Download Print this page

Hino DUTRO XZU 305 Series Manual

Table Of Contents

Table of Contents

Advertisement

Quick Links

This supplement has been prepared to provide information covering general service repairs for DUTRO

which underwent changes in December, 2003.

Applicable models:

For the service specifications and repair procedures of the above model other than those listed in the supple-

ment, refer to the following manuals.

S

DUTRO Chassis Workshop Manual

S

DUTRO Electrical Wiring Diagram

DUTRO Electrical Wiring Diagram

S

N04C−TF Engine Workshop Manual

S

S05C Engine Workshop Manual

S

M550 Manual Transmission Workshop Manual

S

H260 Manual Transmission Workshop Manual

S

H350 Manual Transmission Workshop Manual

S

All information in this manual is based on the latest product information at the time of publication. However,

specifications and procedures are subject to change without notice.

If you find any failures in this manual, you are kindly requested to inform us by using the report form on the

next page.

FOREWORD

XZU 305, 345, 404, 414, 424, 434 series

Manual Name

Pub. No.

S1−YXZE05

S1−YXZE05A−SL

S1−YXZE10A−SL

S5−YN04E01A

S5−YS05E06A

S1−YXZE09A

S1−YXZE07A

S1−YXZE06A

Table of Contents

Advertisement

Table of Contents

Troubleshooting

Need help?

Need help?

Do you have a question about the DUTRO XZU 305 Series and is the answer not in the manual?

