digital tester Sun DIT 9000 e.g. Ahlborn, Therm 2263-2 Temperature measuring instrument with test probe Eichenfeldstrabe 1 - 3 WB24...
  • Page 845 OM600 ENGINE CONTROLS 1F3-7 Test step 1 Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run engine at idle speed. = > Vacuum 500 mbar Lines and connections leaking. Faulty PLA vacuum unit. (Remove the connection hose from vacuum pump) Connect vacuum pump (14) direct to PLA vacuum unit (5) and pressurize with vacuum.
  • Page 846 1F3-8 OM600 ENGINE CONTROLS Detach line downstream of air admission filter (13). Vacuum drops. Faulty thermovalve Fit the line onto air admission filter. Built up vacuum with vacuum pump. Detach the plug from air admission line. Vacuum drops. Faulty filter with restriction. Go to test step 2.
  • Page 847 OM600 ENGINE CONTROLS 1F3-9 Test step 2 Connect vacuum pump (14) with Y adapter to PLA vacuum unit (5). Run the engine at idle speed. Vacuum drops to ‘0’ at approx. 30° C of the thermovalve. Faulty thermovalve. Defective filter with restriction. Stop the engine.

  • Page 848: Vacuum Pump Test

    OM600 ENGINE CONTROLS 1F3-11 VACUUM PUMP TEST 1 Fuel Filter 3 Ancillaries Connection 2 Vacuum Line 4 Vacuum Tester Tools Required 201 589 13 21 00 Vacuum Tester...
  • Page 849 1F3-12 OM600 ENGINE CONTROLS Test Procedure 1. Remove the fuel filter (1) and keep the filter not to be damaged from running engine. 2. Remove the vacuum line (2) from ancillaries connection (3). 3. Connect the vacuum tester (4) to the ancillaries connection (3).

  • Page 850: Vacuum Pump

    OM600 ENGINE CONTROLS 1F3-13 VACUUM PUMP Preceding Work : Remove the poly V-belt 1 Bolt ............10Nm 4 Vacuum Line (Brake Booster) 2 Vacuum Pump 5 Gasket ........... Replace 3 Vacuum Line (Ancillaries)
  • Page 851 1F3-14 OM600 ENGINE CONTROLS Removal & Installation Procedure 1. Remove the vacuum line (3, 4). 2. Remove the bolts (1) evenly. Notice If necessary, rotate the engine until the pressure on the tappet of the vacuum pump is released. 3. Remove the vacuum pump (2). 4.

  • Page 852: Vacuum Unit Replacement

    OM600 ENGINE CONTROLS 1F3-15 VACUUM UNIT REPLACEMENT 1 Bracket 2 Bolt 3 Vacuum Unit 4 Vacuum Line 5 Seal ..........Replace...

  • Page 853: Idle Speed Adjustment

    1F3-16 OM600 ENGINE CONTROLS IDLE SPEED ADJUSTMENT Service Data Engine Idle Speed OM661LA Engine 750 - 850 rpm OM662LA Engine 720 - 820 rpm Tools Required 667 589 00 21 00 TDC Pulse Generato Commercial Tool e.g. Bosch, MOT 001.03 Digital Tester Sun, DIT 9000 Adjustment Procedure...
  • Page 854 OM600 ENGINE CONTROLS 1F3-17 5. Ensure not to damage the idle spring in the governor and adjust idle speed by turning the PLA unit (5) slowly. Clockwise RPM Decrease Counterclockwise RPM Increase Notice Do not rotate the PLA unit over ½ turn from the position marking.

  • Page 855: Fuel Pump Test

    1F3-18 OM600 ENGINE CONTROLS FUEL PUMP TEST Notice Before test, replace the fuel filter cartridge and fuel prefilter. Fuel Feed Test 1. Disconnect the fuel return line (1) and seal up it with plug. 2. Insert the plastic hose (5) and put the end into the measuring beaker (6).
  • Page 856 OM600 ENGINE CONTROLS 1F3-19 Fuel Pressure Test...
  • Page 857 1F3-20 OM600 ENGINE CONTROLS Tools Required 617 589 04 21 00 Tester 1. Disconnect the fuel line (2) from the fuel filter. 2. Remove the banjo bolt (4) from the fuel injection pump and remove the seals (3) and fuel line (2). 3.

  • Page 858: Fuel Pump

    OM600 ENGINE CONTROLS 1F3-21 FUEL PUMP 1 Fuel Injection Pump 5 Gasket ........... Replace 2 Pressure Line ..........13Nm 6 Spring Lock Washer 3 Suction Line 7 Hexagon Nuts 4 Hose Clip ..........Replace 8 Fuel Pump...

  • Page 859: Injection Nozzle Test

    1F3-22 OM600 ENGINE CONTROLS INJECTION NOZZLE TEST Preceding Work : Removal of fuel injection nozzle 1. Fuel Injection Nozzle ..... New : 115 - 125bar 2 Tester Used : min. 100bar 3 Valve A Closed Spray = good B Stringy Spray = poor...
  • Page 860 OM600 ENGINE CONTROLS 1F3-23 Tools Required 000 589 14 27 00 Tester Notice When testing the injection nozzle, do not place your hand into the spray of a nozzle. The spray will penetrate deep into the skin and destroy the tissue. 1.
  • Page 861 1F3-24 OM600 ENGINE CONTROLS 5. Opening pressure test : Open the valve (3) and slowly operate the hand lever at tester (approx. 1 stroke / second) and measure opening pressure. New Nozzle 115 - 125bar Used Nozzle Min. 100bar Difference Between Nozzles Max.

  • Page 862: Injection Nozzles

    OM600 ENGINE CONTROLS 1F3-25 INJECTION NOZZLES 1 Fuel Injection Nozzle ......35-40Nm 2 Fuel Return Hose 3 Plug 4 Nozzle Washer ........Replace 5 Fuel Injection Pipe ........18Nm...
  • Page 863 1F3-26 OM600 ENGINE CONTROLS Tools Required 001 589 65 09 00 Serration Wrench Removal & Installation Procedure 1. Remove the plastic clip from the injection pipe 2. Remove the fuel return hose. 3. Disconnect the injection pipes from the injection nozzles and push them to the side.

  • Page 864: Injection Nozzle Repair

    OM600 ENGINE CONTROLS 1F3-27 INJECTION NOZZLE REPAIR Preceding Work : Removal of fuel injection nozzle 5 Intermediate Disc 1 Nozzle Holder 6 Nozzle Needle 2 Steel Washer 7 Nozzle Body 3 Compression Spring 8 Nozzle Tensioning Nut ........ 80Nm 4 Thrust Pin...
  • Page 865 1F3-28 OM600 ENGINE CONTROLS Tools Required 001 589 65 09 00 Socket Wrench Insert 000 589 00 68 00 Cleaning Set Repair Procedure 1. Clamp the nozzle holder (1) in a vice and remove the nozzle tensioning nut (8). Notice Use protective jaws for clamping.
  • Page 866 OM600 ENGINE CONTROLS 1F3-29 7. Check the fuel injection nozzle and adjust opening pressure if necessary. Opening pressure adjustment Disassemble the fuel injection nozzle and replace the steel washer (2). Notice Each 0.05mm thickness of the washer results in a pressure difference of approx.

  • Page 867: Removal And Installation Of Injection Timing Device

    1F3-30 OM600 ENGINE CONTROLS REMOVAL AND INSTALLATION OF INJECTION TIMING DEVICE Preceding Work : Removal of vacuum pump 1 Cylinder Head Cover 10 Washer 2 Bolt ............10Nm 11 Bolt (Left-Hand Thread) ......46Nm 3 Gasket ........... Replace 12 Camshaft Sprocket 4 Fuel Injection Pump 13 Washer 5 Seal ............
  • Page 868 OM600 ENGINE CONTROLS 1F3-31 Tools Required 601 589 00 08 00 Flange 601 589 05 21 00 Locking Screw 116 589 20 33 00 Sliding Hammer 116 589 02 34 00 Threaded Bolt 667 589 04 63 00 Retaining Plate Removal &...
  • Page 869 1F3-32 OM600 ENGINE CONTROLS 4. Position the no.1 cylinder at ATDC 15° . Notice Do not rotate the engine with camshaft sprocket bolt or opposite direction of the engine rotation. 5. Remove the plug (6) and seal (5) from the fuel injection pump and collect oil in a suitable vessel.
  • Page 870 OM600 ENGINE CONTROLS 1F3-33 8. Remove the chain tensioner (17). Installation Notice Tightening Torque 80 Nm Notice Replace the seal (16). 9. Pull out the 12-sided stretch bolt (14) and washer and remove the camshaft sprocket (12). 10. Pull out the bolt (11) and washer (10). Notice Be careful that the bolt is left-hand thread.
  • Page 871 1F3-34 OM600 ENGINE CONTROLS 12. Push back the timing chain with retaining plate (26) and remove the injection timing device (9). Retaining Plate 667 589 04 63 00 13. Installation should follow the removal procedure in the reverse order. 14. After assembling the engine, check start of delivery and adjust if necessary.

  • Page 872: Injection Timing Device

    OM600 ENGINE CONTROLS 1F3-35 INJECTION TIMING DEVICE Preceding Work : Removal of injection timing device 1 Cam Sprocket ........... Check 4 Segment Flange and Drive Hub 2 Bushing ............ Check 5 Compression Springs 3 Governor Weights...
  • Page 873 1F3-36 OM600 ENGINE CONTROLS Disassembly & Assembly 1. Remove the governor weights (3). 2. Pull out the compression springs (5) and cam sprocket (1) from the segment flange (4). 3. Knock out the bushing with a proper drift. 4. Installation should follow the removal procedure in the reverse order.

  • Page 874: Start Of Delivery Test (Position Sensor, Riv Method)

    OM600 ENGINE CONTROLS 1F3-37 START OF DELIVERY TEST (POSITION SENSOR, RIV METHOD) 1 Position Sensor 4 Seal ............Replace 2 Battery 5 Screw Plug ..........30Nm 3 Fuel Injection Pump Service Data Start of Delivery (RIV) ATDC 14° - 16°...
  • Page 875 1F3-38 OM600 ENGINE CONTROLS Tools Required 617 589 08 21 00 Position Sensor Test Procedure 1. Remove the screw plug (5) and seal (4) and collect oil in a suitable vessel. 2. Install the position sensor (1) into the governor housing of the injection pump to be the guide pin of the position sensor facing up.
  • Page 876 OM600 ENGINE CONTROLS 1F3-39 Digital Tester, RIV Method (Connection Diagram for Testers Without Adapter) 1 Fuel Injection Pump 4 TDC Pulse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Tester...
  • Page 877 1F3-40 OM600 ENGINE CONTROLS (Connection Diagram for Testers With Adapter) 1 Fuel Injection Pump 4 TDC Pulse Sender Unit 2 Rl Sensor 5 Battery 3 Digital Tester 6 Rl Pulse Generator Service Data Start of Delivery (RIV) ATDC 14° - 16° Idle Speed OM661LA : 720 - 820 rpm, OM662LA : 750 - 850 rpm...
  • Page 878 OM600 ENGINE CONTROLS 1F3-41 Tools Required 617 589 09 21 00 Rl Sensor 617 589 10 21 00 Timing Tester 667 589 00 21 00 TDC Pulse Generator Commercial Tools Item Tools Digital Tester With Pulse Generator Bosch, MOT 001.03 Hartmann &...
  • Page 879 1F3-42 OM600 ENGINE CONTROLS After Testing Preceding Work : Start of delivery test Position Sensor (RIV method) 1 Adjusting Screw 4 Bolt ............23Nm 2 Bolt ............23Nm 5 Scale..Rl start of delivery = 14° - 16° ATDC 3 Fuel Injection Pump...
  • Page 880 OM600 ENGINE CONTROLS 1F3-43 Tools Required 617 589 08 21 00 Position Sensor Adjustment Procedure 1. Position the No. 1 cylinder at ATDC 15° Notice Do not rotate the engine in opposite direction of engine rotation. 2. Remove the bolt (2) at the supporting bracket. 3.
  • Page 881 1F3-44 OM600 ENGINE CONTROLS Digital tester (RIV Method) 1 Bolt ............23Nm 3 Bolt ............23Nm 2 Adjusting Screw ..To the right : start of delivery retarded To the left : start of delivery advanced Service Data Start of Delivery (RIV) ATDC 14°...
  • Page 882 OM600 ENGINE CONTROLS 1F3-45 Adjustment Procedure 1. Remove the bolt (3) at the supporting bracket. 2. remove the bolts (1) at the timing case cover. 3. Run the engine at idle speed. 4. Turn the adjusting screw (2) until the specification (15° ± 1° ATDC) is indicated on the digital tester.