Questions and answers

Summary of Contents for Hino DUTRO XZU 305 Series

Page 1 FOREWORD This supplement has been prepared to provide information covering general service repairs for DUTRO which underwent changes in December, 2003. Applicable models: XZU 305, 345, 404, 414, 424, 434 series For the service specifications and repair procedures of the above model other than those listed in the supple- ment, refer to the following manuals.
Page 2 Workshop Manual Quality Report Att.) Service Manager, Your Distributor Pub. No. Issue Date Name of Name of Dealer Reporter Subject Problem Description Correction Proposal...
Page 3 CAUTION This manual does not include all the necessary items about repair and service. This manual is made for the purpose of the use for the persons who have special techniques and certifications. In the cases that non specialized or uncertified technicians perform repair or service only using this manu- al or without proper equipment or tool, that may cause severe injury to you or other people around and also cause damage to your customer’s vehicle.
Page 4 INTRODUCTION PREPARATION SERVICE SPECIFICATIONS DIAGNOSTICS ENGINE CONTROL SYSTEM FUEL EMISSION CONTROL INTAKE ENGINE MECHANICAL EXHAUST COOLING LUBRICATION STARTING & CHARGING TIRE & WHEEL DIFFERENTIAL BRAKE PARKING BRAKE MANUAL TRANSMISSION/TRANSAXLE CLUTCH POWER STEERING HEATER & AIR CONDITIONER WIRING ALPHABETICAL INDEX...
Page 5: Table Of Contents
....... . . 01 32 ABBREVIATIONS USED IN THIS MANUAL . . . 01 32 GLOSSARY OF SAE AND HINO TERMS ..01 37...
Page 6: How To Use This Manual
01 1 INTRODUCTION HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL 010VV 01 GENERAL INFORMATION GENERAL DESCRIPTION This manual is written in accordance with SAE J2008. Repair operations can be separated into 3 main processes: 1. Diagnosis 2. Removing/Installing, Replacing, Disassembling/Reassembling, Checking and Adjusting 3.
Page 7: Terms Definition
01 2 INTRODUCTION HOW TO USE THIS MANUAL Torque specifications, grease application areas and non reusable parts are emphasized in the proce- dures. NOTICE: There are cases where such information can only be explained by using an illustration. In these cases, all the information such as torque, oil, etc.
Page 8: Identification Information
01 3 INTRODUCTION IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION 010VW 01 VEHICLE IDENTIFICATION AND SERIAL NUMBERS VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped on the right frame as shown in the illustration. This number has also been stamped on the manufacturer’s plate. A: Vehicle Identification Number B: Manufacturer’s Plate D33021...
Page 9: Repair Instruction
01 4 INTRODUCTION REPAIR INSTRUCTION REPAIR INSTRUCTION 010VX 01 PRECAUTION BASIC REPAIR HINT HINTS ON OPERATIONS D20200 S Always wear a clean uniform. Looks S Hat and safety shoes must be worn. Vehicle protection S Prepare a grille cover, fender cover, seat cover and floor mat before starting the operation. S When working with 2 or more persons, be sure to check safety for one another.
Page 10 01 5 INTRODUCTION REPAIR INSTRUCTION JACKING UP AND SUPPORTING VEHICLE Care must be taken when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the proper locations (see page 01 14). PRECOATED PARTS Precoated parts are bolts and nuts. They are coated with a seal lock adhesive at the factory.
Page 11 01 6 INTRODUCTION REPAIR INSTRUCTION CLIPS The removal and installation methods of typical clips used in body parts are shown in the table below. HINT: If clips are damaged during a procedure, always replace the damaged clip with a new clip. Shape (Example) Removal/Installation Clip...
Page 12 01 7 INTRODUCTION REPAIR INSTRUCTION Removal/Installation Shape (Example) Removal Installation Screwdriver Push Clip Remover Remove rivet by pushing the center pin through and prying out the rivet shell. Removal Installation Screwdriver Push Clip Remover Remove rivet by unscrewing the center pin and prying out the rivet shell.
Page 13 01 8 INTRODUCTION REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF VACUUM HOSES To disconnect vacuum hose, pull and twist from the CORRECT INCORRECT end of the hose. Do not pull from the middle of the hose as this may cause damage. D31750 When disconnecting vacuum hoses, use tags to identify where they should be reconnected.
Page 14: General Notice
FOR VEHICLES EQUIPPED WITH SRS AIRBAG HINT: The HINO DUTRO is equipped with an SRS (Supplemental Restraint System), such as the driver airbag and seat belt pretensioner. Failure to carry out the service operations in the correct sequence could cause the SRS to unexpectedly deploy during servicing and lead to serious injury.
Page 15 01 10 INTRODUCTION REPAIR INSTRUCTION SPIRAL CABLE (in Combination Switch) The steering wheel must be fitted correctly to the steering column with the spiral cable at the neutral position, otherwise cable disconnection and other troubles may occur. See Pub. No. S1 YXZE05A, page 60 15 concerning the correct installation of the steering wheel.
Page 16: Seat Belt Pretensioner
01 11 INTRODUCTION REPAIR INSTRUCTION SEAT BELT PRETENSIONER Never measure the resistance of the seat belt pretensioner. This may cause the seat belt preten- sioner to activate, which could cause serious injury. Never disassemble the seat belt pretensioner. Never install the seat belt pretensioner on another vehicle. Store the seat belt pretensioner in an area where the ambient temperature is below 80˚C (176˚F), the humidity is not high and electrical noise is not nearby.
Page 17: Repair Instruction
01 12 INTRODUCTION REPAIR INSTRUCTION ELECTRONIC CONTROL Negative ( ) REMOVAL AND INSTALLATION OF BATTERY TERMI- Terminal Cable Before performing electronic work, disconnect the battery negative ( ) terminal cable beforehand to prevent component and wire damage caused by accidental short circuits. When disconnecting the terminal cable, turn the ignition switch and lighting switch OFF and loosen D33130...
Page 18 01 13 INTRODUCTION REPAIR INSTRUCTION REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS PLACE FOR REMOVING AND INSTALLING OF FUEL SYSTEM PARTS Work in a place with good air ventilation that does not have welders, grinders, drills, electric mo- tors, stoves, or any other ignition sources. Never work in a pit or near a pit as vaporized fuel will collect in those places.
Page 19: Vehicle Lift And Support Locations
01 14 INTRODUCTION REPAIR INSTRUCTION 010VY 01 VEHICLE LIFT AND SUPPORT LOCATIONS NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP THE VEHICLE The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavily loaded ve- hicle. When removing heavy equipment such as the engine and transmission, the center of gravity of the vehicle may shift.
Page 20 01 15 INTRODUCTION REPAIR INSTRUCTION REAR FRONT (IFS) FRONT (RFS) : SUPPORT POSITION : JACK POSITION SCREW JACK POSITION : Front (Auxiliary member) : Rear (U bolt seat) D26141...
Page 21: How To Troubleshoot Ecu Controlled Systems
010VZ 01 GENERAL INFORMATION A large number of ECU controlled systems are used in the HINO DUTRO. In general, ECU controlled sys- tems are considered to be very intricate, requiring a high level of technical knowledge to troubleshoot. How- ever, most problem checking procedures only involve inspecting the ECU controlled system’s circuits one by one.
Page 22: How To Proceed With Troubleshooting
01 17 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010W0 01 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. De- tails in the Diagnostic Section show the most effective methods for each circuit. Confirm the troubleshooting procedures for the circuit you are working on before beginning troubleshooting.
Page 23 01 18 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS REPAIR Repair the affected system or part according to the instructions in step 6. CONFIRMATION TEST After completing repairs, confirm that the malfunction no longer exists. If the malfunction does not re- cur, perform a confirmation test under the same conditions and in the same environment as when it occurred the first time.
Page 24 01 19 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CUSTOMER PROBLEM ANALYSIS HINT: In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order to give an accurate judgement. To clearly understand what the problem symptoms are, it is extremely important to ask the customer about the problem and the conditions at the time it occurred.
Page 25 ECU correctly. By using these functions, the problem areas can be narrowed down and troubleshooting is more effec- tive. Diagnostic functions are incorporated in the following systems in the HINO DUTRO: Diagnostic Trouble Input Signal Check Diagnotis Test Mode...
Page 26: System Normal
01 21 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DTC CHECK DTC displayed No DTC displayed TROUBLESHOOTING OF PROBLEM INDICATED BY DTC SYMPTOM CONFIRMATION No symptoms exist Symptoms exist If a DTC was displayed in the initial DTC check, the problem may have occurred in a wire harness or connector in that circuit in the past.
Page 27: Wire Harness
01 22 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS SYMPTOM SIMULATION HINT: The most difficult case in troubleshooting is when no problem symptoms occur. In such cases, a thorough customer problem analysis must be carried out. A simulation of the same or similar conditions and environ- ment in which the problem occurred in the customer’s vehicle should be carried out.
Page 28 01 23 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS WATER SPRINKLING METHOD: When the malfunc- tion seems to occur on a rainy day or in high humid- ity. Sprinkle water onto the vehicle and check if the malfunc- tion occurs. NOTICE: Never sprinkle water directly into the engine compart- ment.
Page 29 01 24 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS DIAGNOSTIC TROUBLE CODE CHART Use Diagnostic Trouble Codes (DTCs) (from the DTC checks) in the table below to determine the trouble area and proper inspection procedure. The Supplemental Restraint System (SRS) DTC chart is shown be- low as an example.
Page 30 01 25 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS PROBLEM SYMPTOMS TABLE The suspected circuits or parts for each problem symptom are shown in the table below. Use this table to troubleshoot when, during a DTC check, a ”Normal” code is displayed but the problem is still occurring. Num- bers in the table show the inspection order in which the circuits or parts should be checked.
Page 31: Circuit Inspection
01 26 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CIRCUIT INSPECTION How to read and use each page is shown below. D Circuit Description D Inspection Procedures The major role, operation of the circuit and its Use the inspection procedures to determine component parts are explained.
Page 32: Electronic Circuit Inspection Procedure
01 27 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS 010W1 01 ELECTRONIC CIRCUIT INSPECTION PROCEDURE BASIC INSPECTION RESISTANCE MEASURING CONDITION OF ELECTRONIC PARTS Unless stated, all resistance measurements should be made at an ambient temperature of 20_C (68_F). Resistance measurements may be outside the specifications if measured at high tem- peratures, i.e.
Page 33 01 28 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Checking the contact pressure of the terminal: Prepare a spare male terminal. Insert it into a fe- male terminal, and check for good tension when in- serting and after full engagement. Same terminal as a male terminal D25088...
Page 34 01 29 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS Check the resistance. Fig. 2 Disconnect connectors A and C, and measure the resistance between them. HINT: Measure the resistance while lightly shaking the wire harness Sensor vertically and horizontally. Fig. 2: Tester Connection Specified Condition Connector A terminal 1...
Page 35 01 30 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK SHORT CIRCUIT Fig. 5 If the wire harness is ground shorted (Fig. 5), locate the C SHORT section by conducting a resistance check with the body ground (below). Z17008 Check the resistance with the body ground. Fig.
Page 36 01 31 INTRODUCTION HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS CHECK AND REPLACE ECU NOTICE: The connector should not be disconnected from the ECU. Perform the inspection from the backside of the connector on the wire harness side. When no measuring condition is specified, perform the inspection with the engine stopped and the igni- tion switch ON.
Page 37: Terms
01 32 INTRODUCTION TERMS TERMS 010W2 01 ABBREVIATIONS USED IN THIS MANUAL Abbreviations Meaning Anti Lock Brake System Air Conditioner Alternating Current Accessory ACIS Acoustic Control Induction System Active Control Engine Mount ACSD Automatic Cold Start Device A.D.D. Automatic Disconnecting Differential Air Fuel Ratio Adaptive Front Lighting System Active Height Control Suspension...
Page 38 01 33 INTRODUCTION TERMS Abbreviations Meaning Control Valve Curb Weight Direct Current Defogger Deflector DIFF. Differential DIFF. LOCK Differential Lock D/INJ Direct Injection Data Link Connector Distributorless Ignition DOHC Double Overhead Camshaft Dash Pot Dead Soak Digital Signal Processor Diagnostic Trouble Code Digital Versatile Disc Electric Brake Force Distribution Electrochoromic...
Page 39 01 34 INTRODUCTION TERMS Abbreviations Meaning Gasoline Ground Gear Shift Actuator Global Positioning System High Altitude Compensator Hatchback H FUSE High Current Fuse High High Intensity Discharge (Head Lamp) Hydraulic Power Unit Housing Hard Top Hybrid Vehicle Heated Windshield System Integrated Circuit Indirect Diesel Injection Independent Front Suspension...
Page 40 01 35 INTRODUCTION TERMS Abbreviations Meaning Multiplex Communication System M/T, MTM Manual Transmission (Transaxle) Mount Mounting Neutral Natural Aspiration Number Oxygen Sensor Oxidation Catalyst Oil Control Valve Overdrive Original Equipment Manufacturing Overhead Camshaft Overhead Valve Option ORVR On board Refilling Vapor Recovery Oversize Power Back Door P &...
Page 41 01 36 INTRODUCTION TERMS Abbreviations Meaning SPEC Specification Single Point Injection Supplemental Restraint System Special Service Materials Special Service Tools Standard Cold Start Fuel Injection Switch System Transaxle TACH Tachometer Throttle Body Electronic Fuel Injection Turbocharger TCCS Computer Controlled System Timing Control Valve Top Dead Center TEMP.
Page 42: Glossary Of Sae And Hino Terms
TERMS 010W3 01 GLOSSARY OF SAE AND HINO TERMS This glossary lists all SAE J1930 terms and abbreviations used in this manual in compliance with SAE rec- ommendations, as well as their HINO equivalents. HINO TERMS SAE TERMS ABBREVIATIONS ABBREVIATIONS...
Page 43 01 38 INTRODUCTION TERMS HO2S Heated Oxygen Sensor Heated Oxygen Sensor (HO Idle Air Control Idle Speed Control (ISC) Intake Air Temperature Intake or Inlet Air Temperature Ignition Control Module Indirect Fuel Injection Indirect Injection (IDL) Inertia Fuel Shutoff Idle Speed Control Knock Sensor Knock Sensor Mass Air Flow...
Page 44 01 39 INTRODUCTION TERMS Transmission Control Module Transmission ECU, ECT ECU Throttle Position Throttle Position Transmission Range Bimetallic Vacuum Switching Valve (BVSV) Thermal Vacuum Valve Thermostatic Vacuum Switching Valve (TVSV) Three Way Catalytic (TWC) Three Way Catalytic Converter Manifold Converter TWC+OC Three Way + Oxidation Catalytic Converter + CCo...
Page 45 PREPARATION ENGINE CONTROL SYSTEM ....PREPARATION ......FUEL .
Page 46: Engine Control System
PREPARATION ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 023W5 0 PREPARATION Recomended Tools 09082 00040 Electrical Tester ECD SYSTEM(N04C TF) Equipment Hand held tester Service Wire Harness Torque wrench 08826 00080 Seal Packing Black or equivalent VENTURI ASSY(N04C TF) (FIPG)
Page 47: Fuel
02 2 PREPARATION FUEL FUEL 023VX 0 PREPARATION 09023 2900 Union Nut Wrench 9mm SUPPLY PUMP ASSY(N04C TF) COMMON RAIL ASSY(N04C TF) INJECTOR ASSY(N04C TF) Recomended Tools Electrical Tester FUEL SYSTEM(N04C TF) 09082 00040 (09083 00 50) Test Lead Set FUEL SYSTEM(N04C TF) Equipment Hand held Tester...
Page 48: Intake
02 3 PREPARATION INTAKE INTAKE 023W6 0 PREPARATION 09992 00242 Turbocharger Pressure Gauge TURBOCHARGER SYSTEM (N04C TF) Recomended Tools Electrical Tester TURBOCHARGER SYSTEM 09082 00040 (N04C TF) Equipment Torque wrench...
Page 49: Engine Mechanical
02 4 PREPARATION ENGINE MECHANICAL ENGINE MECHANICAL 023W8 0 PREPARATION 09023 2900 Union Nut Wrench 9mm PARTIAL ENGINE ASSY(N04C TF) Oil Pan Seal Cutter CAMSHAFT(N04C TF) 09032 00 00 09223 780 0 Crankshaft Oil Seal Replacer CAMSHAFT(N04C TF) OIL PUMP SEAL(N04C TF) ENGINE REAR OIL SEAL(N04C TF) 09992 00025 Cylinder Compression Check Gauge...
Page 50 02 5 PREPARATION ENGINE MECHANICAL 08826 00080 Seal Packing Black or equivalent PARTIAL ENGINE ASSY(N04C TF) (FIPG) CAMSHAFT(N04C TF) ENGINE REAR OIL SEAL(N04C TF) 08833 00080 Adhesive 344 PARTIAL ENGINE ASSY(N04C TF) THREE BOND 344 LOCTITE 242 or equivalent...
Page 51: Exhaust
02 6 PREPARATION EXHAUST EXHAUST 023W3 0 PREPARATION Equipment Torque wrench...
Page 52: Cooling
Radiator cap tester Torque wrench 08826 00080 Seal Packing Black or equivalent THERMOSTAT(N04C TF) (FIPG) WATER PUMP ASSY(N04C TF) Coolant Item Capacity Classification Engine coolant 4.4 liters ( 5.2 US qts, 3.3 lmp. qts) ”Hino Long Life Coolant” or equivalent...
Page 53: Lubrication
02 8 PREPARATION LUBRICATION LUBRICATION 023W7 0 PREPARATION 09228 780 0 Oil Filter Wrench OIL FILTER SUB ASSY(N04C TF) Puller Set OIL PUMP ASSY(N04C TF) 099 0 000 5 (099 000 ) Puller Clamp OIL PUMP ASSY(N04C TF) (099 2 000 0) Puller Slide Hammer OIL PUMP ASSY(N04C TF) (099 3 000 0)
Page 54: Starting & Charging
02 9 PREPARATION STARTING & CHARGING STARTING & CHARGING 023VY 0 PREPARATION Recomended Tools 09082 00040 Electrical Tester STARTING SYSTEM(N04C TF) AC/DC 400 A Probe STARTING SYSTEM(N04C TF) (09083 00350) (09083 00 50) Test Lead Set STARTING SYSTEM(N04C TF) Equipment Ammeter (A) Battery (24 V) Battery gravity gauge...
Page 55: Tire & Wheel
PREPARATION TIRE & WHEEL TIRE & WHEEL 023WE 0 PREPARATION Equipment Dial indicator with magnetic base...
Page 56: Differential
PREPARATION DIFFERENTIAL DIFFERENTIAL 023VR 0 PREPARATION 09223 5020 Oil Seal & Bearing Replacer DIFFERENTIAL CARRIER ASSY REAR(SH 2) Crankshaft Oil Seal Replacer DIFFERENTIAL CARRIER ASSY 09223 780 0 REAR(SH 2) 09308 00 0 Oil Seal Puller REAR DIFFERENTIAL CARRIER OIL SEAL(SH 2) DIFFERENTIAL CARRIER...
Page 57 02−12 PREPARATION − DIFFERENTIAL (09957−04010) Attachment DIFFERENTIAL CARRIER ASSY REAR(SH12) 09950−60010 Replacer Set DIFFERENTIAL CARRIER ASSY REAR(SH12) (09951−00640) Replacer 64 DIFFERENTIAL CARRIER ASSY REAR(SH12) (09951−00650) Replacer 65 DIFFERENTIAL CARRIER ASSY REAR(SH12) 09950−60020 Replacer Set No.2 DIFFERENTIAL CARRIER ASSY REAR(SH12) (09951−00680) Replacer 68 DIFFERENTIAL CARRIER...
Page 58: Brake
PREPARATION BRAKE BRAKE 023WD 0 PREPARATION 09023 00 00 Union Nut Wrench 0 mm ABS & TRACTION ACTUATOR ASSY 09023 38200 Union Nut Wrench 2mm ABS & TRACTION ACTUATOR ASSY 09023 2900 Union Nut Wrench 9mm VACUUM PUMP ASSY 09709 290 8 LSPV Gauge Set LOAD SENSING PROPORTIONING VALVE (LSPV)
Page 59: Manual Transmission/Transaxle
PREPARATION MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION/TRANSAXLE 023VS 0 PREPARATION 09308 000 0 Oil Seal Puller TRANSMISSION REAR BEARING RETAINER OIL SEAL(M550) Transmission & Transfer Bearing TRANSMISSION REAR BEARING 093 6 600 Replacer RETAINER OIL SEAL(M550) (093 6 000 ) Replacer Pipe TRANSMISSION REAR BEARING...
Page 60: Clutch
PREPARATION CLUTCH CLUTCH 023VT 0 PREPARATION 0930 00 20 Clutch Guide Tool CLUTCH UNIT(N04C TF) Input Shaft Front Bearing Puller CLUTCH UNIT(N04C TF) 09303 350 09304 20 2 Input Shaft Front Bearing CLUTCH UNIT(N04C TF) Replacer 09333 000 3 Universal Joint Bearing Remover CLUTCH UNIT(N04C TF) &...
Page 61: Power Steering
PREPARATION POWER STEERING POWER STEERING 023VV 0 PREPARATION 09922 00 0 Variable Open Wrench VANE PUMP ASSY(N04C TF) Equipment Torque wrench Lubricant Item Capacity Classification Power steering fluid (Total) ATF DEXRON II or III...
Page 62: Heater & Air Conditioner
PREPARATION HEATER & AIR CONDITIONER HEATER & AIR CONDITIONER 023VM 02 PREPARATION 95047 0400 Magnet Clutch Stopper COOLER COMPRESSOR (DENSO part No.) ASSY(AUSTRALIA) Snap Ring Pliers COOLER COMPRESSOR 95994 0020 (DENSO Part No.) ASSY(AUSTRALIA) Equipment Belt tension gauge Torque wrench Dial indicator Battery Lubricant...
Page 63 SERVICE SPECIFICATIONS STANDARD BOLT ......DIFFERENTIAL ......03 2 HOW TO DETERMINE BOLT STRENGTH .
Page 64: Standard Bolt
SERVICE SPECIFICATIONS STANDARD BOLT STANDARD BOLT 030Y3 05 HOW TO DETERMINE BOLT STRENGTH Bolt Type Class Hexagon Head Bolt Stud Bolt Weld Bolt Normal Recess Bolt Deep Recess Bolt No Mark No Mark No Mark w/Washer w/Washer B0643...
Page 65: Specified Torque For Standard Bolts
03 2 SERVICE SPECIFICATIONS STANDARD BOLT 030Y4 05 SPECIFIED TORQUE FOR STANDARD BOLTS Specified torque Diameter Pitch Hexagon head bolt Hexagon flange bolt Class Class N·m kgf·cm ft·lbf N·m kgf·cm ft·lbf 48 in.·lbf 52 in.·lbf , 50 56 in.·lbf 65 in.·lbf ,050 ,400 69 in.·lbf...
Page 66: How To Determine Nut Strength
03 3 SERVICE SPECIFICATIONS STANDARD BOLT 030Y5 05 HOW TO DETERMINE NUT STRENGTH Nut Type Old Standard Hexagon Nut Class Present Standard Hexagon Nut Cold Forging Nut Cutting Processed Nut No Mark 5N (4T) No Mark (w/Washer) No Mark (w/Washer) No Mark 7N (5T) 0N (7T)
Page 67: Engine Control System
03 4 SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM 03259 0 SERVICE DATA Venturi assy Standard throttle valve opening percentage 60% or more MAF meter assy Resistance 4 (THA) 5 (E2) at 20_C ( 4_F) 2.5 to 6.9 k at 20_C (68_F) 2.
Page 68: Torque Specification
03 5 SERVICE SPECIFICATIONS ENGINE CONTROL SYSTEM 0325A 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Venturi assy x Intake manifold 28.5 Clamp x Intake air connector pipe 44 in. lbf Clamp x Air hose No. 4 44 in. lbf Accelerator link assy x Body 49 in.
Page 69: Fuel
03 6 SERVICE SPECIFICATIONS FUEL FUEL 0325J 0 SERVICE DATA Common rail pressure at idling 25 to 35 MPa (255 to 357 kgf/cm , 3,625 to 5,075 psi) at 3,000 rpm 80 to 90 MPa (8 6 to 9 8 kgf/cm ,604 to 3,055 psi) Suction control valve at 20 _C (68 _F) 7.6 to 8.2...
Page 70: Torque Specification
03 7 SERVICE SPECIFICATIONS FUEL 0325K 0 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf Diesel fuel filter assy x Fuel filter support Injection pump drive gear x Supply pump assy Timer cover x Supply pump assy 28.5 Timer cover x Engine 28.5 Holder clip x Supply pump assy 28.5...
Page 71: Intake
03 8 SERVICE SPECIFICATIONS INTAKE INTAKE 0325D 0 SERVICE DATA Turbo pressure sensor Standard pressure 50 kPa ( .5 kgf/cm , 2 psi) Turbo pressure sensor Standard voltage 4.5 to 5.5 V Turbo pressure sensor Voltage drop at 0.25 to 0.4 V 93.0 kPa (675 mmHg, 27.5 in.Hg) at .0 to .4 V 50 kPa ( , 25 mmHg, 44 in.Hg)
Page 72: Torque Specification