  • Page 883: Fuel Injection Pump

    1F3-46 OM600 ENGINE CONTROLS FUEL INJECTION PUMP Preceding Work : Removal of vacuum pump Removal of air cleaner housing Removal of intake manifold 18 Chain Tensioner ......... 80Nm 24 Oil Pan 19 Seal ............Replace 25 Fuel Injection Pump 20 Bolt(Left-Hand Thread) ......46Nm 26 Seal ............
  • Page 884 OM600 ENGINE CONTROLS 1F3-47 Removal Procedure 1. Position then no.1 cylinder at 15° ATDC. Notice Do not rotate the engine in opposition direction of engine rotation. 2. Remove the connecting rod (9). 3. Disconnect the vacuum lines (13, 14). 4. Remove the accelerator control damper (10). (Manual transmission vehicle) 5.
  • Page 885 1F3-48 OM600 ENGINE CONTROLS 10. Install the assembly cage (29) and remove the bolt (20) and pull off the washer (21). Notice Be careful that the bolt (20) is left hand thread. Assembly Cage 601 589 05 14 00 11. Remove the chain tensioner (18) and seal (19). 12.
  • Page 886 OM600 ENGINE CONTROLS 1F3-49 Installation Procedure 1. Remove the screw plug (27) and seal (26) and collect oil in a vessel. 2. Insert flange (31) onto the injection pump camshaft and turn until the cam of the governor is visible in the hole. Flange 601 589 00 08 00 3.
  • Page 887 1F3-50 OM600 ENGINE CONTROLS 5. Coat the new seal (23) with engine oil and install it. 6. Insert the fuel injection pump (25) and tighten the bolts (22). Tightening Torque 23 Nm 7. Remove the locking screw (32). 8. Tighten the bolt(12). Tightening Torque 23 Nm 9.
  • Page 888 OM600 ENGINE CONTROLS 1F3-51 11. Assemble the plastic clip (8). 12. Connect the vacuum line (13, 14). 13. Connect the connecting rod (9). 14. Connect the accelerator control damper (10). (Manual transmission vehicle) 15. Install the chain tensioner. 16. Install the vacuum pump. 17.
  • Page 889 SECTION 1G1 M162 ENGINE INTAKE & EXHAUST TABLE OF CONTENTS Intake Air Duct ..... . . 1G1-4 Specifications..... . . 1G1-1 Intake Manifold .

  • Page 890: Air Cleaner

    1G1-2 M162 ENGINE INTAKE & EXHAUST MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER 1 Air - Cleaner Assembly 4 Blot 2 Air - Cleaner Shield Upper Cover 5 Air Intake Shield 3 Blot...
  • Page 891 M162 ENGINE INTAKE & EXHAUST 1G1-3 Removal & Installation Procedure 1. Release the clamp securing HFM sensor and air cleaner. 2. Disengage the air cleaner assembly and HFM sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 4.

  • Page 892: Intake Air Duct

    1G1-4 M162 ENGINE INTAKE & EXHAUST INTAKE AIR DUCT 1 Clamp 2 Sleeve 3 Nut 4 Clamp 5 Intake Air Duct Removal & Installation Procedure 1. Remove the clamp (1) and disconnect the HFM sensor. 2. Remove the nut (3) (arrow). 3.

  • Page 893: Intake Manifold

    M162 ENGINE INTAKE & EXHAUST 1G1-5 INTAKE MANIFOLD Preceding Work : Removal of fuel distributor and injection valve 1 Bolt (M6 X 40, 4 pieces) ......9-11 Nm 13 Bolt (M6 x 40, 4 pieces) ......9-11 Nm 2 Softcap 14 Throttle Body - Electric 3 Resonance Flap 15 Gasket ...........
  • Page 894 1G1-6 M162 ENGINE INTAKE & EXHAUST Removal & Installation Procedure l Upper Intake Manifold 1. Disconnect the vacuum hose (8,9). 2. Loosen the clip (22). 3. Remove the upper intake manifold (5) after unscrewing the bolt (6). Installation Notice Tightening Torque 22.5 - 27.5 Nm Notice Check the gasket and replace it if necessary.

  • Page 895: Resonance Flap

    M162 ENGINE INTAKE & EXHAUST 1G1-7 RESONANCE FLAP 1 Soft Cap (2) 4 Vacuum Hose 2 Bolt (M6 x 25, 4 pieces) ......9-11 Nm 5 Resonance Flap 3 O-ring 6 Gasket ........... Replace Removal & Installation Procedure 1. Remove the 2 soft caps (1). 2.
  • Page 896 1G1-8 M162 ENGINE INTAKE & EXHAUST Function Description A pneumatically actuated resonance flap (5) is located on the intake manifold, and will be opened and closed by load, which operates resonance flap according to engine and controlled by ECU and rpm. 1.

  • Page 897: Exhaust Manifold

    M162 ENGINE INTAKE & EXHAUST 1G1-9 EXHAUST MANIFOLD Preceding Work : Removal of air cleaner 1 Nut ............36-44 Nm 3 Exhaust Manifold 2 Gasket ........... Replace...
  • Page 898 1G1-10 M162 ENGINE INTAKE & EXHAUST Tools Required 103 589 01 39 00 Caulking Bolt Removal & Installation Procedure 1. Remove the flange bolt from the exhaust manifold, and disconnect the front exhaust pipe. Installation Notice Tightening Torque 30 Nm Notice Check for nut damages and replace the nut if necessary.
  • Page 899 M162 ENGINE INTAKE & EXHAUST 1G1-11 Removal and Installation of Exhaust Line 1 Exhaust Manifold 10 Nut 2 Rivet Nut 11 Gasket ........... Replace 3 Bolt ............30 Nm 12 Rubber Pad 4 Front Pipe 13 Nut ............28-47 Nm 5 Oxygen Sensor 14 Center Muffler 6 Bolt ............
  • Page 900 SECTION 1G2 M161 ENGINE INTAKE & EXHAUST TABLE OF CONTENTS Specifications..... . . 1G2-1 Air Intake Shield ..... . 1G2-4 Intake Air Duct .

  • Page 901: On-Vehicle Service

    1G2-2 M161 ENGINE INTAKE & EXHAUST MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER 1 Air Cleaner Assembly 5 Air Inlet Duct 2 Element Assembly 6 Bolt (M8 × 30 ) ........22.5-27.5 Nm 3 Insulator 7 Bolt (M6 × 35 ) ...........9-11 Nm 4 Air Duct Hose...
  • Page 902 M161 ENGINE INTAKE & EXHAUST 1G2-3 Removal & Installation Procedure 1. Release the clamp securing HFM sensor and air cleaner. 2. Disengage the air cleaner assembly and HFM sensor assembly. 3. Unserew the mounting bolt(6) from the bracket. Installation Notice Tightening Torque 22.5 - 27.5 Nm 4.

  • Page 903: Air Intake Shield

    1G2-4 M161 ENGINE INTAKE & EXHAUST AIR INTAKE SHIELD Preceding Work : Removal of air cleaner 1 Air Cleaner 5 Air Intake Shield 2 Gasket 6 Bolt 3 Air Intake Shield Upper Cover 7 Bracket 4 Bolt Removal & Installation Procedure 1.

  • Page 904: Intake Air Duct

    M161 ENGINE INTAKE & EXHAUST 1G2-5 INTAKE AIR DUCT 1 Clamp 2 Sleeve 3 HFM Sensor 4 Intake Air Duct 5 Blow-by Hose 7 Clamp(2 pieces) 8 Intake Air Duct Mounting Bracket Removal & Installation Procedure 1. Release the clamp (1) and intake air duct. 2.
  • Page 905 1G2-6 M161 ENGINE INTAKE & EXHAUST 3. Release the clamp (7) and remove the intake air duct. Notice Completely fit the intake air duct with the mounting bracket (8).

  • Page 906: Intake Manifold

    M161 ENGINE INTAKE & EXHAUST 1G2-7 INTAKE MANIFOLD Preceding Work : Removal of intake air duce Removal of fuel distributor and injector 1 Bolt (M6 X 40, 6 pieces) ....22.5-27.5 Nm 5 Idle Regulator 2 Intake Manifold 6 Intermediate Flange 3 Gasket (2 pieces) ........
  • Page 907 1G2-8 M161 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Disconnect the battery ground cable. 2. Remove idle speed control plug connector (arrow). 3. Disconnect the brake booster vacuum line and other vacuum lines. 4. Disconnector the rod from bearing bracket assembly and remove the connection piece (8).

  • Page 908: Exhaust Manifold

    M161 ENGINE INTAKE & EXHAUST 1G2-9 EXHAUST MANIFOLD 1 Oxygen Sensor ......49.5-60.5 Nm 5 Exhaust Manifold 2 Bolt (4 pieces) ........9-11 Nm 6 Flange Bolt & Exhaust Pipe 3 Upper Cover Mounting Nut ..........30 Nm 4 Nut (11 pieces)....... 31.5-38.5 Nm 7 Gasket ...........
  • Page 909 1G2-10 M161 ENGINE INTAKE & EXHAUST 4. Unscrew the eleven nuts (4) and remove the exhaust manifold (5) and gasket (7). Installation Notice Tightening Torque 31.5 - 38.5 Nm 5. Replace the gasket (7) with new one. 6. Installation should follow the removal procedure in the reverse order.
  • Page 910 M161 ENGINE INTAKE & EXHAUST 1G2-11 Removal and Installation of Exhaust Line 1 Heat Protector-Floor 5 Road Assembly-Muffler Mounting Rear 2 Pipe Assembly-Front Exhaust 6 Heat Pro-Tector Dash 3 Gasket 7 Heat Pro-Tector Floor 4 Heat Protector-Rear Exhaust 8 Heat Pro-Tector Rear Exhaust...
  • Page 911 SECTION 1G3 OM600 ENGINE INTAKE & EXHAUST Caution: Disconnect the negative battery cable before removing or installing any electrical unit or when a tool or equipment could easily come in contact with exposed electrical terminals. Disconnecting this cable will help prevent personal injury and damage to the vehicle. The ignition must also be in LOCK unless otherwise noted.

  • Page 912: Schematic And Routing Diagrams

    1G3-2 OM600 ENGINE INTAKE & EXHAUST SCHEMATIC AND ROUTING DIAGRAMS...

  • Page 913: Maintenance And Repair

    OM600 ENGINE INTAKE & EXHAUST 1G3-3 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE AIR CLEANER AND INLET DUCT & HOSE Air Intake Shield Assembly 5 Bolt ............9-11Nm Air Cleaner Assembly 6 House Mounting Bracket 7 Clamp Air Cleaner Element ... Clean : 20,000km 8 Engine Cover Assembly (Turbo) Replace : 60,000km...
  • Page 914 1G3-4 OM600 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Loosen the air duct hose clamp and then remove the air cleaner and air duct hose. 2. Disconnect the air cleaner housing cover clamp and remove the cover and element. Clean every 20,000km Operating Interval...

  • Page 915: Intake And Exhaust Manifold

    OM600 ENGINE INTAKE & EXHAUST 1G3-5 INTAKE AND EXHAUST MANIFOLD 1 Nut ..........22.5-27.5 Nm 7 Stud Bolt .......... 9.9-12.1 Nm 2 Washer 8 Bolt (M8) ........22.5-27.5 Nm 3 Support Assembly Bar 9 Intake Duct 10 Intake Duct Gasket 4 Nut ..........
  • Page 916 1G3-6 OM600 ENGINE INTAKE & EXHAUST Exhaust Line 1 Heat Protector Assembly 6 Muffler 2 Heat Protector Floor 7 Mounting 3 Exhaust Front Pipe Assembly 8 Heat Protector Front Floor 4 Ring 9 Tail Exhaust Pipe Assembly 5 Exhaust Rear Pipe Assembly...
  • Page 917 1F3-42 OM600 ENGINE CONTROLS After Testing Preceding Work : Start of delivery test Position Sensor (RIV method) 1 Adjusting Screw 4 Bolt ............23Nm 2 Bolt ............23Nm 5 Scale..Rl start of delivery = 14° - 16° ATDC 3 Fuel Injection Pump...
  • Page 918 OM600 ENGINE INTAKE & EXHAUST 1G3-7 Removal & Installation Procedure 1. Remove the bolt from the exhaust manifold and then remove the front exhaust pipe. Installation Notice Tightening Torque 15 - 18 Nm Notice When tightening the nut(3), maintain the clearance between exhaust manifold(1) and front exhaust pipe.

  • Page 919: Turbocharger

    1G3-8 OM600 ENGINE INTAKE & EXHAUST TURBOCHARGER CHARGE AIR SYSTEM DIAGRAM 1 Turbocharger Oil Inlet 6 Air Inlet 2 Turbine Wheel 7 Exhaust Gas Outlet 3 Waste Gate 8 Compressed Air Flow 4 Oil Outlet 9 Intercooler 5 Compressor Wheel 10 Cylinder...

  • Page 920: Intercooler

    OM600 ENGINE INTAKE & EXHAUST 1G3-9 INTERCOOLER 1 Hoses 5 Cover 2 Pipes 6 Bolts 3 Hoses 7 Screws 4 Intercooler 8 Bolts...
  • Page 921 1G3-10 OM600 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Remove the hose connected to turbocharger and intake duct. 2. Remove the protective cover. 3. Loosen the clamps and remove the pipe and hose connected to intercooler. 4. Unscrew the mounting bolts and remove the intercooler. 5.