03 9 SERVICE SPECIFICATIONS INTAKE 0325E 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Turbo water pipe No. x Turbocharger sub assy 24.5 Bracket x Turbocharger sub assy 28.5 Engine side cover RH x Body Front mudguard RH x Body Turbine outlet elbow x Turbocharger sub assy Turbocharger sub assy x Exhaust manifold Intake pipe x Turbocharger sub assy...
Page 73: Engine Mechanical
SERVICE SPECIFICATIONS ENGINE MECHANICAL ENGINE MECHANICAL 0325F 0 SERVICE DATA New V belt deflection Pressing force: 98 N ( 0 kgf, 22 lbf) For fan and generator 0.5 to 2.5 mm (0.4 3 to 0.492 in.) For A/C compressor 8.5 to 0 mm (0.334 to 0.393 in.) Used V belt deflection Pressing force: 98 N ( 0 kgf, 22 lbf) For fan and generator...
Page 74: Torque Specification
SERVICE SPECIFICATIONS ENGINE MECHANICAL 0325G 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf A/C compressor V belt tensioner Nut A 28.5 A/C compressor V belt tensioner Bolt B 52 in. lbf Fan and generator V belt Bolt A 28.5 Fan and generator V belt Bolt B Fan and generator V belt...
Page 75 SERVICE SPECIFICATIONS ENGINE MECHANICAL Part Tightened kgf cm ft lbf Generator sub bracket x Cylinder block ,275 Generator bracket x Cylinder block Compressor bracket x Cylinder block Intake manifold x Cylinder head 28.5 Water by pass pipe x Timing chain or belt cover sub assy 28.5 Crankshaft position sensor x Timing chain or belt cover sub assy Camshaft position sensor x Timing chain or belt cover sub assy...
Page 76: Exhaust
SERVICE SPECIFICATIONS EXHAUST EXHAUST 03258 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Exhaust pipe assy front x Exhaust manifold Exhaust pipe support bracket No. x Frame Exhaust pipe support bracket No. clamp x 25.4 Exhaust pipe support bracket No. Exhaust pipe assy center x Exhaust pipe assy front 29.5 Exhaust pipe support bracket No.
Page 77: Service Data
SERVICE SPECIFICATIONS COOLING COOLING 03254 0 SERVICE DATA Radiator cap sub assy Opening pressure 08 kPa ( . kgf/cm , 5.9 psi) Minimum 93.3 kPa (0.95 kgf/cm , 3.5 psi)
Page 78: Torque Specification
SERVICE SPECIFICATIONS COOLING 03255 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Cylinder block drain cock plug x Drain cock (Cylinder block) Water pump assy x Cylinder block 28.5 Fan x Water pump assy 28.5 Thermostat x Water outlet housing 28.5 Aie hose No.
Page 79: Lubrication
SERVICE SPECIFICATIONS LUBRICATION LUBRICATION 03256 0 SERVICE DATA Oil pressure at idle speed 90 kPa ( .9 kgf/cm , 27 psi) or more at 3,000 rpm 245 to 539 kPa (2.5 to 5.5 kgf/cm , 36 to 78 psi) or more...
Page 80: Torque Specification
SERVICE SPECIFICATIONS LUBRICATION 03257 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Oil pressure switch x Oil cooler assy 29.4 Oil filter sub assy x Oil cooler assy Oil drain plug x Oil pan sub assy 34.5 Oil pump assy x Cylinder block 28.5 Idle gear No.
Page 81: Service Specifications
SERVICE SPECIFICATIONS STARTING & CHARGING STARTING & CHARGING 0325L 0 SERVICE DATA Starter assy Specified current STD Below 20 A Starter relay Specified condition or higher Below (when battery voltage is applied to terminals SW and G) Battery Specific gravity at 20˚C (68˚F) .25 to .29 Voltage...
Page 82 SERVICE SPECIFICATIONS STARTING & CHARGING 0325M 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Lead wire x Terminal M Starter x Transmission ,570 Starter wire x Terminal B Starter wire x Terminal C 22 in. lbf Stiffener plate LH x Transmission assy Generator bracket x Engine Generator bracket x Generator assy 28.5...
Page 83 03 20 SERVICE SPECIFICATIONS TIRE & WHEEL TIRE & WHEEL 0325S 0 SERVICE DATA Cold tire inflation pressure Inflation Pressure Inflation Pressure Ti e Si e Tire Size kPa (kgf/cm , psi) Cab Type Cab Type Countries Countries Models Models Front Rear Front...
Page 84: Differential
03−21 SERVICE SPECIFICATIONS − DIFFERENTIAL DIFFERENTIAL 0325B−01 SERVICE DATA Oil type Hypoid oil API GL−5 Differential oil Recommended oil viscosity Capacity SAE 90 Capacity 5.2 liters (5.5 US qts, 4.8 lmp.qts) Ring gear runout Maximum 0.10 mm (0.0039 in.) Ring gear backlash Gear Ratio 5.571 0.20 to 0.28 mm (0.0079 to 0.0110 in.) 5.833...
Page 85: Torque Specification
03 22 SERVICE SPECIFICATIONS DIFFERENTIAL 0325C 0 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Drain plug Filler plug Rear drive pinion companion flange sub assy rear x Differential carrier 4,440 Differential case LH x Differential case RH ,950 Differential case x Ring gear ,950 Retainer (drive pinion bearing) x Differential carrier Drive pinion bearing cage x Differential carrier...
Page 86: Brake
03 23 SERVICE SPECIFICATIONS BRAKE BRAKE 030YS 02 SERVICE DATA Rear axle load (including vehicle weight) Model Front axle load kg (lb) XZU305R TQMMWQ3 ,350 (2,976) XZU305R HQMMWQ3 ,350 (2,976) XZU305R TKMMWQ3 ,350 (2,976) XZU305R HKMMWQ3 ,350 (2,976) XZU345R TKMMWQ3 ,400 (3,086) XZU345R HKMMWQ3 ,400 (3,086)
Page 87: Torque Specification
03 24 SERVICE SPECIFICATIONS BRAKE 030YT 02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf VACUUM PUMP Nozzle leakage pipe No. 3 x Union bolt Vacuum pump oil pipe x Union bolt Vacuum pipe x Union Bolt Vacuum pump x Timing gear case Vacuum pump x Union tube Fuel pipe x Fuel pump Oil separator x Engine assy...
Page 88: Parking Brake
03 25 SERVICE SPECIFICATIONS PARKING BRAKE PARKING BRAKE 030YY 02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Control cable clamp No. 2 x Control bracket No. 8 Control bracket No. 5 x Control bracket No. 9 Control bracket No. 6 x Control bracket No. 7 Control cable clamp No.
Page 89: Manual Transmission / Transaxle
03 26 SERVICE SPECIFICATIONS MANUAL TRANSMISSION / TRANSAXLE MANUAL TRANSMISSION / TRANSAXLE 030Z8 09 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Filler and drain plugs Engine x Transmission Engine mount bracket x Frame Engine mount bracket x Transmission Clutch release cylinder set bolt Shift and select outer lever x Shift and select transmission control cable Shift and select transmission control cable clamp x Frame Shift transmission control cable x Floor shift assy...
Page 90: Clutch
03 27 SERVICE SPECIFICATIONS CLUTCH CLUTCH 03 CU 02 SERVICE DATA Disc rivet head depth Min. 0.3 mm (0.0 2 in.) Disc runout Max. .0 mm (0.039 in.) Flywheel runout Max. 0. mm (0.004 in.) Diaghargm spring finger wear depth Max. 0.6 mm (0.024 in.) width Max.
Page 91: Torque Specification
03 28 SERVICE SPECIFICATIONS CLUTCH 03 CV 02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf Clutch cover set bolt...
Page 92: Power Steering
03 29 SERVICE SPECIFICATIONS POWER STEERING POWER STEERING 030YN 02 TORQUE SPECIFICATION Part Tightened kgf cm ft lbf VANE PUMP ASSY Radiator pipe x Timing gear case Oil pump to gear box tube x Timing gear case Suction port union set bolt x Vane pump assy Oil pump to gear box tube x Hose support bracket No.
Page 93: Heater And Air Conditioning
03 30 SERVICE SPECIFICATIONS HEATER AND AIR CONDITIONING HEATER AND AIR CONDITIONING 0324X 02 SERVICE DATA V COOLER BELT (N04C TF) V cooler belt Tension New belt 8.5 to 9.5 mm (0.33 to 0.37 in.) Used belt 0.0 to 3.0 mm (0.39 to 0.5 in.) COOLER COMPRESSOR ASSY (N04C TF) Magnetic clutch clearance Standard 0.50...
Page 94: Torque Specification
03 3 SERVICE SPECIFICATIONS HEATER AND AIR CONDITIONING 0324Y 02 TORQUE SPECIFICATION Part tightened N·m kgf·cm ft·lbf V COOLER BELT (N04C TF) Idler pulley bolt (A/C drive belt) Adjusting bolt 53 in.·lbf REFRIGERANT LINE (N04C TF) Liquid tube x liquid tube No. 2 Cooler refrigerant discharge hose No.
Page 95 DIAGNOSTICS ECD SYSTEM (N04C TF) ....ABS & BA SYSTEM (N04C TF) ... . PRECAUTION .
Page 96: Refer To Dutro Workshop Manual Yxze05A)
C 389/ 8 ....... . 05 295 PARKING BRAKE SWITCH CIRCUIT .
Page 97: Ecd System (N04C Tf)
DIAGNOSTICS ECD SYSTEM (N04C TF) ECD SYSTEM (N04C TF) 05DVP 03 PRECAUTION INJECTOR COMPENSATION CODE Example: Injector Since each injector has its own fuel injection characteris- Compensation Code tic, the ECM compensates this by slightly modifying injec- tion duration in order to optimize fuel injection volume. The compensated data for the optimum injection volume, in the form of a 30 digit alphanumeric value, has been imprinted on the head portion of each injector as the injec-...
Page 98: Location
05 2 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L W 0 LOCATION Throttle Control Motor Throttle Position ECT Sensor Sensor Injector Fuel Pressure Sensor Accelerator Position Camshaft Position Sensor Sensor Accelerator R/B No. 2 Pedal Position F E/G Fuse Sensor F STOP Fuse F IGN Fuse Crankshaft Position Sensor F AM2 Fuse...
Page 99 05 3 DIAGNOSTICS ECD SYSTEM (N04C TF) Idle Variable Resistor Switch DLC3 R/B No. and J/B No. F ST Fuse Voltage Converter A96459...
Page 100: How To Proceed With Troubleshooting
05 4 DIAGNOSTICS ECD SYSTEM (N04C TF) 054JB 22 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the ECD system. When using hand held tester: VEHICLE BROUGHT TO WORKSHOP CUSTOMER PROBLEM ANALYSIS (See page 05 9) CONNECT HAND HELD TESTER TO DLC3 HINT: If the display indicates a communication fault in the tester, inspect the DLC3.
Page 101: Basic Inspection
05 5 DIAGNOSTICS ECD SYSTEM (N04C TF) SYMPTOM SIMULATION DTC CHECK (See page 05 29) Result Proceed to Malfunction code No code Go to step 2 DTC CHART (See page 05 38) Go to step 4 BASIC INSPECTION (See page 05 Result Proceed to Wrong parts not confirmed...
Page 102 05 6 DIAGNOSTICS ECD SYSTEM (N04C TF) CIRCUIT INSPECTION Result Proceed to Malfunction not confirmed Malfunction confirmed Go to step 8 CHECK FOR INTERMITTENT PROBLEMS (See page 05 Go to step 8 PARTS INSPECTION IDENTIFICATION OF PROBLEM ADJUST, REPAIR CONFIRMATION TEST...
Page 103 05 7 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: VEHICLE BROUGHT TO WORKSHOP CUSTOMER PROBLEM ANALYSIS (See page 05 9) CHECK AND CLEAR DTC (See page 05 29) PROBLEM SYMPTOM CONFIRMATION Malfunction occurs Malfunction does not occur SYMPTOM SIMULATION (See page 05 22) DTC CHECK (See page 05 29) Malfunction code...
Page 104 05 8 DIAGNOSTICS ECD SYSTEM (N04C TF) PROBLEM SYMPTOMS TABLE (See page 05 22) Wrong circuit confirmed Wrong parts confirmed Go to step 2 CHECK ECM POWER SOURCE CIRCUIT (See page 05 CIRCUIT INSPECTION Malfunction not confirmed Malfunction confirmed Go to step 3 CHECK FOR INTERMITTENT PROBLEMS (See page 05 Go to step 3 PARTS INSPECTION...
Page 105: Customer Problem Analysis Check
05 9 DIAGNOSTICS ECD SYSTEM (N04C TF) 054JC 23 CUSTOMER PROBLEM ANALYSIS CHECK Inspector’s ECD SYSTEM Check Sheet Name Customer’s Name Date Vehicle Production Date Brought in License Plate No. Odometer Reading miles Engine does Engine does not crank No initial combustion No complete combustion not Start Engine cranks slowly...
Page 106: Check For Intermittent Problems
DIAGNOSTICS ECD SYSTEM (N04C TF) 05DVY 04 CHECK FOR INTERMITTENT PROBLEMS HINT: Hand held tester only: Inspect the vehicle’s ECM using check mode. Intermittent problems are easier to be detected when the ECM is in check mode with the hand held tester. In check mode, the ECM uses trip detection logic, which has a higher sensitivity to malfunctions than normal mode (default), which uses 2 trip detection logic.
Page 107: Basic Inspection
DIAGNOSTICS ECD SYSTEM (N04C TF) 05I7H 03 BASIC INSPECTION When the malfunction is not confirmed in the DTC check, troubleshooting should be carried out in all the possible circuits considered as possible causes of the problem. In many cases, by carrying out the basic engine check shown in the following flowchart, the problem can be found quickly and efficiently.
Page 108: Check Engine Coolant
DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ENGINE COOLANT (See page 6 REPLACE ENGINE COOLANT (See page 6 3) CHECK IDLE SPEED AND MAXIMUM SPEED (See page 4 REPLACE INJECTION OR SUPPLY PUMP ASSY (See page CHECK DIAGNOSTIC CIRCUIT REPAIR OR REPLACE CHECK VACUUM PUMP REPAIR OR REPLACE VACUUM PUMP PROCEED TO PROBLEM SYMPTOMS TABLE (See page 05 22)
Page 109: Reading Registered Data
DIAGNOSTICS ECD SYSTEM (N04C TF) 05DVV 03 READING REGISTERED DATA NOTICE: If an injector has been replaced, the injector’s compensation code must be registered to the ECM. If an ECM has been replaced, all of the injector’s compensation code must be registered to the ECM.
Page 110 DIAGNOSTICS ECD SYSTEM (N04C TF) Reading Injector Compensation Codes Select a cylinder number Read the selected cylinder’s injector compensation code Do you want to read the injector compensation code of another cylinder? (Finished with reading injector compensation codes) A91211 A966 0 READ INJECTOR COMPENSATION CODE Example: Injector...
Page 111 DIAGNOSTICS ECD SYSTEM (N04C TF) Enter these menu options in this order: ”DIAGNOSIS / OBD/MOBD / DIAGNOSTIC MENU ECD”. Then select ”INJECTOR COMP”. Press ”ENTER”. A80985 Press ”ENTER” again. A6606 Select ”READ COMP VALUE” and press ”ENTER”. A66063 Select a cylinder number for the compensation code you want to read.
Page 112 DIAGNOSTICS ECD SYSTEM (N04C TF) Confirm the 30 digit alphanumeric code which is dis- played on the hand held tester. This is the injection com- pensation code of the cylinder. HINT: The code shown in the illustration is an example of a 30 digit code.
Page 113: Registration
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L X 0 REGISTRATION NOTICE: If an injector has been replaced, the injector’s compensation code must be registered to the ECM. If an ECM has been replaced, all of the injector’s compensation code must be registered to the ECM.
Page 114 DIAGNOSTICS ECD SYSTEM (N04C TF) Setting Injector Compensation Codes Select a cylinder number Register the selected cylinder’s injector compensation code Will you set injector compensation codes to other cylinders? (Finished with setting the injector compensation codes) A96612 A977 5 SET INJECTOR COMPENSATION CODE Example: Injector HINT:...
Page 115 DIAGNOSTICS ECD SYSTEM (N04C TF) Enter these menu options in this order: ”DIAGNOSIS / OBD/MOBD / DIAGNOSTIC MENU ECD”. Then select ”INJECTOR COMP”. Press ”ENTER”. A80985 Press ”ENTER” again. A6606 Select ”SET COMP VALUE” and press ”ENTER”. A66062 Press ”ENTER”. A66068 Select a cylinder number for the cylinder in which you want to register the compensation code.
Page 116 05 20 DIAGNOSTICS ECD SYSTEM (N04C TF) Input the compensation code (30 digit alphanumeric val- ue). After inputting, press ”ENTER”. A66070 (m) Press ”ENTER” again. A6607 Confirm the injection compensation code displayed on the hand held tester. HINT: The code shown in the illustration is an example. If a wrong compensation code registered, press ”NO”...
Page 117 05 2 DIAGNOSTICS ECD SYSTEM (N04C TF) Press ”NO” to complete the registration. HINT: If you want to register compensation codes other cylin- ders, press ”YES” instead of ”NO”. By pressing ”NO”, the hand held tester returns to the ”DIAGNOSTIC MENU ECD” screen. Turn the ignition switch OFF and wait for 30 seconds or more.
Page 118: Problem Symptoms Table
05 22 DIAGNOSTICS ECD SYSTEM (N04C TF) 054JF 23 PROBLEM SYMPTOMS TABLE When the malfunction code is not confirmed during the diagnostic trouble code check and no problem can be confirmed in the basic inspection, proceed to this problem symptoms tables and troubleshoot according to the numbered order given below.
Page 119 05 23 DIAGNOSTICS ECD SYSTEM (N04C TF) . Injector 2. Fuel line (Air bleed) 3. Compression 4. Valve clearance Rough idling (poor idling) 5. ECM 6. Supply pump 7. Fuel pressure sensor 8. Diesel throttle . Injector 2. ECM power source circuit 3.
Page 120: Terminals Of Ecm
05 24 DIAGNOSTICS ECD SYSTEM (N04C TF) 054KK 22 TERMINALS OF ECM A667 4 HINT: Each ECM terminal’s standard voltage is shown in the table below. In the table, first follow the information under ”Condition”. Look under ”Symbols (Terminal No.)” for the termi- nals to be inspected.
Page 121 05 25 DIAGNOSTICS ECD SYSTEM (N04C TF) IAT sensor (after turbo- Engine is warmed up: Idling, THIA (E4 20) E2 (E4 28) 0.5 to 3.4 V charged) IAT at 0 to 80˚C (32 to 76˚F) Idling, ECT at 80 to 20˚C THW (E4 E2 (E4 28) ECT sensor...
Page 122 05 26 DIAGNOSTICS ECD SYSTEM (N04C TF) Ignition switch ON, shift position is NUSW (E6 E (E5 7) Neutral position switch 8 to 27 V neutral Ignition switch ON, shift position is NUSW (E6 E (E5 7) Neutral position switch 0 to 2 V not neutral Exhaust brake clutch...
Page 123: Diagnosis System
05 27 DIAGNOSTICS ECD SYSTEM (N04C TF) 05I7I 02 DIAGNOSIS SYSTEM DESCRIPTION When troubleshooting Multiplex OBD (M OBD) ve- hicles, the vehicle must be connected to the hand held tester. Various data output from the vehicle’s Engine Control Module (ECM) can then be read. The vehicle’s on board computer illuminates the Malfunction Indicator Lamp (MIL) on the instrument panel when the computer detects a malfunction in...
Page 124: Freeze Frame Data
05 28 DIAGNOSTICS ECD SYSTEM (N04C TF) FREEZE FRAME DATA Freeze frame data records the engine conditions when a mal- function is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 125: Dtc Check/Clear
05 29 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L Y 0 DTC CHECK/CLEAR NOTICE: Hand held tester only: When the diagnosis system is changed from normal mode to check mode, all DTCs and freeze frame data recorded in normal mode will be erased. Before changing, always check and a note of DTCs and freeze frame data and make a note of them.
Page 126: Clear Dtc
05 30 DIAGNOSTICS ECD SYSTEM (N04C TF) Example 0.52 sec. .5 sec. If DTCs 2 and 3 are detected, the MIL flashes once (for 4.5 sec. 4.5 sec. 0.52 seconds) and flashes twice after the .5 seconds in- terval, then flashes 3 times after a 2.5 seconds interval sec.
Page 127: Check Mode Procedure
05 3 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L Z 0 CHECK MODE PROCEDURE HINT: Hand held tester only: Check mode has a higher sensitivity to malfunctions and can detect malfunction that normal mode cannot detect. Check mode can also detect all the malfunctions that normal mode can detect. Using the hand held tester: CHECK MODE PROCEDURE Make sure that the items below are true:...
Page 128 05 32 DIAGNOSTICS ECD SYSTEM (N04C TF) Using the hand held tester: CLEAR DTC Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON. Erase DTCs and freeze frame data with the hand held tester (see the hand held tester instruction manual for operating procedures).
Page 129: Fail Safe Chart
05 33 DIAGNOSTICS ECD SYSTEM (N04C TF) 05DVX 04 FAIL SAFE CHART FAIL SAFE CHART If any of the following codes is recorded, the ECM enters fail safe mode. DTC No. Detection Item Fail safe Operation Fail safe Deactivation Conditions P0087/49 Fuel Rail/System Pressure Too Low Limits engine power Ignition switch OFF...
Page 130 05 34 DIAGNOSTICS ECD SYSTEM (N04C TF) DTC No. Detection Item Fail safe Operation Fail safe Deactivation Conditions P0 90/49 Fuel Rail Pressure Sensor Circuit Limits engine power ”Pass” condition detected Fuel Rail Pressure Sensor Circuit P0 9 /49 Limits engine power ”Pass”...
Page 131: Data List/Active Test
05 35 DIAGNOSTICS ECD SYSTEM (N04C TF) 05DVU 04 DATA LIST/ACTIVE TEST DATA LIST HINT: Using the hand held tester is DATA LIST allows switch, sensor, actuator and other item values to be read without removing any parts. Reading DATA LIST early in troubleshooting is one way to save time. NOTICE: In the table below, the values listed under ”Normal Condition”...
Page 132 05 36 DIAGNOSTICS ECD SYSTEM (N04C TF) Measurement Item/Range Hand held Tester Display Normal Condition * Diagnostic Note (Display) S Idling: 25 to 35 MPa (255 kgf/cm (3,625 psi) to 357 kgf/cm (5,076 Common rail pressure status/ COMN RAIL PRESS psi)) Min.: 0 MPa, Max.: 255 MPa S Engine running at 3,000 rpm: 80...
Page 133 05 37 DIAGNOSTICS ECD SYSTEM (N04C TF) ACTIVE TEST HINT: Performing the hand held tester’s ACTIVE TEST allows relay, VSV, actuator and other items to be operated without removing any parts. Performing the ACTIVE TEST early in trouble shooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST.
Page 134: Diagnostic Trouble Code Chart
05 38 DIAGNOSTICS ECD SYSTEM (N04C TF) 054JD 2 DIAGNOSTIC TROUBLE CODE CHART HINT: Parameters listed in the chart may be different from your readings depending on the type of instrument used and other factors. During the DTC check, refer to the table below if a malfunction code is displayed. For details about each code, refer to the page number in the DTC chart’s left column.
Page 135 05 39 DIAGNOSTICS ECD SYSTEM (N04C TF) S Open or short in IAT sensor circuit P0 3/24 Intake Air Temperature Circuit S IAT sensor (built in MAF meter) (05 74) High Input S ECM S Open or short in ECT sensor circuit P0 5/22 Engine Coolant Temperature Cir- S ECT sensor...
Page 136 05 40 DIAGNOSTICS ECD SYSTEM (N04C TF) S Open or short in EDU circuit P0272/78 Cylinder 4 Contribution/Balance S Injector S EDU S Open or short in crankshaft position sensor circuit P0335/ 2 Crankshaft Position Sensor ”A” S Crankshaft position sensor Circuit S Crankshaft position sensor plate S ECM...
Page 137 05 4 DIAGNOSTICS ECD SYSTEM (N04C TF) S Open or short in accelerator pedal position sensor circuit P2 25/ 9 Throttle/Pedal Position Sensor/ S Accelerator pedal position sensor Switch ”E” Circuit S ECM S Open or short in accelerator pedal position sensor circuit P2 27/ 9 Throttle/Pedal Position Sensor/ S Accelerator pedal position sensor...
Page 138 05 42 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L20 0 P0087/49 FUEL RAIL/SYSTEM PRESSURE P0 90/49 FUEL RAIL PRESSURE SENSOR CIRCUIT P0 9 /49 FUEL RAIL PRESSURE SENSOR CIRCUIT RANGE/PERFORMANCE P0 92/49 FUEL RAIL PRESSURE SENSOR CIRCUIT LOW INPUT P0 93/49 FUEL RAIL PRESSURE SENSOR CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The fuel pressure sensor, mounted on the common rail, converts the fuel pressure into an electric signal and...
Page 139: Wiring Diagram
05 43 DIAGNOSTICS ECD SYSTEM (N04C TF) Fuel Pressure Malfunction S Short in PCR and E2 circuit Approx. 0 MPa (0 kg/cm , 0 psi) or more S Open in VC circuit S Short in PCR and VC circuit Approx. 90 MPa ( ,937 kg/cm , 27,556 psi) or more S Open in PCR circuit S Open in E2 circuit...
Page 140 05 44 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VC VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Specified Condition 8 (VC) E4 28 (E2) 4.5 to 5.5 V REPLACE ECM (See page 0 A66060 CHECK ECM (PCR VOLTAGE) Start the engine.
Page 141 05 45 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (FUEL PRESSURE SENSOR ECM) Disconnect the E4 ECM connector. Wire Harness Side Disconnect the F8 fuel pressure sensor connector. Measure the resistance of the wire harness side connec- tors. Standard: Tester Connection Specified Condition E4 26 (PCR )
Page 142 05 46 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2 P0088/78 FUEL RAIL/SYSTEM PRESSURE HIGH P0627/78 FUEL PUMP CONTROL CIRCUIT / OPEN P 229/78 FUEL PUMP SYSTEM CIRCUIT DESCRIPTION The injection (supply) pump is single type pump and has a circuit for fuel suction that achieves high pressure force feed and reduction of driving torque, and for force feed process.