  • Page 922: Turbocharger Assembly

    OM600 ENGINE INTAKE & EXHAUST 1G3-11 TURBOCHARGER ASSEMBLY 1 Oil Supply Line 3 Nuts 2 Oil Return Line 4 Turbocharger...
  • Page 923 1G3-12 OM600 ENGINE INTAKE & EXHAUST Removal & Installation Procedure 1. Remove the 2 hoses connected to intercooler. 2. Remove the hose(air cleaner to turbocharger) with blow by hose. 3. Disconnect the oil supply pipe. 4. Remove the oil return pipe. 5.
  • Page 924 OM600 ENGINE INTAKE & EXHAUST 1G3-13 7. Remove the turbocharger disconnecting the exhaust pipe from the turbocharger. 8. Installation should follow the removal procedure in the reverse order.

  • Page 925: Specifications

    SECTION 2A SUSPENSION DIAGNOSIS TABLE OF CONTENTS Specifications......2A-1 Damping Force Control Logic ... . . 2A-6 Normal Control .
  • Page 926 2A-2 SUSPENSION DIAGNOSIS GENERAL SPECIFICATIONS (Cont'd) Application Description Body Power Voltage (V) 4.75 - 5.25 Vertical and Consuming Current (mA) Less than 10 Lateral Acceleration Output Current (mA) Less than 2.0 Sensor Operating Characteristics (Vertical Acceleration Sensor) (Lateral Acceleration Sensor) Output Voltage Output Voltage 4.25...

  • Page 927: Diagnosis

    SUSPENSION DIAGNOSIS 2A-3 DIAGNOSIS GENERAL DIAGNOSIS Problems in the steering, the suspension, the tires, and vehicle first. If possible, do this road test with the the wheels involve several systems. Consider all systems customer. when you diagnose a complaint. Some problems, such Proceed with the following preliminary checks.
  • Page 928 2A-4 SUSPENSION DIAGNOSIS Steering Instability Checks Action Incorrect Front wheel Alignment Replace Worn or Loosened Lower Arm Bushing Repair or Replace Vehicle Bottoming Checks Action Worn or Broken Coil Spring Replace...

  • Page 929: Input & Output Devices And Damping

    SUSPENSION DIAGNOSIS 2A-5 INPUT & OUTPUT DEVICES AND DAMPING FORCE CONTROL LOGIC INPUT & OUTPUT DEVICES Damping force of shock absorber will rotate shock absorber control rod in 3 modes by driving actuator on the upper shock absorber when signaled from ECS. Rotary valve in the shock absorber will control hydraulic flow according to rotation of control rod to adjust damping force of shock absorber in SOFT↔MEDIUM↔HARD.

  • Page 930: Damping Force Control Logic

    2A-6 SUSPENSION DIAGNOSIS DAMPING FORCE CONTROL LOGIC Control Logic that applies on damping force variable suspension is comprised of road sensing driving comfort control logic to increase driving comfort and vehicle speed sensing control logic, anti-roll control logic and anti-dive control logic to secure control safety.

  • Page 931: Self-Diagnosis

    SUSPENSION DIAGNOSIS 2A-7 SELF-DIAGNOSIS ECS-ECU indicates ECS circuit defectives to the driver by flickering ECS indicator lamp in the meter cluster 0.5 second of interval if there are defectives. Code Defects Judging Conditions Set Time Remedy Set Time Release Conditions Body vertical Sensor Voltage When sensor output...

  • Page 932: Actuator Inspection

    2A-8 SUSPENSION DIAGNOSIS ACTUATOR INSPECTION Output position of the actuator should be changed as below when battery voltage is applied between actuator connector terminals. Connector Battery Voltage Position of The Actuator Output Remark terminal 1 (White) SOFT Mode 2 (Black) OPEN 3 (Red) 1 (White)

  • Page 933: Schematic And Routing Diagrams

    SUSPENSION DIAGNOSIS 2A-9 SCHEMATIC AND ROUTING DIAGRAMS...
  • Page 934 2A-10 SUSPENSION DIAGNOSIS...
  • Page 935 SUSPENSION DIAGNOSIS 2A-11 Connector Pin Number and Circuits Circuit Circuit Ignition Chassis Ground Actuator R-MEDIUM Actuator R-HEAD Actuator R-SOFT Actuator F-MEDIUM Actuator F-HEAD Actuator F-SOFT Select Switch Brake Switch Speed Sensor Wheel G Sensor Lateral G Sensor Wheel G Sensor Ground Lateral G Sensor Ground Vertical G Sensor Ground Vertical G Sensor...

  • Page 936: Self Diagnosis Test

    2A-12 SUSPENSION DIAGNOSIS SELF DIAGNOSIS TEST DIAGNOSIS TEST Special Tool Requirements : Scanner 1. Position the ignition switch to 'OFF'. 2. Connect Scanner harness connector to the engine compartment diagnosis socket. 3. Turn the ignition switch to 'ON' position. 4. Select "Electronic control vehicle diagnosis" from function selection display and press "Enter".
  • Page 937 SUSPENSION DIAGNOSIS 2A-13 Self - Diagnosis List Fault Defects Service Hint Code 1. Check sensor supply voltage Vertical Acceleration Sensor Condition - IGN ON Standard value - voltage between pin 11 and 8 of ECU : 4.5 - 5.0V 2. Check sensor output voltage Condition - IGN ON Standard value - voltage between pin 20 and 11 of ECU : 0.5 - 4.5V...
  • Page 938 SECTION 2B WHEEL ALIGNMENT TABLE OF CONTENTS Wheel Alignment..... . . 2B-6 Specifications......2B-1 General Description and System Wheel Alignment Specifications .
  • Page 939 2B-2 WHEEL ALIGNMENT DIAGNOSIS TIRE DIAGNOSIS Irregular and Premature Wear Irregular and premature tire wear has many causes. Some of them are incorrect inflation pressures, lack of regular rotation, poor driving habits, or improper wheel alignment. Rotate the tires if : The front tire wear is different from the rear.
  • Page 940 WHEEL ALIGNMENT 2B-3 3. Road test the vehicle. If there is improvement, install the original tires to find the offending tire. If there is no a straight improvement, install good tires in place of all four offending tires. 4. Install original tires one at a time to find the offending tire.

  • Page 941: Specifications

    2B-4 WHEEL ALIGNMENT Radial Tire Lead/Pull Diagnosis Chart Step Action Values(s) 1. Perform wheel alignment preliminary inspection. 2. Check the brakes for dragging. 3. Road test the vehicle. Go to Step 2 System OK Does the vehicle lead/pull? 1. Cross switch the front tire and wheel assemblies. 2.
  • Page 942 WHEEL ALIGNMENT 2B-5 VIBRATION DIAGNOSIS Preliminary Checks Wheel imbalance causes most highway speed vibration Prior to performing any work, always road test the car problems. A vibration can remain after dynamic and perform a careful visual inspection for: balancing because: Obvious tire and wheel runout.

  • Page 943: Maintenance And Repair

    2B-6 WHEEL ALIGNMENT MAINTENANCE AND REPAIR ON VEHICLE SERVICE WHEEL ALIGNMENT Vehicle Height 1. Check the tire for proper inflation. 2. Measure ‘A’ from the center of the lower arm rear mounting bolt end to the ground. 3. Measure ‘B’ from the center of the steering knuckle shaft to the ground.
  • Page 944 WHEEL ALIGNMENT 2B-7 Camber 1. Remove the free wheel hub. 2. Measure camber with a wheel alignment equipment. 0°±30’ Specification 3. If camber measurements are not within specification, adjust it by increasing or decreasing the number of adjusting shims (1) inserted between the upper arm shaft and cross bracket. Camber Change Adjusting Shims Increasing 1 ea...
  • Page 945 2B-8 WHEEL ALIGNMENT 3. If caster measurements are not within specification, adjust it by increasing 1ea (rear) or decreasing 1ea (front). Caster Change FRONT Adjusting Shims Increasing 1ea Decreasing 1ea 0.4 small - 11 ’ + 11 ’ 1.6 small - 43’...

  • Page 946: General Description And System Operation

    WHEEL ALIGNMENT 2B-9 GENERAL DESCRIPTION AND SYSTEM OPERATION FOUR WHEEL ALIGNMENT CASTER The first responsibility of engineering is to design safe Caster is the tilting 91 the uppermost point of the steering steering and suspension systems. Each component axis either forward or backward from the vertical when must be strong enough to withstand and absorb extreme viewed from the side of the vehicle.
  • Page 947 SECTION 2C FRONT SUSPENSION TABLE OF CONTENTS Torsion Bar ......2C-6 Specifications......2C-1 Front Lower and Upper Arm .
  • Page 948 2C-2 FRONT SUSPENSION FASTENER TIGHTENING SPECIFICATIONS Stabilizer Bar Application Stabilizer Bar Retaining Nut 30 - 45 Stabilizer Bar Link Nut 60 - 80 Lower Arm Nut 16 - 22 Torsion Bar Application Torque Arm Bolt 40 - 60 60 - 80 Lower and Upper Arm Application Upper Arm Nut...

  • Page 949: Front Suspension

    FRONT SUSPENSION 2C-3 COMPONENT LOCATOR FRONT SUSPENSION 5 Stabilizer Bar Link 1 Shock Absorber 6 Stabilizer Bar 2 Upper Arm 7 Suspension Bumper 3 Steering Knuckle 4 Lower Arm...

  • Page 950: Maintenance And Repair

    2C-4 FRONT SUSPENSION MAINTENANCE AND REPAIR ON-VEHICLE SERVICE FRONT STABILIZER BAR 1 Front Stabilizer Bar 8 Bushing 2 Bolt ............30-45 Nm 9 Center Washer 3 Fixing Cap 10 Lower Arm 4 Bushing 11 Bushing 5 Nut ............60-80 Nm 12 Outer Washer 6 Stabilizer Bar Link Assembly 13 Nut ............
  • Page 951 FRONT SUSPENSION 2C-5 Removal & Installation Procedure 1. Remove the connecting nuts (1) from stabilizer bar link. Installation Notice Tightening Torque 16 - 22 Nm 2. Remove the connecting nuts (2) of the stabilizer bar and link and then remove the link. Installation Notice Tightening Torque 60 - 80 Nm...
  • Page 952 2C-6 FRONT SUSPENSION TORSION BAR 1 Nut 7 Torsion Bar 2 Torque Arm 8 Dust Cover 3 Washer 9 Height Control Arm Assembly 4 Bolt ..........M10 : 40-60 Nm 10 Height Control Bolt End Piece M12 : 60-80 Nm 11 Height Control Bolt 5 Torsion Bar End Seat 12 Height Control Seat...
  • Page 953 FRONT SUSPENSION 2C-7 Removal & Installation Procedure 1. Remove the fixing nuts and bolts of the shock absorber and lower arm connection. Installation Notice Tightening Torque 60 - 80 Nm 2. Remove the connecting nuts of the stabilizer bar link to the lower arm.

  • Page 954: Front Lower And Upper Arm

    2C-8 FRONT SUSPENSION FRONT LOWER AND UPPER ARM Preceding Work : Removal of the torsion bar spring Removal of the steering knuckle and drive shaft 1 Nut ........... 120-140 Nm 10 Cotter Pin..........Replace 2 Fulcrum Pin and Upper Arm Assembly 11 Nut ...........
  • Page 955 FRONT SUSPENSION 2C-9 Removal & Installation Procedure 1. Remove the shock absorber. Installation Notice Distance between the nut end 6 - 9 mm Upper and the screw end Lower Tightening Torque 60 - 80 Nm 2. Remove the fulcrum pin mounting bolts and nuts and remove the upper arm assembly.

  • Page 956: Front Shock Absorber

    2C-10 FRONT SUSPENSION FRONT SHOCK ABSORBER 1 Front Shock Absorber 4 Center Washer 2 Washer 5 Actuator Mounting Bracket 3 Bush 6 Nut ............40-60Nm...
  • Page 957 FRONT SUSPENSION 2C-11 Removal & Installation Procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice When installing the actuator to the mounting bracket, the wiring should face the front of the frame. 2. Unscrew the upper nut (6). Notice When screwing the nut, actuator contacting surface of the mounting bracket and rod end should be 0.5 - 1.5mm.

  • Page 958: Axle Vertical Acceleration Sensor (Wheel G Sensor)

    2C-12 FRONT SUSPENSION AXLE VERTICAL ACCELERATION SENSOR (WHEEL G SENSOR) 1 Axle Vertical Acceleration Sensor (wheel G 2 Extension Wiring sensor) 3 Bolt (M6) ..........20 - 30Nm Removal & Installation Procedure 1. Disconnect extension wiring connector (2) from the axle vertical acceleration sensor.

  • Page 959: Vertical And Lateral Sensor

    FRONT SUSPENSION 2C-13 VERTICAL AND LATERAL SENSOR Removal & Installation Procedure 1. Disconnect vertical sensor and lateral sensor connectors. Notice When connecting the connectors, connector connection of the lateral sensor (2) should be in the right and connector connection of the vertical sensor (1) should face downward. 2.

  • Page 960: Ecs (Ecu)

    2C-14 FRONT SUSPENSION ECS (ECU) 1 Electronically Controlled Suspension (ECU) 4 Parking Brake Lever 2 Connector 5 Over Voltage Protection Relay 3 Bolts (2 pieces) Removal & Installation Procedure 1. Disconnect each connectors from the console box and remove the console box. 2.