Page 143 05 47 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 144 05 48 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT SUPPLY PUMP ASSY (SUCTION CONTROL VALVE) Measure the resistance of the suction control valve. Suction Standard: 7.5 to 8. at 20_C (68_F) Control Valve REPLACE SUPPLY PUMP ASSY (SUCTION CONTROL VALVE) (See page A96030 CHECK WIRE HARNESS (SUCTION CONTROL VALVE ECM)
Page 145 05 49 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK DTC OUTPUT Read the DTCs using the hand held tester. Result: Display (DTC output) Proceed to P0088/87, P0627/78 or P 229/78 is output P0088/87, P0627/78 or P 229/78 is not output SYSTEM IS OK REPLACE SUPPLY PUMP ASSY (See page...
Page 146: P0093/78
05 50 DIAGNOSTICS ECD SYSTEM (N04C TF) 05CPF 07 P0093/78 FUEL SYSTEM LEAK DETECTED LARGE LEAK CIRCUIT DESCRIPTION Refer to DTC P0087/48 on page 05 42. Refer to DTC P0088/78 on page 05 46. DTC No. DTC Detection Condition Trouble Area DTC is output when following conditions (a), (b) and (c) are all met and if difference of common rail pressure that fuel pres- sure sensor detects before and after fuel injection varies great-...
Page 147: Repair Or Replace
05 5 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK FUEL LEAKAGE Visually check the supply pump, injector and fuel line located between the supply pump and common rail for fuel leaks or fuel pressure leaks. Also, perform the same on the fuel line between the common rail and the injector (see pages 5 and 20).
Page 148 05 52 DIAGNOSTICS ECD SYSTEM (N04C TF) 05CPG 07 P0095/23 INTAKE AIR TEMPERATURE SENSOR 2 CIRCUIT P0097/23 INTAKE AIR TEMPERATURE SENSOR 2 CIRCUIT LOW P0098/23 INTAKE AIR TEMPERATURE SENSOR 2 CIRCUIT HIGH CIRCUIT DESCRIPTION The intake air temperature (IAT) sensor (after turbocharged), (Fig.
Page 149 05 53 DIAGNOSTICS ECD SYSTEM (N04C TF) Temperature Displayed Malfunction 40˚C ( 40˚F) Open circuit 40˚C (284˚F) or more Short circuit WIRING DIAGRAM IAT Sensor (after turbocharged) THIA A96035 INSPECTION PROCEDURE HINT: If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit.
Page 150 05 54 DIAGNOSTICS ECD SYSTEM (N04C TF) When using hand held tester: READ VALUE OF DATA LIST (INTAKE AIR TEMPERATURE) Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / AMBI TEMP SENS.
Page 151 05 55 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR OPEN IN ECM) Disconnect the I9 IAT sensor connector. Connect terminals THIA and E2 of the E4 ECM connector. HINT: IAT Sensor Before checking, do a visual and contact pressure check for the THIA ECM connector.
Page 152 05 56 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR SHORT IN ECM) Disconnect the E4 ECM connector. Turn the ignition switch ON. On the hand held tester, enter the following menus: IAT Sensor DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / AMBI THIA TEMP SENS.
Page 153 05 57 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK ECM (TH A VLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition E4 20 (THIA) 20_C (68_F) 0.2 to 3.8 V E4 28 (E2) E4 20 (THIA)
Page 154 05 58 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM IAT SENSOR) Disconnect the I9 IAT sensor connector. Wire Harness Side Disconnect the E4 ECM connector. IAT Sensor Measure the resistance of the wire harness side connec- tors. Standard: Tester Connection Specified Condition I9 2 (THIA)
Page 155 05 59 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L22 0 P0 00/3 MASS OR VOLUME AIR FLOW CIRCUIT P0 02/3 MASS OR VOLUME AIR FLOW CIRCUIT LOW INPUT P0 03/3 MASS OR VOLUME AIR FLOW CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The Mass Air Flow (MAF) meter uses a platinum hot wire. The hot wire MAF meter consists of a platinum hot wire, thermistor and a control circuit installed in a plastic housing.
Page 156 05 60 DIAGNOSTICS ECD SYSTEM (N04C TF) HINT: After confirming DTC P0 00/3 , P0 02/3 or P0 03/3 , use the hand held tester to confirm the MAF ratio from the MAF menu (to reach the MAF menu: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAF). Air Flow Value (gm/sec.) Malfunction S MAF meter power source circuit open...
Page 157 05 6 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM Voltage Converter MAF Meter VOUT R/B No. 2 MAIN Relay Shielded From Battery GR G GR G MREL A96036...
Page 158 05 62 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 159 05 63 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VG VOLTAGE) Start the engine. Measure the voltage of the ECM connector. VG (+) Standard: Tester Connection Condition Specified Condition E5 24 (VG) Engine is idling .8 to 2.6 V E5 32 (EVG) E5 24 (VG) Engine speed at 3,000 3.0 to 4.0 V...
Page 160 05 64 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (VOLTAGE CONVERTER MAF METER) Disconnect the V8 voltage converter connector. Wire Harness Side Disconnect the A20 MAF meter connector. Measure the resistance of the wire harness side connec- Voltage Converter tors.
Page 161 05 65 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK MASS AIR FLOW METER (POWER SOURCE) Turn the ignition switch ON. Wire Harness Side Disconnect the A20 MAF meter connector. Measure the voltage of the wire harness side connector. Standard: MAF Meter Tester Connection...
Page 162 05 66 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (MAF METER ECM) Disconnect the A20 MAF meter connector. Wire Harness Side Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connec- tors. MAF Meter Standard: Tester Connection Specified Condition A20 3 (VG)
Page 163 05 67 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK VOLTAGE CONVERTER (VIM VOLTAGE) Turn the ignition switch ON. Wire Harness Side Disconnect the V8 voltage converter connector. Voltage Converter Measure the voltage of the converter connector. Standard: Tester Connection Specified Condition (VIN) V8 3 (GND) 8 to 27 V...
Page 164 05 68 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L23 0 P0 05/3 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT P0 07/3 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT LOW INPUT P0 08/3 MANIFOLD ABSOLUTE PRESSURE/BAROMETRIC PRESSURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION By a built in sensor unit, the turbo pressure sensor (manifold absolute pressure sensor) detects the intake manifold pressure Voltage as a voltage.
Page 165 05 69 DIAGNOSTICS ECD SYSTEM (N04C TF) Intake Manifold Pressure (kPa) Malfunction Approximately 0 S Short in PIM circuit S Open or short in VC circuit 370 or more S Open in PIM circuit S Open in E2 circuit WIRING DIAGRAM Turbo Pressure Sensor A96037 INSPECTION PROCEDURE...
Page 166 05 70 DIAGNOSTICS ECD SYSTEM (N04C TF) When using hand held tester: READ VALUE OF DATA LIST (MANIFOLD ABSOLUTE PRESSURE) Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / PIM.
Page 167 05 7 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (PIM VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Condition Specified Condition Negative pressure of 93 E5 28 (PIM) E4 28 (E2) kPa (675 mmHg, 27.5 0.25 to 0.4 V in.Hg) applied E2 ( )
Page 168 05 72 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK ECM (VC VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. VC (+) Standard: Tester Connection Specified Condition 8 (VC) E4 28 (E2) 4.5 to 5.5 V E2 ( ) REPLACE ECM (See page 0...
Page 169 05 73 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (TURBO PRESSURE SENSOR ECM) Disconnect the T2 turbo pressure sensor connector. Wire Harness Side Disconnect the E4 and E5 ECM connectors. Measure the resistance of the wire harness side connec- Turbo Pressure Sensor tors.
Page 170 05 74 DIAGNOSTICS ECD SYSTEM (N04C TF) 05CPL 07 0/24 INTAKE AIR TEMPERATURE CIRCUIT 2/24 INTAKE AIR TEMPERATURE CIRCUIT LOW INPUT 3/24 INTAKE AIR TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The Intake Air Temperature (IAT) sensor is built into the Mass (Fig.
Page 171 05 75 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM IAT Sensor (built in MAF Meter) A96035 INSPECTION PROCEDURE HINT: If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand held tester.
Page 172 05 76 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR OPEN IN WIRE HARNESS) Disconnect the A20 MAF meter connector. Connect terminals 4 and 5 of the MAF meter wire harness side connector. MAF Meter Turn the ignition switch ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / INTAKE AIR.
Page 173 05 77 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR SHORT IN WIRE HARNESS) Disconnect the A20 MAF meter connector. Turn the ignition switch ON. MAF Meter On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / INTAKE AIR.
Page 174 05 78 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK ECM (THA VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition E4 3 (THA) 20_C (68_F) 0.2 to 3.8 V E4 28 (E2) E4 3 (THA)
Page 175 05 79 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM IAT SENSOR) Disconnect the A20 MAF meter connector. Wire Harness Side Disconnect the E4 ECM connector. Measure the resistance of the wire harness side connec- MAF Meter tors. Standard: Tester Connection Specified Condition A20 5 (THA)
Page 176 05 80 DIAGNOSTICS ECD SYSTEM (N04C TF) 05CPM 07 5/22 ENGINE COOLANT TEMPERATURE CIRCUIT 7/22 ENGINE COOLANT TEMPERATURE CIRCUIT LOW INPUT 8/22 ENGINE COOLANT TEMPERATURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION A thermistor is built in the Engine Coolant Temperature (ECT) sensor and changes the resistance value ac- cording to the ECT.
Page 177 05 8 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected.
Page 178 05 82 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR OPEN IN WIRE HARNESS) Disconnect the E ECT sensor connector. Connect terminals and 2 of the ECT sensor wire har- ness side connector. ECT sensor Turn the ignition switch ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / COOL- ANT TEMP.
Page 179 05 83 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR SHORT IN WIRE HARNESS) Disconnect the E ECT sensor connector. Turn the ignition switch ON. ECT Sensor On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / COOL- ANT TEMP.
Page 180 05 84 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK ECM (THW VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition 9 (THW) 20_C (68_F) 0.2 to 3.8 V E4 28 (E2) 9 (THW) 80_C ( 76_F)
Page 181 05 85 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM ECT SENSOR) Disconnect the E ECT sensor connector. Wire Harness Side Disconnect the E4 ECM connector. Measure the resistance of the wire harness side connec- ECT Sensor tors. Standard: Tester Connection Specified Condition (THW)
Page 182 05 86 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L24 0 P0 20/4 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT P0 22/4 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT LOW INPUT P0 23/4 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”A” CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The throttle position sensor is mounted in the throttle body and Throttle Position detects the throttle valve (intake shutter) opening angle.
Page 183 05 87 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM Throttle Position Sensor A963 3 INSPECTION PROCEDURE HINT: If DTCs that are related to different systems are output simultaneously while terminal E2 is used as a ground terminal, terminal E2 may have an open circuit. Read freeze frame data using the hand held tester.
Page 184 05 88 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VC VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. VC (+) Standard: Tester Connection Specified Condition 8 (VC) E4 28 (E2) 4.5 to 5.5 V E2 ( ) REPLACE ECM (See page 0 A66060 CHECK ECM (VLU VOLTAGE)
Page 185 05 89 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM THROTTLE POSITION SENSOR) Disconnect the E4 and E5 ECM connectors. Wire Harness Side Disconnect the T7 throttle position sensor connector. Measure the resistance of the wire harness side connec- tors.
Page 186 05 90 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VLU VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Accelerator Pedal Tester Connection Specified Condition Condition E5 20 (VLU) Released 3.5 to 4.0 V E4 28 (E2) E5 20 (VLU) E2 ( ) VLU (+)
Page 187 05 9 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM THROTTLE POSITION SENSOR) Disconnect the E4 and E5 ECM connectors. Wire Harness Side Disconnect the T7 throttle position sensor connector. Measure the resistance of the wire harness side connec- tors.
Page 188: P0 68/39
05 92 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L25 0 P0 68/39 FUEL TEMPERATURE TOO HIGH P0 80/39 FUEL TEMPERATURE SENSOR ”A” CIRCUIT P0 82/39 FUEL TEMPERATURE SENSOR ”A” CIRCUIT LOW INPUT P0 83/39 FUEL TEMPERATURE SENSOR ”A” CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The fuel temperature sensor senses the fuel temperature.
Page 189 05 93 DIAGNOSTICS ECD SYSTEM (N04C TF) HINT: After confirming DTC ”P0 80/39, P0 82/39 or P0 83/39”, use the hand held tester to confirm the fuel tem- perature from the FUEL TEMP menu (to reach the FUEL TEMP menu: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / FUEL TEMP).
Page 190 05 94 DIAGNOSTICS ECD SYSTEM (N04C TF) When using hand held tester: READ VALUE OF DATA LIST (FUEL TEMPERATURE) Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / FUEL TEMP.
Page 191 05 95 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR OPEN IN ECM) Disconnect the F 0 sensor connector. Connect terminals THF and E2 of the E4 ECM connector. HINT: Fuel Temperature Sensor Before checking, do a visual and contact pressure check for the ECM connector.
Page 192 05 96 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (CHECK FOR SHORT IN ECM) Disconnect the E4 ECM connector. Turn the ignition switch ON. On the hand held tester, enter the following menus: Fuel Temperature Sensor DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / Fuel temp. Read the values.
Page 193 05 97 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT FUEL TEMPERATURE SENSOR Remove the fuel temperature sensor. Ohmmeter Using an ohmmeter, measure the resistance between ter- minals. Standard: Connection Specified Condition 20_C (68_F) 2.32 to 2.59 k 80_C ( 76_F) 0.3 0 to 0.326 k NOTICE: Acceptable If checking the ECT sensor in the water, be careful not to...
Page 194: P0200/97
05 98 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L26 0 P0200/97 INJECTOR CIRCUIT / OPEN CIRCUIT DESCRIPTION The EDU has been adopted to drive the injector at high speeds. The EDU has realized high speed driving under high fuel pressure conditions through the use of a DC/DC converter that provides a high voltage, quick charging system.
Page 195 05 99 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM GR G GR G MREL To Battery To Battery R/B No. 2 EDU Relay MAIN Relay IREL Injector No. +B E 0 INJ# IJT# Injector No. 2 COM2 IJT#2 INJ#2 LG B IJT#3 Injector No.
Page 196 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 197 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT INJECTOR ASSY Measure the resistance between the terminals. Standard: 0.35 to 0.55 at 20_C (68_F) Injector Assy REPLACE INJECTOR ASSY (See page A8 503 REPAIR OR REPLACE HARNESS AND CONNECTOR CHECK WIRE HARNESS (EDU ECM) Disconnect the E 7 EDU connector.
Page 198 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM Inspect using an oscilloscope. While the engine is idling, check the waveform of the ECM connectors. Standard: Tester Connection Specified Condition E4 24 (# ) E5 7 (E ) E4 23 (#2) E5 7 (E ) Correct waveform is as shown E4 22 (#3) E5 7 (E )
Page 199 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L27 0 P0263/78 CYLINDER CONTRIBUTION/BALANCE P0266/78 CYLINDER 2 CONTRIBUTION/BALANCE P0269/78 CYLINDER 3 CONTRIBUTION/BALANCE P0272/78 CYLINDER 4 CONTRIBUTION/BALANCE HINT: These DTCs indicate a malfunction related to the primary circuit. If DTC P0263/78 is displayed, check injector No. circuit.
Page 200 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK EDU (+B VOLTAGE) Disconnect the E 0 and E 7 EDU connectors. Wire Harness Side Measure the voltage of the wire harness side connectors. Standard: +B (+) Tester Connection Condition Specified Condition E 0 8 (+B) (GND) Ignition switch ON 8 to 27 V...
Page 201 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT INJECTOR ASSY Measure the resistance between the terminals. Standard: 0.35 to 0.55 at 20_C (68_F) Injector Assy REPLACE INJECTOR ASSY (See page A8 503 REPAIR OR REPLACE HARNESS AND CONNECTOR CHECK WIRE HARNESS (EDU ECM) Disconnect the E 7 EDU connector.
Page 202 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM Inspect using an oscilloscope. While the engine is idling, check the waveform of the ECM connectors. Standard: Tester Connection Specified Condition E4 24 (# ) E5 7 (E ) E4 23 (#2) E5 7 (E ) Correct waveform is as shown E4 22 (#3) E5 7 (E )
Page 203: P0335/ 2
DIAGNOSTICS ECD SYSTEM (N04C TF) 05B5I P0335/ 2 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT P0339/ 3 CRANKSHAFT POSITION SENSOR ”A” CIRCUIT INTERMITTENT CIRCUIT DESCRIPTION The crankshaft position sensor (NE signal) consists of a magnet, iron core and pickup coil. The crankshaft angle sensor plate has 32 teeth and is installed on the injection pump drive gear. The NE signal sensor generates 32 signals of every engine revolution.
Page 204 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM Camshaft Position Sensor Crankshaft Position Sensor (Shielded) A96040...
Page 205 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 206 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (CRANKSHAFT POSITION SENSOR ECM) Disconnect the C3 sensor connector. Wire Harness Side Disconnect the E4 ECM connector. Measure the resistance of the wire harness side connec- Crankshaft Position Sensor tors. Standard: Tester Connection Specified Condition (Crankshaft position sensor) E4 27 (NE+)
Page 207: P0340/ 2
DIAGNOSTICS ECD SYSTEM (N04C TF) 05B5J P0340/ 2 CAMSHAFT POSITION SENSOR ”A” CIRCUIT (BANK OR SINGLE SENSOR) CIRCUIT DESCRIPTION The camshaft position sensor (G signal) consists of a magnet and MRE element. The camshaft drive gear has 5 teeth on its inner circumference. When the camshaft gear rotates, air gap changes between the protrusion on the gear and the pickup coil.
Page 208 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK CAMSHAFT POSITION SENSOR Inspect using an oscilloscope. While the engine is idling, check the waveform of the ECM connector. Standard: Tester Connection Specified Condition E5 23 (G+) E5 3 (G ) Correct waveform is as shown 5 V/ G+ and NE Signal Waveforms Division...
Page 209 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (CAMSHAFT POSITION SENSOR ECM) Disconnect the C camshaft position sensor connector. Wire Harness Side Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connec- Camshaft position Sensor tors. Standard: Tester Connection Specified Condition...
Page 210 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK DTC OUTPUT Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DTC INFO / CUR- RENT CODES.
Page 211: P0488/ 5
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L28 0 P0488/ 5 EXHAUST GAS RECIRCULATION THROTTLE POSITION CONTROL RANGE/PERFORMANCE CIRCUIT DESCRIPTION The throttle control motor opens and closes the throttle valve according to a duty cycle (signal) from the ECM. DTC No. DTC Detection Condition Trouble Area Conditions (a) or (b) continue for more than second...
Page 212 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK THROTTLE CONTROL MOTOR (+B VOLTAGE) Turn the ignition switch ON. Wire Harness Side Disconnect the I 2 throttle control motor connector. Measure the voltage of the wire harness side connector. Throttle Control Motor Standard: Tester Connection Specified Condition I 2 2 (+B)
Page 213 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (THROTTLE CONTROL MOTOR ECM) Disconnect the I 2 throttle control motor connector. Wire Harness Side Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connec- Throttle Control Motor tors.
Page 214: P0500/42
DIAGNOSTICS ECD SYSTEM (N04C TF) 05B5L P0500/42 VEHICLE SPEED SENSOR ”A” CIRCUIT DESCRIPTION The speed sensor for skid control ECU detects the wheel speed and sends the appropriate signals to the skid control ECU. The skid control ECU converts these signals into a 4 pulse signal and outputs it to the combination meter. After this signal is converted into a more precise rectangular waveform by the waveform shaping circuit in- side the combination meter, it is then transmitted to the ECM.
Page 215 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 216 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (COMBINATION METER ECM) Disconnect the C5 meter connector. Wire Harness Side Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connec- tors. Standard: Tester Connection Specified Condition 9 (SPD) Below C5 37 (Combination meter) 9 (SPD)
Page 217: P0504/5
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L29 0 P0504/5 BRAKE SWITCH ”A”/”B” CORRELATION CIRCUIT DESCRIPTION In this system, signals of the stop lamp switch are used to judge whether the brake system is abnormal or not. The stop lamp switch has a duplex system (signals STP and ST ) to memorize the abnormality when the signals of depressing and releasing the brake pedal are detected simultaneously.
Page 218 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM R/B No. and J/B No. Stop Lamp Switch ECU IG Ignition Switch STOP R/B No. 2 Main Battery Battery : Except Standard Roof : Standard Roof A96043...
Page 219 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 220 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (STP SIGNAL AND ST VOLTAGE) Turn the ignition switch ON. On the hand held tester, enter the following menus: Brake Pedal Brake Pedal DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / STOP Depressed Released LIGHT SW.
Page 221 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK OPERATION OF STOP LAMP Check if the stop lamps turn on and off normally when the brake pedal is depressed and released. REPAIR OR REPLACE STOP LAMP SWITCH CIRCUIT INSPECT STOP LAMP SWITCH ASSY Measure the resistance of the switch.
Page 222 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (STOP LAMP SWITCH ECM) Disconnect the S 5 stop lamp switch connector. Wire Harness Side Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connec- Stop Lamp Switch tors.
Page 223 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2A 02 ACCELERATOR POSITION SENSOR CIR- CUIT HIGH CIRCUIT DESCRIPTION The outer accelerator position sensor, mounted on the acceler- Accelerator ator bellcrank, is used to control the PTO. The sensor converts Position Sensor the opening degrees of the accelerator pedal into voltage of 0 to 5 V and output it to the ECM.
Page 224 DIAGNOSTICS ECD SYSTEM (N04C TF) When using hand held tester: READ VALUE OF DATA LIST Connect the hand held tester (with 24 V VIM) to the DLC3. Start the engine. Turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / PTO SW.
Page 225 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT ACCELERATOR POSITION SENSOR ASSY Disconnect the A4 sensor connector. Measure the resistance of the sensor. Accelerator Position Sensor Standard: Accelerator Pedal Tester Connection Specified Condition Condition A4 3 ( ) .6 to 2.4 k Resistance changes A4 2 (SIG) A4 3 ( )
Page 226 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK ECM (VCP VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Specified Condition E5 35 (VCP) E5 34 (E2P) 4.5 to 5.5 V VCP (+) E2P ( ) REPLACE ECM (See page 0...
Page 227 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM ACCELERATOR POSITION SENSOR) Disconnect the A4 sensor connector. Wire Harness Side Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connec- Accelerator Position sensor tors. Standard: Tester Connection Specified Condition E5 35 (VCP) E5 28 (E2P)
Page 228 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2B 0 43/ 9 IDLE VARIABLE RESISTOR SWITCH CIRCUIT MALFUNCTION (SHORT) CIRCUIT DESCRIPTION The throttle knob (idle variable resistor switch) is on the instru- ment panel. The drives use the knob to idle up the engine with manual operation.
Page 229 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 230 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VICM VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Idle Variable Resistor Tester Connection Specified Condition Switch Condition 2 (VICM) 0.5 to 0.9 V E4 28 (E2) 2 (VICM) E2 ( ) VICM (+)
Page 231 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM IDLE VARIABLE RESISTOR SWITCH) Disconnect the I 3 switch connector. Wire Harness Side Disconnect the E4 and E6 ECM connectors. Measure the resistance of the wire harness side connec- Idle Variable Resistor Switch tors.
Page 232 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VICM VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Idle Variable Resistor Tester Connection Specified Condition Switch Condition 2 (VICM) 0.5 to 0.9 V E4 28 (E2) 2 (VICM) E2 ( ) VICM (+)
Page 233 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM IDLE VARIABLE RESISTOR SWITCH) Disconnect the I 3 switch connector. Wire Harness Side Disconnect the E4 and E6 ECM connectors. Measure the resistance of the wire harness side connec- Idle Variable Resistor Switch tors.
Page 234 DIAGNOSTICS ECD SYSTEM (N04C TF) 05CQ2 04 P 60 /89 INJECTOR CORRECTION CIRCUIT MALFUNCTION (EEPROM) CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S Injector compensation code is not registered S Injector compensation code P 60 /89 S Wrong injector compensation code is registered S ECM INSPECTION PROCEDURE CHECK INJECTOR COMPENSATION CODE (See page 05...
Page 235 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2C 0 / 7 RUN PULSE MALFUNCTION CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area P 6 / 7 ECM inside error INSPECTION PROCEDURE REPLACE ECM (See page 0...
Page 236 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2D 0 P 674/36 SOLENOID FOR EXHAUST BRAKE CIRCUIT MALFUNCTION CIRCUIT DESCRIPTION The exhaust brake VSV, mounted on the exhaust retarder, opens and closes according to the signals from the ECM. The ECM receives the signals from the clutch switch and exhaust retarder switch. Through the brake VSV, the ECM controls the negative pressure applied to the diaphragm in the retarder.
Page 237 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected. When troubleshooting, freeze frame data can help determine if the vehicle was running or stopped, if the engine was warmed up or not, if the air fuel ratio was lean or rich, and other data from the time the malfunction occurred.
Page 238 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM EXHAUST BRAKE SOLENOID) Disconnect the E3 exhaust brake solenoid connector. Wire Harness Side Disconnect the E5 ECM connector. Measure the resistance of the wire harness side connec- Exhaust Brake Solenoid tors. Standard: Tester Connection Specified Condition...
Page 239 DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2E 0 P2 20/ 9 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT P2 2 / 9 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT RANGE/PERFORMANCE P2 22/ 9 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D” CIRCUIT LOW INPUT P2 23/ 9 THROTTLE/PEDAL POSITION SENSOR/SWITCH ”D”...
Page 240 DIAGNOSTICS ECD SYSTEM (N04C TF) CIRCUIT DESCRIPTION HINT: This electrical throttle system does not use a throttle cable. This accelerator pedal position sensor is non contact type. The accelerator pedal position sensor is mounted on the accelerator pedal and detects the opening angle of the accelerator pedal.
Page 241: P2 20/ 9
DIAGNOSTICS ECD SYSTEM (N04C TF) DTC No. DTC Detecting Condition Trouble Area Condition (a) continues for second or more: S Open or short in accelerator pedal position sensor circuit (a) VPA less than 0.2 V and VPA2 greater than 0.97 deg, or P2 20/ 9 S Accelerator pedal position sensor S ECM...
Page 242 DIAGNOSTICS ECD SYSTEM (N04C TF) WIRING DIAGRAM Accelerator Pedal Position Sensor VCP2 VCP2 GR G EPA2 VPA2 VPA2 VCPA LG B BR R A96046 INSPECTION PROCEDURE HINT: Read freeze frame data using the hand held tester. Freeze frame data records the engine conditions when a malfunction is detected.
Page 243 DIAGNOSTICS ECD SYSTEM (N04C TF) When using hand held tester: READ VALUE OF DATA LIST (ACCEL POS # AND ACCEL POS #2) Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ETCS / ACCEL POS # and ACCEL POS #2.
Page 244 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VCPA, VCP2 VOLTAGE) Disconnect the A sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Accelerator Pedal Standard: Position Sensor Connector Tester Connection Specified Condition E7 20 (VCPA) E7 28 (EPA) 4.5 to 5.5 V E7 2 (VCP2)
Page 245 DIAGNOSTICS ECD SYSTEM (N04C TF) When not using hand held tester: CHECK WIRE HARNESS (ECM ACCELERATOR PEDAL POSITION SENSOR) Disconnect the A sensor connector. Wire Harness Side Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connec- Accelerator Pedal Position Sensor tors.
Page 246 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (VCPA, VCP2 VOLTAGE) Disconnect the A sensor connector. Turn the ignition switch ON. Measure the voltage of the ECM connector. Accelerator Pedal Standard: Position Sensor Connector Tester Connection Specified Condition E7 20 (VCPA) E7 28 (EPA) 4.5 to 5.5 V E7 2 (VCP2)
Page 247: P2226
DIAGNOSTICS ECD SYSTEM (N04C TF) 05CQ5 04 P2226/A5 BAROMETRIC PRESSURE CIRCUIT P2228/A5 BAROMETRIC PRESSURE CIRCUIT LOW INPUT P2229/A5 BAROMETRIC PRESSURE CIRCUIT HIGH INPUT CIRCUIT DESCRIPTION The atmospheric pressure sensor, built in the ECM, detects the atmospheric pressure. According to the val- ue of the atmospheric pressure, the ECM corrects the injection timing, the injection volume and the amount of common rail internal fuel pressure for an optimum combustion.
Page 248: Ecm Power Source Circuit
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2F 0 ECM POWER SOURCE CIRCUIT CIRCUIT DESCRIPTION When the ignition switch is turned ON, battery positive voltage is applied to the coil, closing the contacts of the MAIN relay and supplying power to terminal +B of the ECM. WIRING DIAGRAM IGSW R/B No.
Page 249 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK ECM (+B VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition (+B) E5 7 (E ) 8 to 27 V E ( ) +B (+) PROCEED TO NEXT CIRCUIT INSPECTION SHOWN PROBLEM SYMPTOMS TABLE...
Page 250 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT RELAY (MAIN) Remove the MAIN relay from the R/B No. 2. Measure the resistance of the relay. Standard: Tester Connection Specified Condition or higher Below (when battery voltage is applied to terminals and 2) REPLACE RELAY B60778 CHECK WIRE HARNESS (MAIN RELAY...
Page 251 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (MREL VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition 3 (MREL) E5 7 (E ) 7 to 28 V MREL (+) E ( ) REPLACE ECM (See page 0 A 8294 CHECK WIRE HARNESS (MAIN RELAY...
Page 252 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (IGSW VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connectors. Standard: Tester Connection Specified Condition 6 (IGSW) E5 7 (E ) 7 to 28 V E ( ) IGSW (+) REPLACE ECM (See page 0 A 8294 INSPECT FUSE (IGN)
Page 253 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT IGNITION SWITCH ASSY Measure the resistance between the switch terminals. Tester Connection Condition Specified Condition LOCK 5 (AM2) 8 (IG2) LOCK or higher 5 (AM2) 8 (IG2) Below START REPLACE IGNITION SWITCH ASSY A92700 INSPECT RELAY (IG2) Remove the IG2 relay from the R/B No.
Page 254 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (IG2 RELAY ECM, IG2 RELAY BODY GROUND) Check the wire harness between the IG2 relay and ECM. Wire harness Side Remove the IG2 relay from the R/B No. 2. R/B No. 2 Disconnect the E7 ECM connector.
Page 255: Starter Signal Circuit
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2G 0 STARTER SIGNAL CIRCUIT CIRCUIT DESCRIPTION When the engine is being cranked, the intake air flow is slow, so fuel vaporization is poor. A rich mixture is therefore necessary in order to achieve good startability. While the engine is being cranked, the battery posi- tive voltage is applied to terminal STA of the ECM.
Page 256 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is being cranked under normal conditions. If the engine does not crank, proceed to the problem symptoms table on page 05 22. When using hand held tester: READ VALUE OF DATA LIST (STA SIGNAL) Connect the hand held tester (with 24 V VIM) to the DLC3.
Page 257 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK WIRE HARNESS (ECM STARTER RELAY) Disconnect the E5 ECM connector. Wire Harness Side Remove the STARTER relay from the R/B No. 2. Measure the resistance of the wire harness side connec- tors. Standard: Tester Connection Specified Condition 8 (STA) Below...
Page 258 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT FUSE (ST) Remove the ST fuse from the R/B No. and J/B No. . Measure the resistance of the fuse. Standard: Below R/B No. J/B No. ST Fuse REPLACE FUSE A96305 CHECK WIRE HARNESS (ECM STARTER RELAY) Disconnect the E5 ECM connector.
Page 259: Mil Circuit
DIAGNOSTICS ECD SYSTEM (N04C TF) 05B62 MIL CIRCUIT CIRCUIT DESCRIPTION If the ECM detects a malfunction, the Malfunction Indicator Lamp (MIL) is illuminated. At this time, the ECM records the DTC in its memory. WIRING DIAGRAM Combination Meter Assy R/B No. and J/B No.
Page 260: Clear Dtc
DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Use the chart below to troubleshoot each trouble symptom. MIL remains on Start inspection from step MIL is not illuminated Start inspection from step 3 CLEAR DTC Connect the hand held tester (with 24 V VIM) to the DLC3. Turn the ignition switch ON and turn the hand held tester ON.
Page 261 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT COMBINATION METER ASSY (See Pub. No. S YXZE05A, page 7 REPAIR OR REPLACE BULB OR COMBINATION METER ASSY CHECK AND REPLACE HARNESS AND CONNECTOR (COMBINATION METER ASSY ECM)
Page 262: Black Smoke
DIAGNOSTICS ECD SYSTEM (N04C TF) 05L2H 0 BLACK SMOKE HINT: Specified values in the following troubleshooting flowchart are the reference information. Because of resultant values in DATA LIST vary depending on measuring conditions or vehicle’s model years. Do not judge the vehicle normal even if the DATA LIST values indicate a standard level. There is a possibility that factors of the malfunction are hiding.
Page 263 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST Start the engine and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / INJ VOLUME and INJ VOL FB # to #4. Read the values. Standard: Item Engine Speed *...
Page 264 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST (MASS AIR FLOW RATE) Start the engine and turn the hand held tester ON. On the hand held tester, enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL / MAF.
Page 265 DIAGNOSTICS ECD SYSTEM (N04C TF) READ VALUE OF DATA LIST Start the engine and turn the hand held tester ON. Enter the following menus: DIAGNOSIS / OBD/MOBD / DATA LIST / ALL. Select the following items in order and read values displayed on the hand held tester respectively. COMMON RAIL PRESS INJ VOLUME M INJ/PILOT ON...
Page 266 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK HARNESS AND CONNECTOR (INJECTOR EDU) HINT: DTC P0200/97 ( trip detection logic) will be present if there is an open or short in the EDU circuit. Disconnect the I2, I3, I4 or I5 injector connector. Wire Harness Side Disconnect the E 0 EDU connector.
Page 267 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (THW VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition Idling, engine coolant tem- 9 (THW) perature is 80 to 20˚C 0.4 to .0 V 28 (E2) ( 76 to 248˚F) Go to step 8...
Page 268 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (NE+ SIGNAL) Inspect using an oscilloscope. While the engine is idling, check the waveform of the ECM connector. Standard: Tester Connection Specified Condition E4 27 (NE+) E4 34 (NE ) Correct waveform is as shown 5 V/ G+ and NE Signal Waveforms Division...
Page 269 DIAGNOSTICS ECD SYSTEM (N04C TF) CHECK ECM (THA VOLTAGE) Turn the ignition switch ON. Measure the voltage of the ECM connector. Standard: Tester Connection Condition Specified Condition 3 (THA) Idling, intake air tempera- 0.5 to 3.4 V 28 (E2) ture at 20˚C (68˚F) Go to step 22 A80455 CHECK ECM (PCR , PCR2 VOLTAGE)
Page 270 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT ENGINE COOLANT TEMPERATURE SENSOR Remove the ECT sensor. Ohmmeter Measure the resistance between the terminals. ECT Sensor Standard: Tester Connection Condition Specified Condition 20_C (68_F) 2.2 to 2.69 k 80_C ( 76_F) 0.29 to 0.354 k NOTICE: If checking the ECT sensor in water, be careful not to allow Acceptable...
Page 271 DIAGNOSTICS ECD SYSTEM (N04C TF) REPLACE TURBO PRESSURE SENSOR INSPECT CRANKSHAFT POSITION SENSOR Disconnect the C4 sensor connector. Measure the resistance of the sensor. Crankshaft Position Sensor Standard: Tester Connection Condition Specified Condition Cold ,630 to 2,740 2,065 to 3,225 NOTICE: In the above section, the terms ”Cold”...
Page 272 DIAGNOSTICS ECD SYSTEM (N04C TF) INSPECT MASS AIR FLOW METER (See page 0 3) REPLACE MASS AIR FLOW METER REPAIR OR REPLACE HARNESS AND CONNECTOR INSPECT COMMON RAIL ASSY (FUEL PRESSURE SENSOR) Disconnect the F8 fuel pressure sensor connector. Measure the resistance of the sensor connector. Fuel Pressure Sensor Standard: PFUEL...
Page 273 DIAGNOSTICS ECD SYSTEM (N04C TF) REPLACE ECM (See page 0 REPLACE INJECTION OR SUPPLY PUMP ASSY (See page...
Page 274: Abs & Ba System (N04C Tf)
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) ABS & BA SYSTEM (N04C TF) 057EK 03 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the ABS & BA system. The hand held tester should be used in steps 3, 6 and 8. Fail safe function: When a malfunction occurs in the ABS system, the ABS warning lamp is illuminated and the ABS op- eration is prohibited.
Page 275 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) PROBLEM SYMPTOMS TABLE (See page 05 If the fault is not listed on the problem symptoms table, proceed to A. If the fault is listed on the problem symptoms table, proceed to B. CHECK FOR FLUID LEAKAGE AND Go to step 9 OVERALL ANALYSIS AND TROUBLESHOOTING...
Page 276: Customer Problem Analysis Check
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057EL 03 CUSTOMER PROBLEM ANALYSIS CHECK ABS & BA SYSTEM Check Sheet Inspector’s Name Production Date Customer’s Name License Plate No. Date Vehicle Odometer Reading miles Brought In Date Problem First Occurred Frequency the Problem Occurs Continuously Intermittently ( times a day)
Page 277: Diagnosis System
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2P 0 PRE CHECK DIAGNOSIS SYSTEM Check the ABS warning lamp. When the ignition switch is turned ON, check that the ABS warning lamp illuminates for 3 seconds. HINT: If the indicator check result is abnormal, proceed to the trouble- shooting for the ABS warning lamp circuit (see page 05 247 or 05 250).
Page 278 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) When using the hand held tester: Hand held Tester Check the DTC. Connect the hand held tester (with 24 V VIM) to the DLC3. NOTICE: Be sure to use the 24 V VIM, because the hand held tester DLC3 will be damaged if you do not use the 24 V VIM.
Page 279 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) When using hand held tester: Hand held Tester CHECK SENSOR SIGNAL (TEST MODE) Check sensor signal. Connect the hand held tester (with 24 V VIM) to the DLC3. NOTICE: DLC3 Be sure to use the 24 V VIM, because the hand held tester will be damaged if you do not use the 24 V VIM.
Page 280 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Check that test mode is entered after the ABS warn- ing lamp is on for 3 seconds (initial value check) and Ignition Switch the ECU code is output. Do not depress the brake pedal until test mode is entered.
Page 281 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Check master cylinder pressure sensor. Turn the ignition switch OFF and then ON again. HINT: Do not start the engine. After releasing the brake pedal for second or more, depress it again with a force of 86 N ( 9 kgf, 42 lbf) or more.
Page 282 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) HINT: If the ABS warning lamp does not illuminate after de- pressing the brake pedal continuously, the vacuum sen- sor may be defective. When the parking brake is released, the vacuum warning buzzer may sound. After the warning lamp changes from blinking to illumi- nated, stop depressing the brake pedal.
Page 283 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Check the ABS warning lamp condition after the check is completed. Lighting condition when the speed sensor check is fin- ished normally: Vehicle Condition Lighting Condition of ABS Warning Lamp Flashing (ON) (It flashes even if test mode (It flashes even if test mode Vehicle stopped Vehicle stopped...
Page 284 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) DATA LIST Using the hand held tester’s DATA LIST allows switch, sensor, actuator and other item values to be read witchout removing any parts. Reading the DATA LIST early in troubleshooting is one way to save time. Connect the hand held tester to the DLC3.
Page 285: Test Mode
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Measurement Item/ Item Normal Condition Diagnostic Note Range (Display) DECELERAT SEN G sensor (GLT) open detection Open: Momentary interruption DECELERAY SEN2 G sensor (GL2) open detection Open: Momentary interruption NORMAL: Min. 0 V BSVUUM SENS Vacuum sensor detection...
Page 286 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) ACTIVE TEST HINT: Performing the hand held tester’s ACTIVE TEST allows relay, VSV actuator and other items to be operated without removing any parts. Preforming the ACTIVE TEST early in troubleshooting is one way to save time. The DATA LIST can be displayed during the ACTIVE TEST.
Page 287: Diagnostic Trouble Code Chart
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057EM 04 DIAGNOSTIC TROUBLE CODE CHART NOTICE: When removing any parts, turn the ignition switch OFF. HINT: Using SST 09843 8040, connect terminals TC and CG of the DLC3. If no abnormality is found when inspecting the parts, inspect the ECU. If a DTC is displayed during the DTC check, check the circuit listed for that code.
Page 288 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) C 238/38 S Right rear speed sensor Foreign matter is attached on tip of right front sensor S Sensor rotor (05 206) C 239/39 S Left rear speed sensor Foreign matter is attached on tip of right front sensor S Sensor rotor (05 206) S Battery...
Page 289 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) S Left rear speed sensor S Sensor installation C 274/74 Low Output Voltage of Left Rear Speed Sensor S Left rear speed sensor rotor S Left rear speed sensor circuit Abnormal Change in Output Voltage of Right Front Speed S Right front speed sensor rotor C 275/75 S Right front speed sensor...
Page 290: Location
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2Q 0 LOCATION Rear Speed Sensor Rotor Rear Speed Sensor Master Cylinder Pressure Sensor Stop Lamp Front Speed Rear Speed Sensor Sensor Rotor Stop Lamp Rear Speed Sensor Rotor Front Speed Sensor Rotor STOP Fuse Front Speed Sensor ABS Fuse...
Page 291 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) R/B No. and J/B No. Combination Meter Assy F ABS Warning Lamp F Parking Brake Warning Lamp GAUGE Fuse Brake Fluid Level Warning Switch Assy ECU IG Fuse Vacuum Sensor DLC3 Stop Lamp Switch Assy Skid Control ECU Assy Parking Brake Switch Assy F48693...
Page 292: Terminals Of Ecu
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057F3 04 TERMINALS OF ECU CHECK SKID CONTROL ECU ASSY B82697 Symbols (Terminals No.) Wiring Color Condition Specified Condition SRLH (S 7) GND (S 4 2) Ignition switch ON, ABS warning lamp OFF 20 to 32 V SRLR (S ) GND (S 4 2)
Page 293 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) E4 (S 2 Ignition switch OFF Below GND (S 4 2) ISS (S 2 20) Shielded Ignition switch OFF Below GND (S 4 2) PMC (S 2 25) Ignition switch ON, Stop lamp switch OFF 0.3 to 0.7 V GND (S 4 2) PSS (S 2...
Page 294 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) PKB (S 3 2 ) Ignition switch ON, Parking brake switch OFF 0 V or more GND (S 4 2) R+ (S 4 GND (S 4 2) Ignition switch ON, ABS warning lamp OFF 20 to 32 V If the result is not as specified, the ECU may have a malfunction.
Page 295: Problem Symptoms Table
DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057EO 04 PROBLEM SYMPTOMS TABLE If a normal code is displayed during the DTC check but the problem still occurs, check the circuits for each problem symptom in the order given in the table below and proceed to the relevant troubleshooting page. NOTICE: When replacing the skid control ECU, sensor, wire harness and other electrical components, turn the ignition switch OFF.
Page 296: Circuit Description
05 200 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2R 0 C0200/3 RIGHT FRONT SPEED SENSOR CIRCUIT C0205/32 LEFT FRONT SPEED SENSOR CIRCUIT C 235/35 FOREIGN MATTER IS ATTACHED ON TIP OF RIGHT FRONT SENSOR C 236/36 FOREIGN MATTER IS ATTACHED ON TIP OF LEFT FRONT SENSOR CIRCUIT DESCRIPTION The speed sensor detects the wheel speed and sends the ap-...
Page 297: Wiring Diagram
05 20 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) For abnormality in or 2 wheels, BRAKE ASSIST can be performed under the condition that the brake system is normal. For abnormality in 3 or 4 wheels, the ECU cuts off current to the solenoid relay and BRAKE ASSIST is prohibited.
Page 298: Inspection Procedure
05 202 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Start the inspection from step if using the hand held tester. If not, start from step 2. READ VALUE OF HAND HELD TESTER (FRONT SPEED SENSOR) Connect the hand held tester (with 24 V VIM) to the DLC3. Start the engine.