  • Page 961: General Specifications

    SECTION 2D REAR SUSPENSION TABLE OF CONTENTS Heating ......2D-3 Specifications......2D-1 Component Locator .

  • Page 962: Diagnosis

    2D-2 REAR SUSPENSION DIAGNOSIS NOISE (DURING STRAIGHT DRIVING) Check Action Lack of Oil Replenish Low Viscosity of Oil Replace Insufficient Oil Replace Excessive Backlash of Ring Gear Adjust Worn or Damaged Tooth of Ring and Pinion Gear Replace Worn or Damaged Drive Pinion Bearing Replace Worn Spline of Side Bearing and Side Gear Replace...
  • Page 963 REAR SUSPENSION 2D-3 HEATING Check Action Lack of Oil Replenish Insufficient Backlash of Gears Adjust Excessive Preload of Bearing Adjust...
  • Page 964 2D-4 REAR SUSPENSION COMPONENT LOCATOR 1 Spring Seat 5 Upper Arm 2 Coil Spring 6 Lower Arm 3 Lateral Rod 7 Connecting Link 4 Shock Absorber 8 Stabilizer Bar...
  • Page 965 REAR SUSPENSION 2D-5 MAINTENANCE AND REPAIR ON-VEHICLE SERIVCE REAR SUSPENSION (5 - LINK) 1 Spring Seat 5 Upper Arm 2 Coil Spring 6 Lower Arm 3 Lateral Rod 7 Connecting Link 4 Shock Absorber 8 Stabilizer Bar...
  • Page 966 2D-6 REAR SUSPENSION Removal & Installation Procedure Stabilizer bar 1. Remove the upper nut of the connecting link. Installation Notice Distance Between the Nut 10 - 13 mm end and the Screw end Tightening Torque 16 - 22 Nm 2. Remove the stabilizer bar cap fixing bolts (arrow) and remove the stabilizer bar.
  • Page 967 REAR SUSPENSION 2D-7 Shock Absorber. 1. Remove the lower mounting nut. Installation Notice Tightening Torque 50 - 65 Nm 2. Remove the upper mounting nut and remove the shock absorber. Installation Notice Distance between the nut 6 - 9 mm end and the screw end Tightening Torque 30 - 45 Nm...
  • Page 968 2D-8 REAR SUSPENSION 2. Remove the lower arm fixing nut from the frame. Installation Notice Tightening Torque 150 - 180 Nm 3. Remove the lower arm fixing nut from the rear axle and remove the lower arm. Installation Notice Tightening Torque 150 - 180 Nm...
  • Page 969 REAR SUSPENSION 2D-9 REAR SHOCK ABSORBER 1 Rear Shock Absorber 4 Center Washer 2 Washer 5 Actuator Mounting Bracket 3 Bush 6 Nut (M12 x 1.25) ......... 40 - 60Nm...
  • Page 970 2D-10 REAR SUSPENSION Removal & Installation Procedure 1. Disconnect actuator connector and unscrew bolt and remove actuator assembly. Notice l When installing the actuator to the mounting bracket, the wiring should face outward of the frame. l Actuator wiring should be fixed 40 - 50mm away from the wiring ends when fixing it with the frame open clip.
  • Page 971 SECTION 2E TIRES AND WHEELS TABLE OF CONTENTS Specifications......2E-1 Wheel Disc ......2E-3 General Specifications .
  • Page 972 2E-2 TIRES AND WHEELS DIAGNOSIS WEAR PATTERN DIAGNOSIS Wear Pattern Possible Cause Remedy Wear on Both Tread Shoulders Under Inflation Adjust Adjust Wear on Tread Center Over Inflation Adjust Tread Torn Out Under Inflation Adjust Incorrect Camber or Toe-in One-sided Tread Wear Adjust Incorrect Toe-in Feather Edging of Tread...
  • Page 973 TIRES AND WHEELS 2E-3 IDENTIFICATION RADIAL TIRE P 215/75 R 15 94 H M+S Four Season Mud & Snow Speed Rating (max. 210km/h) Load Range (below 670kg) Rim Diameter (inch) Radial Tire Aspect Ratio = (Section Height ÷ Section Width) x 100 Section Width (mm) Passenger Car 215/65 R 16 93 V...

  • Page 974: Component Locator

    2E-4 TIRES AND WHEELS COMPONENT LOCATOR WHEEL AND TIRE 1 Wheel Bolts ....Steel Wheel : 80-120 Nm 4 Tire ......Aluminium Wheel : 110-130 Nm 5 Steel Wheel Weight Balance 2 Steel Wheel 6 Hub Cap 3 Aluminium Wheel...