Page 299 05 203 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ASSY FRONT SPEED SENSOR) Disconnect the S 4 ECU connector. Wire Harness Side Disconnect the A2 and A3 sensor connectors. Skid Control ECU Assy Measure the resistance according to the table below. Standard: Tester Connection Specified Condition...
Page 300 05 204 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT SPEED SENSOR TIP Check the speed sensor installation. The installation bolt is tightened properly and there is no clearance between the sensor and front steering knuckle. Torque: 8.0 N m (82 kgf cm, 7 in. lbf) NOTICE: Check the speed sensor signal last (see page 05 8 ).
Page 301 05 205 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT SPEED SENSOR ROTOR Remove the front speed sensor rotor Disc Type (see Pub. No. S YXZE05A, page 32 9 ). Check the sensor rotor serrations. Standard: No scratches, missing teeth or foreign objects. HINT: If a foreign object is present, remove it and check the output wa- veform after reassembling.
Page 302 05 206 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2S 0 C02 0/33 RIGHT REAR SPEED SENSOR CIRCUIT C02 5/34 LEFT REAR SPEED SENSOR CIRCUIT C 238/38 FOREIGN MATTER IS ATTACHED ON TIP OF RIGHT REAR SENSOR C 239/39 FOREIGN MATTER IS ATTACHED ON TIP OF LEFT REAR SENSOR CIRCUIT DESCRIPTION Refer to DTC C0200/3 , C0205/32, C 235/35, C 236/36 on page 05 200.
Page 303 05 207 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) WIRING DIAGRAM Skid Control ECU Assy Speed Sensor (Shielded) Rear RH (Shielded) Speed Sensor Rear LH (Shielded) (Shielded) F48678...
Page 304 05 208 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Start the inspection from step if using the hand held tester. If not start from step 2. READ VALUE OF HAND HELD TESTER (REAR SPEED SENSOR) Connect the hand held tester (with 24 V VIM) to the DLC3. Start the engine.
Page 305 05 209 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT REAR SPEED SENSOR Disconnect the sensor connector. Rear Speed Sensor RH, LH Measure the resistance according to table below. Standard: Tester Connection Specified Condition .03 to .07 k at 25_C (85_F) Body ground or higher Body ground...
Page 306 05 2 0 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK SPEED SENSOR AND SENSOR ROTOR SERRATIONS Connect an oscilloscope to terminals RR+, RL+ and GND Normal Signal Waveform of the skid control ECU. Drive the vehicle at about 30 km/h ( 9 mph), and check the signal waveform.
Page 307 05 2 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT SPEED SENSOR ROTOR Remove the rear axle hub (see Pub. No. S YXZE05A, page 30 62). Check the sensor rotor serrations. No scratches, missing teeth or foreign objects. HINT: If a foreign object is present, remove it and check the output wa- veform after reassembling.
Page 308 05 2 2 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2T 0 C0226/2 SFR SOLENOID CIRCUIT C0236/22 SFL SOLENOID CIRCUIT C0246/23 SRR SOLENOID CIRCUIT C0256/24 SRL SOLENOID CIRCUIT C 225/25 SM SOLENOID CIRCUIT C 227/27 SRM SOLENOID CIRCUIT CIRCUIT DESCRIPTION This solenoid turns on when signals are received from the ECU and controls brake force by the pressure acting on the wheel cylinders.
Page 309 05 2 3 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) WIRING DIAGRAM R/B No. 2 Skid Control ECU Assy ABS SOL ABS SOL MAIN Relay ABS Actuator SFLH LG B LG B SFLH SFLR SFLR SFRH SFRH SFRR SFRR SRLH SRLH SRLR R/B No.
Page 310 05 2 4 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE INSPECT ABS ACTUATOR Disconnect the actuator connector. Measure the resistance according to the table below. Standard: Tester Connection Specified Condition 6 (BS) A 3 6 (SFLH) 3 .7 to 35.7 6 (BS) A 3 7 (SFRR) 5.9 to 7.9...
Page 311 05 2 5 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Tester Connection Specified Condition 6 (AST) Body ground 0 k or higher 7 (SRLH) Body ground 0 k or higher 8 (SFRR) Body ground 0 k or higher 6 (SFRH) Body ground 0 k or higher S 4 6 (SRM )
Page 312 05 2 6 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2U 0 C0273/ 3 OPEN CIRCUIT IN ABS MTR RELAY CIRCUIT C0274/ 4 B+ SHORT CIRCUIT IN ABS MTR RELAY CIRCUIT CIRCUIT DESCRIPTION The ABS MTR relay supplies power to the ABS pump motor. While the ABS is activated, the ECU turns the motor relay ON and operates the ABS pump motor.
Page 313 05 2 7 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) WIRING DIAGRAM Skid Control ECU Assy ABS MTR R/B No. 2 Relay R/B No. 2 ABS Actuator From Battery BR W BR W F4868 INSPECTION PROCEDURE HINT: Start the inspection from step if using the hand held tester.
Page 314 05 2 8 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) Go to step 3 Go to step 4 INSPECT RELAY (Marking: ABS MTR) Measure the resistance according to the tale below. ABS MTR Relay Standard: Tester Connection Specified Condition or higher Below (when battery voltage is applied to terminals and 2)
Page 315 05 2 9 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (ABS MTR RELAY SKID CONTROL ECU ASSY) Remove the ABS MTR relay. Wire Harness Side Disconnect the S 4 ECU connector. Disconnect the A 3 actuator connector. R/B No.
Page 316 05 220 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2V 0 C0278/ OPEN CIRCUIT IN ABS SOLENOID RELAY CIRCUIT C0279/ 2 SHORT CIRCUIT IN ABS SOLENOID RELAY CIRCUIT CIRCUIT DESCRIPTION This relay supplies power to each ABS solenoid. After the ignition switch is turned ON, if the initial check is OK, the relay will turn ON.
Page 317 05 22 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) WIRING DIAGRAM Skid Control ECU Assy R/B No. 2 ABS SOL ABS SOL MAIN Relay ABS Actuator SFLH LG B LG B SFLH SFLR SFLR SFRH SFRH SFRR SFRR SRLH SRLH SRLR R/B No.
Page 318 05 222 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK RELAY (Marking: ABS SOL MAIN) (VOLTAGE) Remove the relay from the R/B No. 2. R/B No. 2 Measure the voltage according to the table below. SOL MAIN Standard: Relay Tester Connection Specified Condition...
Page 319 05 223 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (ABS SOL MAIN RELAY SKID CONTROL ECU ASSY) Remove the relay from the R/B No. 2. Wire Harness Side Disconnect the A 3 actuator connector. Disconnect the S ECU connector.
Page 320: Replace Fuse
05 224 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT FUSE (ABS SOL) Remove the ABS SOL fuse from the R/B No. 2. Measure the resistance. Standard: Below REPLACE FUSE REPAIR OR REPLACE HARNESS AND CONNECTOR...
Page 321 05 225 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057EU 04 C 24 /4 LOW BATTERY POSITIVE VOLTAGE OR ABNORMALLY HIGH BATTERY POSITIVE VOLTAGE CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area Vehicle speed is 3 km/h ( .9 mph) or more and voltage of S Battery C 24 /4 ECU terminal IG remains below 9 V for more than 0...
Page 322: Inspect Battery
05 226 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE INSPECT BATTERY Check battery voltage. Standard: 20 to 32 V CHECK AND REPAIR CHARGING SYSTEM INSPECT FUSE (ECU IG) Remove the ECU IG fuse from the R/B No. . Measure the resistance.
Page 323 05 227 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ASSY BODY GROUND) Disconnect the S and S 4 ECU connectors. Wire Harness Side Measure the resistance according to the table below. Skid Control ECU Assy Standard: Tester Connection Specified Condition...
Page 324 05 228 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2W 0 C 246/46 MALFUNCTION IN MASTER CYLINDER PRESSURE SENSOR CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area , 2, 3, 4 or 5 is detected: . Condition that IG terminal voltage is 9 to 32 V and VCM terminal voltage is 4.3 to 5.8 V (out of range) for .2 sec.
Page 325 05 229 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Start the inspection from step if using the hand held tester. If not, start from step 2. READ VALUE OF HAND HELD TESTER (MASTER CYLINDER PRESSURE SEN- SOR OUTPUT VALUE) Connect the hand held tester (with 24 V VIM) to the DLC3.
Page 326 05 230 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (MASTER CYLINDER PRESSURE SENSOR SKID CON- TROL ECU ASSY) Disconnect the M sensor connector. Wire Harness Side Disconnect the S 2 ECU connector. Measure the resistance according to the table below. Master Cylinder Pressure Sensor Standard: Tester Connection...
Page 327 05 23 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK SKID CONTROL ECU ASSY (STP, PMC VOLTAGE) Remove the ECU but do not disconnect the connectors. Skid Control ECU Assy Measure the voltage between terminal STP of the S 3 ECU connector and the body ground when the brake ped- al is depressed.
Page 328 05 232 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2X 0 C 249/49 OPEN CIRCUIT IN STOP LIGHT SWITCH CIRCUIT CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area ECU terminal IG voltage is 9 to 36 V and ABS is not S Stop lamp bulb C 249/49 operating, and open circuit in stop lamp switch circuit con-...
Page 329 05 233 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) WIRING DIAGRAM Skid Control ECU Assy Diode (Stop 2) Diode (Stop ) Stop Lamp Switch Assy Rear Combination R/B No. 2 Lamp RH STOP Rear Combination STOP STOP Lamp LH W B* W B* Main W B*...
Page 330 05 234 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK STOP LAMP SWITCH ASSY (OPERATION) Check that the stop lamp illuminates when the brake pedal is depressed and turns off when the brake pedal is released. OK: Stop lamp switch function normal. Go to step 3 INSPECT SKID CONTROL ECU (STP VOLTAGE) Disconnect the S 3 ECU connector.
Page 331 05 235 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT STOP LAMP SWITCH ASSY Disconnect the stop lamp switch connector. Stop Lamp Switch Assy Measure the resistance according to the table below. Standard: Tester Condition Switch Condition Specified Condition Switch pin free Below Switch pin pushed in or higher...
Page 332 05 236 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2Y 0 C 25 /5 PUMP MOTOR IS LOCKED/OPEN CIRCUIT IN PUMP MOTOR GROUND CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S ABS actuator C 25 /5 Actuator pump motor does not operate correctly S ABS actuator circuit HINT: If the brake pedal is depressed firmly, the brake force may be lowered.
Page 333 05 237 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: Start the inspection from step if using the hand held tester. If not, start from step 2. PERFORM ACTIVE TEST BY HAND HELD TESTER (ABS PUMP MOTOR OPERATION) Connect the hand held tester (with 24 V VIM) to the DLC3.
Page 334 05 238 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (ABS MTR RELAY ABS ACTUATOR SKID CONTROL ECU ASSY) Remove the ABS MTR relay from the R/B No. 2. Wire Harness Side Disconnect the A 3 ABS actuator connector. Disconnect the S 4 ECU connector.
Page 335 05 239 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) RECONFIRM DTC Check the DTC (see page 05 9 ). HINT: After erasing the DTC and driving the vehicle at more than 7 km/h (4 mph), check for DTCs. Malfunction Code No DTC code output NO PROBLEM REPLACE SKID CONTROL ECU ASSY (See page 0...
Page 336 05 240 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L2Z 0 C 265/65 VACUUM SENSOR MALFUNCTION CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area , 2, 3, 4 or 5 is detected: . When ignition switch is ON and VCP (VCP2) terminal voltage is within range of 4.3 to 5.8 V, PIM terminal volt- age is 0.4 to 4.5 V (out of range) for .2 sec.
Page 337 05 24 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK WIRE HARNESS (VACUUM SENSOR SKID CONTROL ECU ASSY) Disconnect the S 2 ECU connector. Wire Harness Side Disconnect the V and V2 sensor connectors. Skid Control ECU Assy Measure the resistance according to the table below.
Page 338 05 242 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT VACUUM SENSOR (NO. , NO. 2) Check the vacuum sensor No. and No. 2. HINT: Before checking vacuum sensor, check for cracks or damage on the vacuum hoses. Connect 3 dry batteries of .5 V in series. Connect the VC terminal to the battery’s positive (+) terminal and the E2 terminal to the battery’s nega- tive ( ) terminal.
Page 339 05 243 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK SKID CONTROL ECU ASSY (VCP, VCP2 VOLTAGE) Remove the ECU but not disconnect the connectors. Turn the ignition switch ON. Measure the voltage according to the table below. Skid Control ECU Assy Standard: Tester Connection Specified Condition...
Page 340 05 244 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L30 0 C 266/66 EXHAUST RETARDER PREVENTION SIGNAL CIRCUIT CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S EXO circuit With vehicle speed of 6 km/h (4 mph) or more, open or C 266/66 S Skid control ECU assy short circuit of signal circuit continues for 0.3 sec.
Page 341 05 245 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK WIRE HARNESS (SKID CONTROL ECU ASSY ECM) Disconnect the S 3 ECU connector. Wire Harness Side Disconnect the E7 ECM connector. Measure the resistance according to the table below. Skid Control ECU Assy Standard: Tester Connection...
Page 342 05 246 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) RECONFIRM DTC Check the DTC (see page 05 9 ). HINT: After erasing the DTC and driving the vehicle at more than 7 km/h (4 mph), check for DTCs. Malfunction Code No DTC code output NO PROBLEM REPLACE SKID CONTROL ECU ASSY (See page 0...
Page 343 05 247 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L3 AlwaysON MALFUNCTION IN ABS ECU CIRCUIT DESCRIPTION DTC No. DTC Detection Condition Trouble Area S Battery , 2 or 3 is detected: S Fuse . ECU connectors are disconnected from ECU S ABS warning lamp circuit Always ON 2.
Page 344 05 248 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE INSPECT BATTERY Check the battery voltage. Standard: 20 to 32 V CHECK AND REPAIR CHARGING SYSTEM (See Pub. No. S YXZE05A, page 9 5) CHECK SKID CONTROL ECU ASSY (POWER SOURCE) When using the hand held tester: Connect the hand held tester (with 24 V VIM) to the DLC3.
Page 345 05 249 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ASSY BODY GROUND) Disconnect the S and S 4 ECU connectors. Wire Harness Side Measure the resistance according to the table below. Skid Control ECU Assy Standard: Tester Connection Specified Condition...
Page 346 05 250 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L32 0 ABS WARNING LAMP CIRCUIT (DOES NOT LIGHT UP) CIRCUIT DESCRIPTION If the ECU detects a malfunction, the ABS warning lamp is illuminated and ABS control is prohibited. Then the ECU records the DTC in memory. HINT: Connect terminals TC and CG of the DLC3 to cause the ABS warning lamp to flash and output the DTC.
Page 347 05 25 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK OTHER WARNING LAMP After the ignition switch is turned ON, check if the warning lamps other than the ABS warning lamp illuminate. CHECK COMBINATION METER (See Pub. No. YXZE05A, page 7 INSPECT ABS WARNING LAMP Disconnect the C5 combination meter connector.
Page 348: Combination Meter
05 252 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ASSY COMBINATION METER ASSY) Disconnect the S 3 ECU connector. Wire Harness Side Disconnect the C5 meter connector. Measure the resistance according to the table below. Skid Control ECU Assy Standard: Tester Connection...
Page 349 05 253 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L33 0 BRAKE WARNING LAMP CIRCUIT (REMAINS ON) CIRCUIT DESCRIPTION The brake warning lamp illuminates when the brake fluid is insufficient, the parking brake is applied or the vacuum created by the vacuum pump is below the standard level. WIRING DIAGRAM Diode Skid Control ECU Assy...
Page 350 05 254 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE RECONFIRM DTC Check the DTC (see page 05 9 ). HINT: After erasing the DTC and driving the vehicle at more than 30 km/h ( 9 mph), check for DTCs. No DTC Code output Malfunction Code REPAIR CIRCUIT INDICATED BY OUTPUT...
Page 351 05 255 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (PARKING BRAKE SWITCH ASSY SKID CONTROL ECU ASSY AND BODY GROUND) Disconnect the S 3 ECU connector. Wire Harness Side Skid Control ECU Assy Disconnect the P7 switch connector. Measure the resistance according to the table below.
Page 352 05 256 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECT VACUUM SENSOR (NO. , NO. 2) Check the vacuum sensor No. and No. 2. HINT: Before checking vacuum sensor, check for cracks or damage on the vacuum hoses. Connect 3 dry batteries of .5 V in series. Connect the VC terminal to the battery’s positive (+) terminal and the E2 terminal to the negative ( ) ter- minal.
Page 353: Brake Fluid Level
05 257 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK BRAKE FLUID LEVEL IN RESERVOIR Check the fluid level and add fluid, if necessary. NOTICE: Immediately wipe off any brake fluid that does not belong. CHECK AND REPAIR BRAKE FLUID LEAKAGE AND ADD FLUID INSPECT BRAKE FLUID LEVEL WARNING SWITCH ASSY Remove the reservoir tank cap and strainer.
Page 354 05 258 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ASSY COMBINATION METER ASSY) Disconnect the S 3 ECU connector. Wire Harness Side Disconnect the C5 meter connector. Measure the resistance according to the table below. Skid Control ECU Assy Standard: Tester Connection...
Page 355 05 259 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 05L34 0 BRAKE WARNING LAMP CIRCUIT (DOES NOT LIGHT UP) CIRCUIT DESCRIPTION Refer to brake warning lamp circuit (remains ON) (see page 05 253). WIRING DIAGRAM Refer to brake warning lamp circuit (remains ON) (see page 05 253). INSPECTION PROCEDURE CHECK COMBINATION METER ASSY (POWER SOURCE) Remove the combination meter but do not disconnect the...
Page 356 05 260 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) CHECK BRAKE WARNING LAMP Remove the skid control ECU but do not disconnect the connectors. Skid Control ECU Assy Using a service wire, connect terminals BRL (S 3 and GND (S 4, 5, S 4 2, 3) of the skid control ECU.
Page 357 05 26 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057F2 03 TC TERMINAL CIRCUIT CIRCUIT DESCRIPTION Connecting terminals TC and CG of the DLC3 causes the ECU to output a DTC by flashing the ABS warning lamp. WIRING DIAGRAM Skid Control ECU Assy DLC3 S 3 TC...
Page 358 05 262 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK DLC3 Turn the ignition switch ON. Measure the voltage and resistance according to the DLC3 table below. Standard: Tester Connection Specified Condition 3 (TC) D3 4 (CG) 20 to 28 V D3 4 (CG) Body ground Below...
Page 359 05 263 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) 057F TS TERMINAL CIRCUIT CIRCUIT DESCRIPTION The sensor check circuit detects abnormalities in the speed sensor signal, master cylinder pressure sensor signal and vacuum sensor signal. These abnormalities cannot be detected with the DTC check. Switching to the sensor check mode can be performed by connecting terminals TS and CG of the DLC3 and turning the ignition switch from OFF to ON.
Page 360 05 264 DIAGNOSTICS ABS & BA SYSTEM (N04C TF) INSPECTION PROCEDURE INSPECT DLC3 Turn the ignition switch to the ON position. Measure the voltage and resistance according to the DLC3 table below. Standard: Tester Connection Specified Condition 2 (TS) D3 4 (CG) 20 to 28 V D3 4 (CG) Body ground...
Page 361 05 265 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBF 02 HOW TO PROCEED WITH TROUBLESHOOTING HINT: Use this procedure to troubleshoot the easy & smooth starting system (ES starting system). The hand held tester should be used in steps 3, 6 and 8. VEHICLE BROUGHT TO WORKSHOP CUSTOMER PROBLEM ANALYSIS CHECK AND PROBLEM SYMPTOM CHECK (See page 05 267)
Page 362 05 266 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) PROBLEM SYMPTOMS TABLE (See page 05 280) If the fault is not listed on the problem symptoms table, proceed to A. If the fault is listed on the problem symptoms table, proceed to B. Go to step 9 OVERALL ANALYSIS AND TROUBLESHOOTING PRE CHECK (see page 05 268)
Page 363 05 267 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBG 02 CUSTOMER PROBLEM ANALYSIS CHECK EASY & SMOOTH STARTING SYSTEM Check Sheet Inspector’s name Production Date Customer’s Name License Plate No. Date Vehicle Odometer Reading miles Brought in Date Problem First Occurred Constant Intermittent ( times a day)
Page 364: Self Check
05 268 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYP 0 PRE CHECK SELF CHECK Turn the ignition switch ON. Check the buzzer and ES start indicator lamp on the combination meter. OK: The buzzer emits a beep and the ES start indicator lamp turns on for 3 seconds. NOTICE: If only the ES start indicator lamp turns on, perform the clutch stroke sensor adjustment or can- cel position initial setting.
Page 365 05 269 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) DIAGNOSIS SYSTEM Description The ECU controls the vehicle’s easy & smooth start- ing system (ES starting system) functions. ES start- ing system data and the Diagnostic Trouble Code (DTCs) can be read through the vehicle’s Data Link Connector 3 (DLC3) or ABS warning lamp.
Page 366 05 270 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) DTC CHECK/CLEAR (USING HAND HELD TESTER) Hand held Tester Check the DTC. Connect the hand held tester (with 24V VIM) to the DLC3. Turn the ignition switch ON. Read the DTCs on the tester’s screen. HINT: DLC3 Refer to the hand held tester operator’s manual for further de-...
Page 367 05 27 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Codes are explained in the code table on page 05 276. After completing the check, disconnect terminals TC and CG of the DLC3, and turn off the display. Clear the DTC. Using SST, connect terminals TC and CG of the DLC3.
Page 368 05 272 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Indicator Lamp Buzzer Type Warning Contents Countermeasures vehicle moves when shift S Securely engage parking lever is in neutral position brake Beeps Vehicle moving warning while ES starting system is S Increase foot pressure activated applied to brake pedal...
Page 369 05 273 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Using SST, connect terminals TC and CG of the DLC3. 09843 8040 Disengage the clutch. Move the shift lever into the 2nd 2 3 4 5 6 7 gear. 2 3 4 5 6 B50 54 Press FAST of the ES start timing switch for 3 seconds.
Page 370 05 274 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Press FAST of the ES start timing switch once. Push FAST F48 77 HINT: Buzzer Sound The buzzer sounds. 0. sec. Remove the SST from the terminals of the DLC3 and turn 0.5 sec.
Page 371: Active Test
05 275 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Measurement Item/ Item Normal Condition Diagnostic Note Display (Range) Parking brake switch/ ON: Parking brake pulled PKB SW2 ON or OFF OFF: Parking brake not pulled Neutral Switch/ ON: Shift position neutral NEUTRAL SW ON or OFF OFF: Shift position except neutral...
Page 372 05 276 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBI 02 DIAGNOSTIC TROUBLE CODE CHART HINT: If a malfunction code is displayed during the DTC check, check the circuit indicated by the DTC. For details of each code, see the page for the respective ”DTC No.” in the DTC chart. DTC No.
Page 373 05 277 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYI 0 LOCATION Clutch Pedal Stroke Sensor Vehicle Speed Sensor Neutral Position Switch Combination Meter Assy F ES Start Indicator Lamp F ABS Warning Lamp ES Start Buzzer R/B No. and J/B No.
Page 374 05 278 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBK 02 TERMINALS OF ECU CHECK SKID CONTROL ECU C52040 F49 75 Disconnect the S , S 2, S 3 and S 4 ECU connectors. Measure the voltage and resistance of each terminal of the wire harness side connectors. Symbols (Terminal No.) Wiring Color Terminal Description...
Page 375 05 279 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) Reconnect the S , S 2, S 3 and S 4 ECU connectors. Measure the voltage of each terminal of the connectors. Symbols (Terminal No.) Wiring Color Terminal Description Condition Specified Condition WL (S 3 2) ES start indicator lamp...
Page 376: Problem Symptoms Table
05 280 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBL 02 PROBLEM SYMPTOMS TABLE Symptom Suspected Area See Page . ES start switch 05 30 2. Parking brake switch 05 30 3. Skid control ECU 05 30 ES starting system does not operate 4.
Page 377: Circuit Description
05 28 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYJ 0 C 382/ 2 MALFUNCTION IN CLUTCH STROKE SEN- CIRCUIT DESCRIPTION The clutch stroke sensor detects the depressed volume of the clutch pedal and sends signals to the skid control ECU.
Page 378: Inspection Procedure
05 282 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 379 05 283 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU CLUTCH PEDAL STROKE SEN- SOR) Disconnect the S 4 ECU connector. Wire Harness Side Disconnect the C 0 sensor connector. Measure the resistance of the wire harness side connec- Skid Control ECU tors.
Page 380 05 284 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYK 0 C 383/ MALFUNCTION IN VEHICLE SPEED SEN- CIRCUIT DESCRIPTION The vehicle speed sensor detects vehicle speed and sends signals to the skid control ECU. DTC No. DTC Detection Condition Trouble Area All conditions listed below are met and no vehicle speed signal is output for 3 sec.
Page 381 05 285 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 382 05 286 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBT 02 C 384/ 3 MALFUNCTION IN NEUTRAL SWITCH CIRCUIT DESCRIPTION The neutral position switch detects neutral position and sends signals to the skid control ECU. DTC No. DTC Detection Condition Trouble Area While vehicle is accelerated to 50 km/h (3 mph) from 5 S Neutral position switch...
Page 383 05 287 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (NEUTRAL POSITION SWITCH SKID CONTROL ECU AND BODY GROUND) Disconnect the N switch connector. Wire Harness Side Disconnect the S ECU connector. Measure the resistance of the wire harness side connec- Neutral Position Switch tors.
Page 384 05 288 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYL 0 C 386/ 6 MALFUNCTION IN ES STARTING OPERA- TION/RELEASE SWITCH CIRCUIT DESCRIPTION The ES start main switch controls the ES starting system. The skid control ECU detects a malfunction in the ES start main switch, based on the conditions of the ON input terminal and the OFF input terminal, which are set from the ES start main switch.
Page 385 05 289 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 386 05 290 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK FOR DTCS Clear the DTC (see page 05 268). Drive the vehicle at the vehicle speed of 7 km/h (4 mph) or more. Check that no code is output. REPLACE SKID CONTROL ECU...
Page 387 05 29 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBV 02 C 387/ 5 MALFUNCTION IN ES STARTING RELEASE TIMING SWITCH CIRCUIT DESCRIPTION The ES start timing switch can adjust the timing of releasing the brake hydraulic pressure. When the timing switch is operated, a release timing input signal (FAST input signal or SLOW input signal) is input to the skid control ECU.
Page 388 05 292 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 389 05 293 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK FOR DTCS Clear the DTC (see page 05 268). Drive the vehicle at the vehicle speed of 7 km/h (4 mph) or more. Check that no code is output. REPLACE SKID CONTROL ECU...
Page 390 05 294 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYM 0 C 388/ 7 MALFUNCTION IN ES STARTING INI- TIALIZATION CIRCUIT DESCRIPTION The clutch stroke sensor detects the depressed volume of the clutch pedal and sends signals to the skid control ECU.
Page 391 05 295 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBM 02 C 389/ 8 MALFUNCTION IN TACHOMETER SENSOR CIRCUIT DESCRIPTION The ECM detects engine revolutions and sends signals to the skid control ECU. DTC No. DTC Detection Condition Trouble Area All conditions listed below are met and no engine S ECM revolution signal is input for 3 sec.
Page 392 05 296 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 393 05 297 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK FOR DTCS Clear the DTC (see page 05 268). Drive the vehicle at the vehicle speed of 7 km/h (4 mph) or more. Check that no code is output. REPLACE SKID CONTROL ECU...
Page 394 05 298 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBN 02 C 390/42 MALFUNCTION IN BATTERY POWER SUP- PLY VOLTAGE CIRCUIT DESCRIPTION Power is supplied to the skid control ECU via the ECU+B fuse. DTC No. DTC Detection Condition Trouble Area S ECU+B fuse Battery voltage is 9 V or more for 0 sec.
Page 395 05 299 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 396 05 300 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ECM) Disconnect the S 2 ECU connector. Wire Harness Side Disconnect the E7 ECM connector. Measure the resistance of the wire harness side connec- Skid Control ECU tors.
Page 397 05 30 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYN 0 ES STARTING SYSTEM DOES NOT OPERATE CIRCUIT DESCRIPTION The skid control ECU controls the ES starting system. When the ABS & BA system has a malfunction, the ES starting system does not operate.
Page 398 05 302 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) WIRING DIAGRAM Skid Control ES Start Switch (ES Start Main Switch) S/OFF From S/MAIN Ignition Switch PKB2 Parking Brake Switch J 3* Diode (Parking Brake) R/B No. J/B No. GAUGE ECU IG * : LHD From...
Page 399 05 303 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE CHECK FOR DTCS Check for DTCs. Result: Result Proceed to No DTC is output ABS & BA system DTC is output ES starting system DTC is output Go to ABS & BA SYSTEM (See page 05 Go to DTC CHART (See page 05 276) INSPECT ES START SWITCH (ES START MAIN SWITCH) Remove the ES start switch.
Page 400 05 304 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (ES START SWITCH SKID CONTROL ECU AND BAT- TERY) Disconnect the S 2 ECU connector. Wire Harness Side Disconnect the E 9 switch connector. Measure the voltage and resistance of the wire harness side connectors.
Page 401 05 305 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU BATTERY AND BODY GROUND) Disconnect the S 3 ECU connector. Wire Harness Side Measure the voltage and resistance of the wire harness S 3 Skid Control ECU side connector.
Page 402 05 306 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05BBP 02 ES BUZZER CIRCUIT CIRCUIT DESCRIPTION The skid control ECU operates the ES start buzzer. WIRING DIAGRAM Skid Control ES Start Buzzer R/B No. ECU+B J/B No. From Battery F4865 INSPECTION PROCEDURE HINT:...
Page 403 05 307 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK ES START BUZZER (BATTERY VOLTAGE) Disconnect the E20 buzzer connector. Measure the vlotage of the buzzer. ES Start Buzzer Standard: Tester Connection Specified Condition Body ground 20 to 28 V REPAIR OR REPLACE HARNESS AND CON- F48654 NECTOR...
Page 404 05 308 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) CHECK WIRE HARNESS (SKID CONTROL ECU ES START BUZZER AND BODY GROUND) Disconnect the S 3 and S 4 ECU connectors. Wire Harness Side Disconnect the E20 buzzer connector. Measure the resistance of the wire harness side connec- tors.
Page 405 05 309 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) 05KYO 0 PARKING BRAKE SWITCH CIRCUIT CIRCUIT DESCRIPTION The parking brake switch detects the parking brake position and sends signals to the skid control ECU. WIRING DIAGRAM Skid Control PKB2 Parking Brake Switch From...
Page 406 05 3 0 DIAGNOSTICS EASY & SMOOTH STARTING SYSTEM (N04C TF) INSPECTION PROCEDURE HINT: As the ES starting system is controlled by the skid control ECU, a malfunction in the ABS & BA system may affect ES starting system operation. Before proceeding to the flowchart below, check for ABS & BA system’s DTCs.
Page 407 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) ....10 1 ON VEHICLE INSPECTION ....10 1 INSPECTION .
Page 408: Ecd System (N04C Tf)
10 1 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) ECD SYSTEM (N04C TF) 100P6 01 ON VEHICLE INSPECTION INSPECT MAF METER Connect the hand held tester (with 24V VIM) to the DLC3. NOTICE: Be sure to 24 V VIM, because the hand held tester will be damaged if you do not use the 24 V VIM.
Page 409 10 2 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) Inspect the air assist system. Start the engine and check that the MIL does not illuminate. Allow the engine to warm up to normal operating temperature. Turn the A/C compressor ON to OFF, and check the idle speed. Idle speed (Transmission in neutral): 600 to 700 rpm NOTICE: Perform the inspection with all electrical loads shut OFF.
Page 410: Inspection
10 3 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) 100P7 01 INSPECTION INSPECT MAF METER Check the output voltage. Apply battery voltage across terminals 1 (+B) and 2 (E2G). Using a voltmeter, connect the positive (+) tester probe to terminal VG, and negative ( ) tester probe to terminal E2G.
Page 411 10 4 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) INSPECT ECT SENSOR Measure the resistance between each terminals. Standard: Tester Connection Condition Specified Condition Approx. 20_C (68_F) 2.32 to 2.59 k Approx. 80_C (176_F) 0.31 to 0.326 k Body ground Approx.
Page 412 10 5 ENGINE CONTROL SYSTEM ECD SYSTEM (N04C TF) INSPECT CRANKSHAFT POSITION SENSOR Measure the resistance between the terminals. Standard: Temperature Specified Condition Cold 1,630 to 2,740 2,065 to 3,225 If the result is not as specified, replace the sensor. NOTICE: ”Cold”...
Page 413: Venturi Assy (N04C Tf)
10 6 ENGINE CONTROL SYSTEM VENTURI ASSY (N04C TF) VENTURI ASSY (N04C TF) 100P8 01 COMPONENTS Venturi Assy Clamp 5.0 (51, 44 in. lbf) Intake Air Connector Pipe 28.5 (291, 21) Intake Air Connector Pipe Clamp Air Hose No. 4 Clamp 5.0 (51, 44 in.
Page 414: Replacement
10 7 ENGINE CONTROL SYSTEM VENTURI ASSY (N04C TF) 100P9 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE INTAKE AIR CONNECTOR PIPE Loosen the hose clamp and disconnect the pipe. REMOVE VENTURI ASSY Disconnect the connectors. Remove the 2 bolts, 2 nuts and venturi. INSTALL VENTURI ASSY 70 mm (2.75 in.) Remove any oil packing material from the contact sur-...
Page 415 10 8 ENGINE CONTROL SYSTEM VENTURI ASSY (N04C TF) CONNECT BATTERY NEGATIVE TERMINAL...
Page 416: Accelerator Link Assy (N04C Tf)
10 9 ENGINE CONTROL SYSTEM ACCELERATOR LINK ASSY (N04C TF) ACCELERATOR LINK ASSY (N04C TF) 100PA 01 REPLACEMENT REMOVE ACCELERATOR LINK ASSY Disconnect the connector. Remove the 2 nuts and accelerator link. NOTICE: Do not drop the accelerator link. Do not disassemble the accelerator link. A92236 INSTALL ACCELERATOR LINK ASSY Install the accelerator link with the 2 nuts.
Page 417: Ecm (N04C Tf)
10 10 ENGINE CONTROL SYSTEM ECM (N04C TF) ECM (N04C TF) 100PB 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE INSTRUMENT COVER LOWER CENTER (See pub. No. S1 YXZE05A, on pages 71 13 and 71 17) REMOVE ECM Disconnect the connectors. Remove the 4 screws and ECM.
Page 418 FUEL FUEL SYSTEM (N04C TF) ....11 1 PRECAUTION ......11 1 ON VEHICLE INSPECTION .
Page 419: Fuel System (N04C Tf)
11 1 FUEL FUEL SYSTEM (N04C TF) FUEL SYSTEM (N04C TF) 1114D 01 PRECAUTION CAUTION: Before working on the fuel system, disconnect the negative ( ) terminal cable from the battery. Do not smoke or be near an open flame when working on the fuel system. Keep fuel away from rubber or leather parts.
Page 420: On Vehicle Inspection
11 2 FUEL FUEL SYSTEM (N04C TF) 1114E 01 ON VEHICLE INSPECTION CHECK FUEL PRESSURE Hand held Tester Connect the hand held tester (with 24 V VIM) to the DLC3. NOTICE: Be sure to use the 24 V VIM, because the hand held tester will be damaged if you do not use the 24 V VIM.
Page 421: Inspection
11 3 FUEL FUEL SYSTEM (N04C TF) 1114F 01 INSPECTION INSPECT SUCTION CONTROL VALVE Suction Control Valve Measure the resistance between the terminal 1 and 2. Standard: 7.6 to 8.2 at 20_C (68_F) If the result is not as specified, replace the supply pump assy. A96297 INSPECT FUEL TEMPERATURE SENSOR Measure the resistance between the terminal 1 and 2.
Page 422 11 4 FUEL FUEL SYSTEM (N04C TF) INSPECT LEVEL WARNING SWITCH Measure the resistance between the terminal 1and 2. Standard: Condition Specified Condition Upper end of float Below 1 Lower end of float 10 k or higher If the result is not as specified, replace the level warning switch. A96302...
Page 423: Fuel Filter Element (N04C Tf)
11 5 FUEL FUEL FILTER ELEMENT (N04C TF) FUEL FILTER ELEMENT (N04C TF) 1114G 01 REPLACEMENT HINT: If only installing or removing the fuel element, steps 2 and 3 are not necessary. REMOVE FUEL FILTER ELEMENT SUB ASSY Disconnect the level warning switch connector. Level Warning Switch...
Page 424 11 6 FUEL FUEL FILTER ELEMENT (N04C TF) When fuel stops draining from the drain plug, tighten the drain plug and air bleed plug. A97026 Disengage the claw. Then, remove the cover by turning it counterclockwise approximately 120_. Remove the fuel filter element. OPEN CLOSE Cover...
Page 425 11 7 FUEL FUEL FILTER ELEMENT (N04C TF) Install the fuel filter cover by turning it clockwise until the claw is engaged. OPEN CLOSE Claw Cover Turn A96304 Connect the level warning switch connector. Level Warning Switch Connector A96789 BLEED AIR FROM FUEL SYSTEM Loosen the fuel filter’s air bleed plug.
Page 426 11 8 FUEL FUEL FILTER ELEMENT (N04C TF) Tighten the air bleed plug. A97027 CHECK FOR FUEL LEAKS (See page 11 2)
Page 427: Supply Pump Assy (N04C Tf)
11 9 FUEL SUPPLY PUMP ASSY (N04C TF) SUPPLY PUMP ASSY (N04C TF) 1114H 01 COMPONENTS Fuel Filter to Injection Pump Fuel Pipe 44 (449, 32) Injection Pipe Clamp 44 (449, 32) Fuel Pipe Sub assy Fuel Pipe No. 4 24.5 (250, 18) Gasket 28.5 (291, 21)
Page 428: Replacement
11 10 FUEL SUPPLY PUMP ASSY (N04C TF) 1114I 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL SET NO. 1 CYLINDER TO TDC/COMPRESSION Matchmark Turn the crankshaft pulley clockwise, and align the match- marks as shown in the illustration. Check that the matchmarks of the flywheel housing and flywheel are aligned as shown in the illustration.
Page 429 11 11 FUEL SUPPLY PUMP ASSY (N04C TF) REMOVE CRANKSHAFT POSITION SENSOR Remove the bolt and sensor. Remove the O ring from the sensor. REMOVE SUPPLY PUMP ASSY Disconnect the fuel temperature sensor connector. Remove the bolt and holder clip. Remove the 4 bolts and supply pump.
Page 430 11 12 FUEL SUPPLY PUMP ASSY (N04C TF) Align the matchmarks of the timer cover and front end plate, then install the supply pump. Matchmarks A96319 When the crankshaft position sensor’s installation hole Crank Angle Sensor Plate can be seen directly: Check that the knock pin of the injection pump drive gear is at the center of the hole.
Page 431 11 13 FUEL SUPPLY PUMP ASSY (N04C TF) Install the 4 bolts. Torque: 28.5 N m (291 kgf cm, 21 ft lbf) Install the holder clip with the bolt. Torque: 28.5 N m (291 kgf cm, 21 ft lbf) Connect the fuel temperature sensor connector. A96853 INSTALL CRANKSHAFT POSITION SENSOR Apply a light amount of engine oil to a new O ring.
Page 432 11 14 FUEL SUPPLY PUMP ASSY (N04C TF) Install the engine side cover with the bolt. Torque: 11.5 N m (117 kgf cm, 8.0 ft lbf) ADD FUEL BLEED AIR FROM FUEL SYSTEM (See page 11 5) CONNECT BATTERY NEGATIVE TERMINAL CHECK FOR EXHAUST GAS LEAKS (See page 15 2) CHECK FOR FUEL LEAKS (See page 11 2)
Page 433: Common Rail Assy (N04C Tf)
11 15 FUEL COMMON RAIL ASSY (N04C TF) COMMON RAIL ASSY (N04C TF) 1114J 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL REMOVE VENTILATION PIPE NO. 2 (See page 11 20) DISCONNECT INTAKE AIR CONNECTOR PIPE (See page 11 10) REMOVE VENTILATION PIPE SUB ASSY (See page 11 20) REMOVE BRACKET Remove the 4 bolts and bracket.
Page 434 11 16 FUEL COMMON RAIL ASSY (N04C TF) REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE Remove the nut and clamp. Using SST, remove the injection pump fuel pipe. 09023 12900 A96328 REMOVE COMMON RAIL ASSY Disconnect the fuel pressure sensor connector. Remove the 2 bolts, bracket and common rail.
Page 435 11 17 FUEL COMMON RAIL ASSY (N04C TF) Use the 2 nuts to install the 2 clamps around the 4 pipes. Tighten each nut until each clamp’s edges make contact with its respective engine side clamp’s edges. A96356 INSTALL OIL SEPARATOR ASSY (See page 11 10) INSTALL BRACKET Install the bracket with the 4 bolts.
Page 436 11 18 FUEL INJECTOR ASSY (N04C TF) INJECTOR ASSY (N04C TF) 1114K 01 COMPONENTS Ventilation Pipe No. 2 28.5 (290, 21) Clamp Clamp 28.5 (290, 21) Breather Pipe 5.0 (51, 44 in. lbf) Hose Clamp Intake Air Connector Pipe Hose Clamp 5.0 (51, 44 in.
Page 437: Injector Assy (N04C
11 19 FUEL INJECTOR ASSY (N04C TF) Oil Filler Cap Sub assy 28.5 (290, 21) Cylinder Head Cover No. 2 Injector Connector 28.5 (290, 21) Cushion Stay Cylinder Head Cover Sub assy z Gasket 13 (133, 10) z Gasket Nozzle Leakage Pipe No. 1 25 (255, 18) Gasket Nozzle Holder...
Page 438: Replacement
11 20 FUEL INJECTOR ASSY (N04C TF) 1114L 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL CHECK INJECTOR COMPENSATION CODE (see page 05 13) REMOVE ENGINE SIDE COVER SUB ASSY LH Remove the bolt and engine side cover. REMOVE VENTILATION PIPE NO. 2 Loosen the 2 clamps and disconnect the 2 hoses from the ventilation pipe.
Page 439 11 21 FUEL INJECTOR ASSY (N04C TF) Remove the 5 union bolts and nozzle leakage pipe No. 1. Remove the 5 gaskets from the nozzle leakage pipe No. NOTICE: When removing the nozzle leakage pipe, place a shop rag under the pipe to protect the cylinder head from the fuel re- maining inside the pipe.
Page 440 11 22 FUEL INJECTOR ASSY (N04C TF) Install the 4 nozzle holder seals and 4 gaskets. A96874 Install the 4 nozzle holder clamps with the 4 bolts. Torque: 25 N m (255 kgf cm, 18 ft lbf) A96359 Install 5 new gaskets and the nozzle leakage pipe with the 5 bolts.
Page 441: Install Bracket
11 23 FUEL INJECTOR ASSY (N04C TF) INSTALL BRACKET Install the bracket with the 4 bolts. Torque: 28.5 N m (290 kgf cm, 21 ft lbf) INSTALL BREATHER PIPE Install the breather pipe with the 2 bolts. Torque: 28.5 N m (290 kgf cm, 21 ft lbf) Connect the 2 hoses to the oil separator with the 2 clamps.
Page 442: Fuel Tank Assy (N04C Tf)
11 24 FUEL FUEL TANK ASSY (N04C TF) FUEL TANK ASSY (N04C TF) 1114M 01 COMPONENTS 80 Liter Tank Fuel Vapor Separate Valve Sub assy 4.9 (50, 43 in. lbf) Fuel Main No. 2 Tube Fuel Hose 1.5 (15, 13 in. lbf) Fuel Tank Vent Tube Sub assy 1.5 (15, 13 in.
Page 443 11 25 FUEL FUEL TANK ASSY (N04C TF) 100 Liter Tank Fuel Vapor Separate Valve Sub assy 4.9 (50, 43 in. lbf) Fuel Main No. 2 Tube Fuel Hose 1.5 (15, 13 in. lbf) Fuel Tank Vent Tube Sub assy 1.5 (15, 13 in.
Page 444: Replacement
11 26 FUEL FUEL TANK ASSY (N04C TF) 1114N 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL REMOVE SIDE BUMPER BAR Remove the 2 bolts and bumper bar. DISCONNECT FUEL MAIN NO.2 TUBE FUEL HOSE DISCONNECT RETURN TUBE, NO.2 FUEL HOSE REMOVE FUEL VAPOR SEPARATE VALVE Disconnect the 2 hoses from the fuel tank.
Page 445: Emission Control System
EMISSION CONTROL EMISSION CONTROL SYSTEM (N04C TF) ......12 1 ON VEHICLE INSPECTION .
Page 446 12 1 EMISSION CONTROL EMISSION CONTROL SYSTEM (N04C TF) EMISSION CONTROL SYSTEM (N04C TF) 120ES 01 ON VEHICLE INSPECTION VISUALLY CHECK HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. HINT: Be sure to check the areas indicated by the arrow marks. If the hoses, gaskets or connections are damaged, repair or re- place parts as necessary.
Page 447 12 2 EMISSION CONTROL EMISSION CONTROL SYSTEM (N04C TF) 120ET 01 INSPECTION INSPECT OIL SEPARATOR ASSY Check oil separator operation. Port A Check oil separator operations. Condition Specified Condition Port B Close ports B and C, then apply vacuum to port A (1.96 kPa No leaks (14.7 mmHg, 0.58 in.Hg)) Close port C,...
Page 448 INTAKE TURBOCHARGER SYSTEM (N04C TF) ..13 1 PRECAUTION ......13 1 ON VEHICLE INSPECTION .
Page 449: Turbocharger System (N04C Tf)
13 1 INTAKE TURBOCHARGER SYSTEM (N04C TF) TURBOCHARGER SYSTEM (N04C TF) 13094 01 PRECAUTION MAINTENANCE PRECAUTION Do not stop the engine immediately after pulling a trailer or after high speed or uphill driving. ldle the engine for 20 to 120 seconds depending on how hard vehicle has been driven.
Page 450 13 2 INTAKE TURBOCHARGER SYSTEM (N04C TF) If the engine is running without the air cleaner, case cover and hose, entry of foreign particles will damage the wheels, which run at extremely high speed. A92232...
Page 451: On Vehicle Inspection
13 3 INTAKE TURBOCHARGER SYSTEM (N04C TF) 13095 01 ON VEHICLE INSPECTION CHECK INTAKE AIR SYSTEM Check for leakage or clogging between the air cleaner housing and turbocharger inlet, and between the turbo- charger outlet and cylinder head. If the air cleaner is clogged, clean or replace the ele- ment.
Page 452 13 4 INTAKE TURBOCHARGER SYSTEM (N04C TF) CHECK MIL Turn the ignition switch ON, and check that the MIL turns Start the engine, and check that the MIL turns OFF. Connect SST (turbocharger pressure gauge) to the turbo pressure sensor. Idle the engine.
Page 453: Turbocharger Sub Assy
13 5 INTAKE TURBOCHARGER SUB ASSY (N04C TF) TURBOCHARGER SUB ASSY (N04C TF) 13096 01 COMPONENTS Engine Side Cover RH Radiator 24.5 (250, 18) Turbo Water Pipe No. 1 11.5 (117, 8) Reservoir Tank z Gasket Front Mudguard RH Bracket 28.5 (291, 21) z O Ring Turbo Insulator No.
Page 454: Replacement
13 6 INTAKE TURBOCHARGER SUB ASSY (N04C TF) 13097 01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16 3) REMOVE ENGINE SIDE COVER RH REMOVE FRONT MUDGUARD RH REMOVE AIR HOSE ASSY Loosen the hose clamp. Remove the 2 bolts and pipe. REMOVE VENTILATION PIPE NO.
Page 455 13 7 INTAKE TURBOCHARGER SUB ASSY (N04C TF) INSTALL TURBO WATER PIPE NO. 2 Install 4 new gaskets and the pipe with the bolt and 2 union bolts. Torque: 24.5 N m (250 kgf cm, 18 ft lbf) for union bolt 28.5 N m (291 kgf cm, 21 ft lbf) for bolt INSTALL TURBO OIL OUTLET PIPE Install 2 new gaskets and the pipe with the 4 bolts.
Page 456: Charge Air Cooler Assy
13 8 INTAKE CHARGE AIR COOLER ASSY (N04C TF) CHARGE AIR COOLER ASSY (N04C TF) 13098 01 COMPONENTS Air Hose No. 2 Hose Clamp 18 (184, 13) Charge Air Clamp Cooler Assy 5.0 (51, 44 in. lbf) 7.5 (77, 66 in. lbf) Intake Pipe Stay 18 (184, 13) Intake Air Connector Pipe...