  • Page 975: Maintenance And Repair

    TIRES AND WHEELS 2E-5 MAINTENANCE AND REPAIR ON-VEHICLE SERVICE WHEELS AND TIRES Removal & Installation Procedure 1. Inspection of tire Check tread area for tread surface, crack, damage by nail in or stones. Replace or repair if necessary. 2. Wear limit. 1.6mm Limit Replace the tire if tread-wear indicator of the tread...
  • Page 976 2E-6 TIRES AND WHEELS 4. Tire pressure inspection. Tire pressure. Front & Rear 2.1kg/cm (30PSI) (P235/75R15) Check tread contact with road. Notice If underinflated, tire may come away from the wheel during rapid steering. An overinflated tire will cause a hard riding and uneven wear.
  • Page 977 TIRES AND WHEELS 2E-7 To correct unbalance, install equal weights 180° opposite each other, one on the inside of the wheel and one on the outside, at the point of unbalance. Balance Weight 0.4oz 0.7oz 1.10oz 1.40oz 1.80oz 2.1oz 6. Cautions for installation and removal. Clean the mounting surfaces of hub and wheel.
  • Page 978 SECTION 3A FRONT DRIVE AXLE TABLE OF CONTENTS Maintenance and Repair ....3A-6 Specifications......3A-1 On-Vehicle Service .
  • Page 979 3A-2 FRONT DRIVE AXLE FASTENER TIGHTENING SPECIFICATIONS Steering Knuckle and Drive Shaft Application Drive Shaft to Front Axle Inner Shaft 25 - 35 Wheel Speed Sensor 85 - 105 Drive Shaft Cover Bolt 50 - 60 Locking Hub Washer Screw 2 - 4 Hub Flange Bolt 70 - 90...
  • Page 980 FRONT DRIVE AXLE 3A-3 COMPONENT LOCATOR FRONT AXLE 1 Drive Shaft 5 Brake Disc 2 Axle Housing Mounting Bolt 6 Hub-Wheel 3 Axle Housing 7 Locking Hub 4 Cross Member...
  • Page 981 3A-4 FRONT DRIVE AXLE AUTO-LOCKING HUB 1 Cap 11 Body 2 Filter 12 Return Spring 3 Vacuum Diaphragm 13 Bearing 4 Diaphragm Retainer 14 O-ring 5 Piston 15 Retaining Ring 6 Bolt (M10) 16 Inner Drive Gear 7 Lock Washer 17 Oil Seal 8 O-ring 18 Oil Seal Race...
  • Page 982 FRONT DRIVE AXLE 3A-5 VACUUM CIRCUIT 1 Engine 6 Auto locking Hub Solenoid Valve 2 Vacuum Pump 7 T-connector Hose 3 3-way Connector 8 Hub Hose (left) 4 T-connector 9 Hub Hose (right) 5 Check Valve...
  • Page 983 3A-6 FRONT DRIVE AXLE MAINTENANCE AND REPAIR ON-VEHICLE SERVICE VACUUM LINE 1 Vacuum Auto-locking Hub Assembly 12 Check Valve 2 Bolt ............50-60 Nm 13 Hose (L :100, green) 3 Cam Washer 14 Auto Locking Hub Solenoid Valve 4 Auto-locking Hub Cap 15 Bolt 5 Retainer Ring 16 Hose (L :100, green)
  • Page 984 FRONT DRIVE AXLE 3A-7 Removal & Installation Procedure 1. Be careful not to change the valve when connecting the check valve and each hose. 2. Adjust the clearance between the retainer ring (5) and locking hub (7) using the shim(6). Normal Max.
  • Page 985 3A-8 FRONT DRIVE AXLE STEERING KNUCKLE AND DRIVE SHAFT 1 Front Axle Inner Shaft 4 Bolt ............45-60 Nm 2 Front Axle Drive Shaft 5 Steering Knuckle 3 Spring Washer...
  • Page 986 FRONT DRIVE AXLE 3A-9 Removal & Installation Procedure 1. Remove the tire. Installation Notice Steel Wheel 80 - 120 Nm Tightening Torque Aluminum Wheel 110 - 130 Nm 2. Remove the autolocking hub vacuum hose. 3. With ABS Remove the wheel speed sensor from the steering knuckle. Installation Notice Tightening Torque 6 - 8 Nm...
  • Page 987 3A-10 FRONT DRIVE AXLE With part time transfer case. 5-1. Remove the cover mounting bolts and pull off the cover. Installation Notice Tightening Torque 50 - 60 Nm 5-2. Remove the snap ring of the drive shaft and pull off the hub body.
  • Page 988 FRONT DRIVE AXLE 3A-11 6-2. Unscrew the bolts and remove hub flange. Installation Notice Tightening Torque 70 - 90 Nm Before installation, apply loctite on the mating surface. Remove the hub nut with special tool. Tightening Torque 15 Nm Remove the hub and disk assembly. Remove the disk brake dust shield.
  • Page 989 3A-12 FRONT DRIVE AXLE 10. Remove the cotter pin and slotted nut and then remove the steering knuckle arm and tie-rod. Installation Notice Tightening Torque 35 - 45 Nm Replace the cotter pin with new one. 11. Remove the cotter pin and nut from the steering knuckle arm and upper arm ball joint connection.
  • Page 990 FRONT DRIVE AXLE 3A-13 14. Remove the drive shaft mounting bolts and remove the drive shaft. Installation Notice Tightening Torque 45 - 60 Nm Observe the tighening torque and sequence. 15. Installation should follow the removal precedure in the reverse order.
  • Page 991 3A-14 FRONT DRIVE AXLE FRONT AXLE Preceding Work : Removal of the front axle drive shaft Removla of the steering gear box 1 Axle Mounting Bracket 9 Bushing 2 Breather Hose 10 Nut ............. 95-142 Nm 3 Bolt (Rear) 11 Front Axle Assembly 4 Nut .............
  • Page 992 FRONT DRIVE AXLE 3A-15 Removal & Installation Procedure 1. Remove the propeller shaft from the front axle input shaft. Notice Before removal, place the alignment marks. Installation Notice Tightening Torque 70 - 80 Nm 2. Remove the breather hose. 3. Remove the axle housing mounting nuts (1) from the cross member.
  • Page 993 3A-16 FRONT DRIVE AXLE UNIT REPAIR AXLE HOUSING Preceding Work : Removal of the axle housing...
  • Page 994 FRONT DRIVE AXLE 3A-17 1 Front Axle Housing Mounting Bracket 20 Bearing 2 Inner Shaft (Left) 21 Oil Slinger 3 Bolt ............55-65 Nm 22 Drive Pinion 4 Oil Seal ..........Replace 23 Oil Filler Plug ........28-41 Nm Apply Grease to the Sealing Rib 24 Bolt ............
  • Page 995 3A-18 FRONT DRIVE AXLE Disassembly Procedure 1. Remove the drain plug and drain the oil. Reinstall the drain plug. Installation Notice Tightening Torque 28 - 41 Nm 2. Unscrew the axle housing and housing mounting bracket bolts and remove the bracket and inner shaft assembly. 3.
  • Page 996 FRONT DRIVE AXLE 3A-19 5. Unscrew the bearing cap bolts and remove the bearing caps. Pull out the differential carrier assembly. Notice Place alignment marks on the bearing cap not to change the caps before removal. When pulling out the differential carrier assembly, be careful not to damage the axle housing.
  • Page 997 3A-20 FRONT DRIVE AXLE 2. Assemble the parts of the drive pinion. Tightening Torque of the 240 - 310 Nm Lock Nut 3. Assemble the parts of the differential carrier. Tightening Torque of the 75 - 90 Nm Ring Gear Bolts 4.
  • Page 998 FRONT DRIVE AXLE 3A-21 6. Measure backlash of the drive pinion and ring gear. Specified Value 0.13 - 0.20 mm 7. Install the axle housing cover. Tightening Torque 39 - 46 Nm 8. Assemble the parts of the front axle shaft and housing mounting bracket.
  • Page 999 3A-22 FRONT DRIVE AXLE Inspection of Ring Gear Tooth Contact Pattern Normal Contact Apply gear-marking compound (prussian blue / red lead) on the ring gear teeth. Rotate the ring gear and check the tooth contact pattern. Abnormal Contact Tooth Contact pattern Possible Cause Remedy 1.

  • Page 1000: Specifications

    SECTION 3C PROPELLER SHAFT TABLE OF CONTENTS Specifications......3C-1 Maintenance and Repair ....3C-3 General Specifications .

Table of Contents