Page 457: Replacement
13 9 INTAKE CHARGE AIR COOLER ASSY (N04C TF) 13099 01 REPLACEMENT REMOVE INTAKE AIR CONNECTOR PIPE Disconnect the IAT sensor and vacuum sensor connectors. Remove the 2 bolts. Loosen the 2 clamps and disconnect the pipe. DISCONNECT AIR HOSE NO. 2 Loosen the 2 clamps and disconnect the hose.
Page 458: Engine Mechanical
ENGINE MECHANICAL ENGINE (N04C TF) ..... . 14 1 INSPECTION ......14 1 DRIVE BELT (N04C TF) .
Page 459: Inspection
14 1 ENGINE MECHANICAL ENGINE (N04C TF) ENGINE (N04C TF) 141UI 01 INSPECTION INSPECT COOLANT (See page 16 3) INSPECT ENGINE OIL (See page 17 3) INSPECT BATTERY INSPECT AIR CLEANER FILTER ELEMENT SUB ASSY INSPECT DRIVE BELT Measuring Points for Belt Deflection Check the belt deflection by pressing on the belt at the points indicated by the arrow marks in the illustration with Idler Pulley...
Page 460 14 2 ENGINE MECHANICAL ENGINE (N04C TF) After installing a new belt, run the engine for approximate- ly 5 minutes and then recheck the tension. CHECK TAPPET FOR ABNORMAL NOISE INSPECT IDLE SPEED AND MAXIMUM SPEED HINT: The check should be done under the following conditions: Engine at normal operating temperature Air cleaner installed All pipes and hoses of air induction system connected...
Page 461 14 3 ENGINE MECHANICAL ENGINE (N04C TF) Check the compression pressure. Install the gasket and SST (attachment) to the injec- tion nozzle hole with the holder clamp and bolt. S0955 21060, S0955 21090 Torque: 25 N·m (255 kgf·cm, 18 ft·lbf) Connect a SST (compression gauge) to the SST (attachment).
Page 462: Drive Belt (N04C Tf)
14 4 ENGINE MECHANICAL DRIVE BELT (N04C TF) DRIVE BELT (N04C TF) 141UA 01 REPLACEMENT REMOVE FAN AND GENERATOR V BELT Loosen bolts A and B. Loosen the adjusting bolt C and remove the belt. A97034 REMOVE A/C COMPRESSOR V BELT Loosen bolt A.
Page 463: Valve Clearance (N04C Tf)
14 5 ENGINE MECHANICAL VALVE CLEARANCE (N04C TF) VALVE CLEARANCE (N04C TF) 141UB 01 ADJUSTMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL DRAIN ENGINE COOLANT (See page 16 3) REMOVE VENTILATION PIPE NO. 2 (See page 14 14) REMOVE INTAKE AIR CONNECTOR PIPE (See page 14 14) REMOVE OIL FILLER CAP SUB ASSY REMOVE CYLINDER HEAD COVER NO.
Page 464 14 6 ENGINE MECHANICAL VALVE CLEARANCE (N04C TF) Crankshaft pulley side: No. 1 and No. 4 Cylinder Turn the crankshaft clockwise to align the matchmark on the crankshaft pulley with the pointer on the Timing chain or belt cover. HINT: If not, turn the crankshaft 1 revolution (360_) to align the match- mark.
Page 465: Adjust Valve Clearance
14 7 ENGINE MECHANICAL VALVE CLEARANCE (N04C TF) ADJUST VALVE CLEARANCE No. 1 and No. 4 Cylinder Flywheel side: Turn the crankshaft clockwise to align the matchmark on the flywheel the line between the 2 numbers with the edge on the flywheel housing. Matchmark No.
Page 466 14 8 ENGINE MECHANICAL VALVE CLEARANCE (N04C TF) Loosen the lock nut on the valve rocker arm and loosen the adjusting screw. Insert a 0.30 mm (0.012 in.) feeler gauge for the intake or a 0.45 mm (0.018 in.) feeler gauge for the exhaust be- tween the adjusting screw on the valve rocker arm and the valve bridge.
Page 467: Partial Engine Assy (N04C Tf)
14 9 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) PARTIAL ENGINE ASSY (N04C TF) 141UH 01 COMPONENTS Radiator Reserve Tank Assy Front Side Cover RH Rear Arch Cover 11.5 (117, 9) Front Mudguard RH Vacuum Reservoir 11.5 (117, 8) 18 (184, 13) 11 (112, 8) Pulley Bracket...
Page 468 14 10 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) Floor Shift Cable Transmission Control Shift Floor Shift Cable Transmission Control Select 17.5 (178, 13) Water Hose Generator Assy Water Hose Fuel Return Hose Fuel Hose Clutch Release Cylinder Assy 11.8 (120, 9) 98 (1,000, 72) Starter Assy Water Hose...
Page 469 14 11 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) Oil Level Gauge z Nozzle Holder Seal Injection Pipe 44 (449, 32) Oil Level Gauge Guide Breather Pipe Fuel Pipe Clamp 28.5 (291, 21) Water By pass Pipe Bracket Venturi Assy 28.5 (291, 21) 24.5 (250, 18) z Gasket...
Page 470 14 12 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 24.5 (250, 18) z Gasket Turbo Water Pipe No. 1 28.5 (291, 21) z O Ring 28.5 (291, 21) z Gasket Turbo 36 (367, 27) Insulator No. 1 Turbocharger Sub assy Turbine Outlet Elbow 69 (704, 51) z Gasket...
Page 471 14 13 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 28.5 (291, 21) 28.5 (291, 21) Water Pump Assy Vacuum Pipe 24.5 (250, 18) Vacuum Pump Assy z O Ring z Gasket 28.5 (291, 21) 12.7 (130, 9) 55 (561, 41) Nozzle Leakage Fuel Pipe Support Injection Pump...
Page 472 14 14 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 141UC 01 REPLACEMENT BLOCK WHEEL OF VEHICLE A64407 DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN ENGINE OIL (See page 17 3) DRAIN ENGINE COOLANT (See page 16 3) DRAIN FUEL DRAIN POWER STEERING FLUID REMOVE FRONT MUDGUARD RH REMOVE FRONT MUDGUARD LH REMOVE RADIATOR RESERVE TANK ASSY...
Page 473 14 15 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) REMOVE RADIATOR ASSY (See page 16 10) REMOVE VENTILATION PIPE NO. 2 Disconnect the breather hose. Remove the 3 bolts and ventilation pipe. SEPARATE A/C COMPRESSOR ASSY Disconnect the compressor connector. Remove the 4 bolts and compressor.
Page 474 14 16 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) REMOVE ENGINE ASSY Front Install the engine hanger with the 2 bolts as shown in the illustration. Torque: 108 N m (1,100 kgf cm, 80 ft lbf) A97340 Using a chain block and an engine sling device, hang the engine together with the transmission.
Page 475 14 17 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) REMOVE VANE PUMP ASSY Remove the 2 bolts and pump. A97344 REMOVE TURBO INSULATOR NO. 1 (See page 13 6) REMOVE TURBO OIL INLET PIPE SUB ASSY (See page 13 6) REMOVE TURBO OIL OUTLET PIPE (See page 13 6) REMOVE TURBO WATER PIPE NO.
Page 476 14 18 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) REMOVE FUEL PIPE NO. 4 Remove the 2 union bolts, 4 gaskets and pipe. REMOVE FUEL FILTER TO INJECTION PUMP FUEL PIPE Remove the nut and clamp. Using SST, remove the fuel pipe. 09023 12900 REMOVE COMMON RAIL ASSY Remove the 2 bolts, bracket and common rail.
Page 477 14 19 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) INSTALL HEATER PIPE 29.6 mm (1.16 in.) Remove any oil packing material from the contact sur- face. Apply a continuous bead of seal packing (diameter: 1.5 to 2.5 mm (0.06 to 0.10 in.)) as shown in the illustration. Seal packing: Part No.
Page 478 14 20 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 102. INSTALL EXHAUST MANIFOLD Install a new gasket to the cylinder head as shown in the CORRECT INCORRECT illustration. A97346 Install the manifold with the 8 bolts. Uniformly, tighten the 8 nuts in the order shown in the illustration. Torque: 59 N m (602 kgf cm, 44 ft lbf) Retighten the bolts in the same order as step (b).
Page 479 14 21 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 111. INSTALL RADIATOR PIPE Install a new gasket and the pipe with the 2 bolts. Torque: 18 N m (184 kgf cm, 13 ft lbf) 112. INSTALL INTAKE PIPE Install a new gasket and the pipe with the 2 nuts. Torque: 18 N m (184 kgf cm, 13 ft lbf) 113.
Page 480 14 22 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) Using a chain block and an engine sling device, hang the engine assy together. Install the transmission (see page 41 3). Install the engine to the engine mounting brackets with the 2 nuts. Torque: 98 N m (1,000 kgf cm, 72 ft lbf) A97341 120.
Page 481 14 23 ENGINE MECHANICAL PARTIAL ENGINE ASSY (N04C TF) 137. INSTALL FAN Install the fan pulley and fan temporarily with the 4 nuts. Install the fan and generator V belt. Holding the V belt, tighten the 4 nuts completely to install the fan pulley and fan properly. Torque: 11 N m (112 kgf cm, 8 ft lbf) 138.
Page 482: Camshaft (N04C Tf)
14 24 ENGINE MECHANICAL CAMSHAFT (N04C TF) CAMSHAFT (N04C TF) 141UD 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL DRAIN ENGINE OIL (See page 17 3) DRAIN ENGINE COOLANT (See page 16 3) DRAIN POWER STEERING FLUID REMOVE FRONT MUDGUARD RH REMOVE FRONT MUDGUARD LH REMOVE RADIATOR RESERVE TANK ASSY REMOVE ENGINE SIDE COVER RH...
Page 483 14 25 ENGINE MECHANICAL CAMSHAFT (N04C TF) SET NO. 1 CYLINDER TO TDC/COMPRESSION No. 1 and No. 4 Cylinder Turn the crankshaft clockwise to align the matchmark (the line between the 1 and 4) on the flywheel with the edge on the flywheel housing.
Page 484: Install Camshaft
14 26 ENGINE MECHANICAL CAMSHAFT (N04C TF) REMOVE OIL SEAL (See page 14 34) REMOVE CAMSHAFT Remove the 2 bolts and camshaft. INSTALL CAMSHAFT Matchmark Apply engine oil to the camshaft journal and bearing. Match the matchmarks of the camshaft timing gear and oil pump gear and install the camshaft.
Page 485 14 27 ENGINE MECHANICAL CAMSHAFT (N04C TF) INSTALL OIL PAN SUB ASSY Remove any oil packing material from the contact sur- face. Apply a continuous bead of seal packing (diameter: 3 to Seal 4 mm (0.11 to 0.15 in.)) as shown in the illustration. Packing Seal packing: Part No.
Page 486 14 28 ENGINE MECHANICAL CAMSHAFT (N04C TF) INSTALL OIL FILLER CAP SUB ASSY INSTALL INTAKE AIR CONNECTOR PIPE (See page 14 14) INSTALL GENERATOR ASSY (See page 19 7) INSTALL EXHAUST PIPE ASSY FRONT (See page 15 2) INSTALL A/C COMPRESSOR ASSY (See page 14 14) INSTALL VENTILATION PIPE NO.
Page 487: Cylinder Head Gasket (N04C Tf)
14 29 ENGINE MECHANICAL CYLINDER HEAD GASKET (N04C TF) CYLINDER HEAD GASKET (N04C TF) 141UE 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN FUEL DRAIN ENGINE OIL (See page 17 3) DRAIN ENGINE COOLANT (See page 16 3) DRAIN POWER STEERING FLUID REMOVE FRONT MUDGUARD RH REMOVE FRONT MUDGUARD LH REMOVE RADIATOR RESERVE TANK ASSY...
Page 488 14 30 ENGINE MECHANICAL CYLINDER HEAD GASKET (N04C TF) Loosen the rocker arm support bolts in the order as shown in the illustration. A97332 REMOVE VALVE PUSH ROD NOTICE: Organize the parts so that each parts location can be remembered for reassembly. REMOVE VALVE BRIDGE NOTICE: Organize the parts so that each parts location can be remembered for reassembly.
Page 489 14 31 ENGINE MECHANICAL CYLINDER HEAD GASKET (N04C TF) INSTALL CYLINDER HEAD SUB ASSY HINT: Since the cylinder head bolts are unique to this engine, do not substitute them with ordinary bolts for them. Uniformly install and tighten the 18 cylinder head bolts in the order shown in the illustration.
Page 490 14 32 ENGINE MECHANICAL CYLINDER HEAD GASKET (N04C TF) INSTALL VALVE ROCKER SHAFT SUB ASSY NO.1 Lubricate the rocker arm shaft and bush. NOTICE: Confirm that oil hole of the rocker arm No. 1 support aligns with the shaft oil hole. Improper installation will result in burning of the entire valve assy.
Page 491 14 33 ENGINE MECHANICAL CYLINDER HEAD GASKET (N04C TF) INSTALL WATER BY PASS PIPE (See page 14 14) INSTALL BRACKET (See page 14 14) INSTALL BREATHER PIPE INSTALL CYLINDER HEAD COVER SUB ASSY (See page 11 20) INSTALL CYLINDER HEAD COVER NO. 2 (See page 11 20) INSTALL OIL FILLER CAP SUB ASSY INSTALL INTAKE AIR CONNECTOR PIPE (See page 14 14) INSTALL GENERATOR ASSY (See page 19 7)
Page 492: Oil Pump Seal (N04C Tf)
14 34 ENGINE MECHANICAL OIL PUMP SEAL (N04C TF) OIL PUMP SEAL (N04C TF) 141UF 01 REPLACEMENT DRAIN ENGINE OIL (See page 17 3) DRAIN ENGINE COOLANT (See page 16 3) REMOVE CHARGE AIR COOLER ASSY (See page 13 9) REMOVE RADIATOR ASSY (See page 16 10) REMOVE CRANKSHAFT PULLEY Using a 46 mm socket wrench, remove the nut, spacer...
Page 493 14 35 ENGINE MECHANICAL OIL PUMP SEAL (N04C TF) INSTALL RADIATOR ASSY (See page 16 10) INSTALL CHARGE AIR COOLER ASSY (See page 13 9) ADD ENGINE COOLANT (See page 16 3) ADD ENGINE OIL (See page 17 3) CHECK FOR ENGINE OIL LEAKS CHECK FOR ENGINE COOLANT LEAKS (See page 16 1)
Page 494: Engine Rear Oil Seal (N04C Tf)
14 36 ENGINE MECHANICAL ENGINE REAR OIL SEAL (N04C TF) ENGINE REAR OIL SEAL (N04C TF) 141UG 01 REPLACEMENT DRAIN ENGINE OIL (See page 17 3) REMOVE TRANSMISSION ASSY (See page 41 3) REMOVE CLUTCH DISC ASSY (See page 42 2) REMOVE FLYWHEEL SUB ASSY Uniformly loosen and remove the 6 bolts in the order shown in the illustration.
Page 495 14 37 ENGINE MECHANICAL ENGINE REAR OIL SEAL (N04C TF) INSTALL ENGINE REAR OIL SEAL RETAINER Using SST and a hammer, tap in a new retainer until it low- ers by 4 mm (0.16 in.) from the upper edge of the flywheel housing.
Page 496 14 38 ENGINE MECHANICAL ENGINE REAR OIL SEAL (N04C TF) HINT: Insert a screwdriver through the inspection hole of the flywheel housing into the ring gear of the flywheel to keep it from turning together with the crankshaft. A97094 Using a dial indicator, measure the runout of the flywheel. Maximum runout: 0.15 mm (0.0059 in.) If the runout is greater than the maximum, resurface the sliding surface.
Page 497 EXHAUST EXHAUST PIPE ASSY (N04C TF) ..15 1 COMPONENTS ......15 1 REPLACEMENT .
Page 498 15 1 EXHAUST EXHAUST PIPE ASSY (N04C TF) EXHAUST PIPE ASSY (N04C TF) 150CY 01 COMPONENTS Exhaust Pipe No. 1 Support Bracket Lower 24 (245, 18) Exhaust Pipe Support Exhaust Pipe 24 (245, 18) Bracket No. 2 Bracket 24 (245, 18) 50 (510, 37) z Gasket 70 (714, 52)
Page 499 15 2 EXHAUST EXHAUST PIPE ASSY (N04C TF) 150CZ 01 REPLACEMENT REMOVE EXHAUST PIPE ASSY CENTER Disconnect the exhaust retarder hose. Remove the 4 bolts, exhaust retarder and 2 gaskets from the exhaust pipes. Remove the 2 nuts from the bracket No. 2 and bracket lower. Remove the 4 washers, 4 cushions and pipe from the brackets.
Page 500 COOLING COOLING SYSTEM (N04C TF) ... . 16 1 ON VEHICLE INSPECTION ....16 1 INSPECTION .
Page 501: Cooling System (N04C Tf)
The engine coolant level should be between the ”LOW” and ”FULL” lines, when the engine is cold. If low, check for leaks and add ”HINO Long Life Coolant” or similar high quality ethylene glycol based non silicate, non amine, non nitrite, non borate coolant with long life hybrid organic acid technolo- gy up to the ”FULL”...
Page 502: Inspection
16 2 COOLING COOLING SYSTEM (N04C TF) 160WY 01 INSPECTION INSPECT RADIATOR CAP SUB ASSY NOTICE: If the reservoir cap is contaminated with foreign mat- ter, always rinse it with water. Before using a radiator cap tester, wet the relief valve and pressure valve with engine coolant or water.
Page 503: Coolant (N04C Tf)
Use of improper coolants may damage the engine cooling system. Only use ”HINO Long Life Coolant” or similar high quality ethylene glycol based non silicate, non amine, non nitrite, non borate coolant with long life hybrid organic acid technology. (Coolant with long life hybrid organic acid technology consists of a combination of low phosphates and organic acids.)
Page 504 16 4 COOLING COOLANT (N04C TF) If the coolant amount is below the ”FULL” line, repeat steps (c) to (g) until the coolant amount stays the same from steps (c) to (g). (m) Install the radiator cap and then check the radiator reservoir tank coolant amount. If it is below the ”FULL”...
Page 505: Water Pump Assy (N04C Tf)
16 5 COOLING WATER PUMP ASSY (N04C TF) WATER PUMP ASSY (N04C TF) 160X0 01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16 3) REMOVE ENGINE SIDE COVER RH REMOVE ENGINE SIDE COVER LH DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR RESERVE TANK ASSY DISCONNECT RADIATOR HOSE NO.
Page 506 16 6 COOLING WATER PUMP ASSY (N04C TF) INSTALL FAN AND GENERATOR V BELT Install the V belt. Stretch the belt tight and tighten the 4 nuts. Torque: 28.5 N m (291 kgf cm, 21 ft lbf) INSTALL A/C COMPRESSOR V BELT (See page 14 4) INSPECT DRIVE BELT DEFLECTION AND TENSION (See page 14 1) CONNECT RADIATOR HOSE NO.
Page 507: Thermostat (N04C Tf)
16 7 COOLING THERMOSTAT (N04C TF) THERMOSTAT (N04C TF) 160X1 01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16 3) REMOVE ENGINE SIDE COVER RH DISCONNECT RADIATOR HOSE INLET REMOVE AIR HOSE NO. 1 Remove the 2 hose clamps. Remove the 2 bolts and hose. REMOVE THERMOSTAT Remove the 3 bolts and water inlet.
Page 508 16 8 COOLING THERMOSTAT (N04C TF) INSTALL AIR HOSE NO. 1 Install the 2 hose clamps. Install the hose with the 2 bolts. Torque: 18 N m (184 kgf cm, 13 ft lbf) CONNECT RADIATOR HOSE INLET ADD ENGINE COOLANT (See page 16 3) CHECK FOR ENGINE COOLANT LEAKS (See page 16 1) INSTALL ENGINE SIDE COVER RH...
Page 509: Radiator Assy (N04C Tf)
16 9 COOLING RADIATOR ASSY (N04C TF) RADIATOR ASSY (N04C TF) 160X2 01 ON VEHICLE CLEANING INSPECT FINS BLOCKAGE If the fins are clogged, wash them with water or use a steam cleaner. Dry with compressed air. NOTICE: If the distance between the steam cleaner and the core is too close, the fins may become damaged.
Page 510: Replacement
16 10 COOLING RADIATOR ASSY (N04C TF) 160X3 01 REPLACEMENT DRAIN ENGINE COOLANT (See page 16 3) REMOVE ENGINE SIDE COVER RH REMOVE ENGINE SIDE COVER LH DISCONNECT RADIATOR HOSE INLET DISCONNECT RADIATOR HOSE OUTLET DISCONNECT RADIATOR RESERVE TANK ASSY DISCONNECT RADIATOR HOSE NO.
Page 511 16 11 COOLING RADIATOR ASSY (N04C TF) REMOVE RADIATOR BRACKET NO.3 Remove the 3 bolts and bracket. REMOVE SUPPORT SEAL NO. 1 INSTALL SUPPORT SEAL NO. 1 INSTALL RADIATOR BRACKET NO.3 Install the bracket with the 3 bolts. Torque: 18 N m (184 kgf cm, 13 ft lbf) INSTALL FAN SHROUD Install the shroud with the 4 bolts.
Page 512 16 12 COOLING RADIATOR ASSY (N04C TF) CHECK FOR ENGINE COOLANT LEAKS (See page 16 1) INSTALL ENGINE SIDE COVER RH INSTALL ENGINE SIDE COVER LH...
Page 513 LUBRICATION LUBRICATION SYSTEM (N04C TF) ..17 1 ON VEHICLE INSPECTION ....17 1 OIL FILTER SUB ASSY (N04C TF) .
Page 514: Lubrication System (N04C Tf)
17 1 LUBRICATION LUBRICATION SYSTEM (N04C TF) LUBRICATION SYSTEM (N04C TF) 170LA 01 ON VEHICLE INSPECTION CHECK ENGINE OIL LEVEL Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the level gauge guide low level mark and full level mark. If the oil level is low, check for leakage and add oil up to the full level mark.
Page 515 17 2 LUBRICATION LUBRICATION SYSTEM (N04C TF) INSTALL OIL PRESSURE SWITCH Adhesive Remove the oil pressure gauge. Apply adhesive to 2 or 3 threads of the oil pressure switch. Adhesive: Part No. 08833 00080, THREE BOND 1344, LOCTITE 242 or equivalent Using a 24 mm deep socket wrench, install the oil pres- sure switch.
Page 516: Oil Filter Sub Assy (N04C Tf)
17 3 LUBRICATION OIL FILTER SUB ASSY (N04C TF) OIL FILTER SUB ASSY (N04C TF) 170LB 01 REPLACEMENT CAUTION: Prolonged and repeated contact of mineral oil with the skin will deplete the skin’s natural fats, leading to dryness, irritation and dermatitis. In addition, used engine oil contains harmful con- taminants which may cause skin cancer.
Page 517 17 4 LUBRICATION OIL FILTER SUB ASSY (N04C TF) Install the oil filler cap. CHECK FOR ENGINE OIL LEAKS...
Page 518: Oil Pump Assy (N04C Tf)
17 5 LUBRICATION OIL PUMP ASSY (N04C TF) OIL PUMP ASSY (N04C TF) 170LC 01 REPLACEMENT DRAIN ENGINE OIL REMOVE CAMSHAFT (See page 14 24) REMOVE IDLE GEAR NO.1 Remove the bolt. Using SST, remove the gear shaft, gear and thrust plate. 09910 00015 (09911 00011, 09912 00010, 09913 00010) A97511...
Page 519 17 6 LUBRICATION OIL PUMP ASSY (N04C TF) INSTALL IDLE GEAR NO.1 Matchmark Facing the oil hole of the idle gear shaft No. 1 downward, install the thrust plate, gear and idle gear shaft. NOTICE: If the oil hole is not facing downward, seizure and abnorml wear occurs.
Page 520: Oil Cooler Assy (N04C Tf)
17 7 LUBRICATION OIL COOLER ASSY (N04C TF) OIL COOLER ASSY (N04C TF) 170LD 01 REPLACEMENT DRAIN ENGINE OIL REMOVE TURBOCHARGER SUB ASSY (See page 13 6) REMOVE OIL FILTER SUB ASSY (See page 17 3) REMOVE OIL PRESSURE SWITCH (See page 17 1) REMOVE OIL W/BRACKET COOLER ASSY Remove the 14 bolts and bracket.
Page 521: Starting & Charging
STARTING & CHARGING STARTING SYSTEM (N04C TF) ... 19 1 INSPECTION ......19 1 STARTER ASSY (N04C TF) .
Page 522: Starting System (N04C Tf)
19 1 STARTING & CHARGING STARTING SYSTEM (N04C TF) STARTING SYSTEM (N04C TF) 190YL 01 INSPECTION INSPECT STARTER ASSY NOTICE: These tests must be performed within 3 to 5 seconds to avoid burning out the coil. Perform a pull in test. Disconnect the lead wire from terminal M.
Page 523 19 2 STARTING & CHARGING STARTING SYSTEM (N04C TF) Perform a no load performance test. Terminal C Connect the lead wire to terminal M. Make sure that the lead is not grounded. Torque: 13.5 N m (138 kgf cm, 10 ft lbf) Clamp the starter in a vise.
Page 524: Starter Assy (N04C Tf)
19 3 STARTING & CHARGING STARTER ASSY (N04C TF) STARTER ASSY (N04C TF) 190YM 01 REPLACEMENT NOTICE: Before replacing the starter, check the following again: Connector connection Accessory installation DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE STIFFENER PLATE LH Remove the 2 bolts and stiffener plate. A96294 REMOVE STARTER ASSY Disconnect the starter connector.
Page 525: Charging System (N04C Tf)
19 4 STARTING & CHARGING CHARGING SYSTEM (N04C TF) CHARGING SYSTEM (N04C TF) 190YN 01 PRECAUTION CAUTION: Check that the battery cables are connected to the correct terminals. Disconnect the battery cables before the battery is quickly charged. Do not perform tests with a high voltage insulation resistance tester. Never disconnect the battery while the engine is running.
Page 526 19 5 STARTING & CHARGING CHARGING SYSTEM (N04C TF) 190YO 01 ON VEHICLE INSPECTION CHECK BATTERY ELECTROLYTE LEVEL Check the electrolyte quantity of each cell. Maintenance free battery: If the electrolyte quantity is below the recommended amount, replace the battery. Except maintenance free battery: If the electrolyte quantity is below the recommended amount, add distilled water.
Page 527 19 6 STARTING & CHARGING CHARGING SYSTEM (N04C TF) INSPECT CHARGE WARNING LAMP CIRCUIT Turn the ignition switch ON. Check that the charge warning lamp turns ON. Start the engine and check that the lamp turns OFF. If the lamp does not operate as specified, troubleshoot the charge warning lamp circuit. INSPECT CHARGING CIRCUIT WITHOUT LOAD Ammeter Disconnect Wire...
Page 528 19 7 STARTING & CHARGING GENERATOR ASSY (N04C TF) GENERATOR ASSY (N04C TF) 190YP 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN ENGINE COOLANT (See page 16 3) REMOVE ENGINE SIDE COVER SUB ASSY RH (See page 14 14) REMOVE RADIATOR HOSE INLET (See page 16 10) REMOVE AIR HOSE NO.1 (See page 14 14) REMOVE GENERATOR ASSY Loosen the bolts labeled A and B.
Page 529 TIRE & WHEEL TIRE AND WHEEL ..... . . INSPECTION ......REFER TO DUTRO WORKSHOP MANUAL (Pub.
Page 530 TIRE & WHEEL TIRE AND WHEEL TIRE AND WHEEL 28054 0 INSPECTION INSPECT TIRES Visually check the tires for wear. Check the tires’ inflation pressure when they are cold, according to the table below. Cold tire inflation pressure: Inflation Pressure Inflation Pressure Tire Size Tire Size...
Page 531 DIFFERENTIAL DIFFERENTIAL SYSTEM (SH 2) ... PRECAUTION ......PROBLEM SYMPTOMS TABLE .
Page 532 DIFFERENTIAL DIFFERENTIAL SYSTEM (SH 2) DIFFERENTIAL SYSTEM (SH 2) 2907L 02 PRECAUTION Before overhaul, clean the outside of the differential assembly to prevent sand or mud from en- tering inside the differential carrier during overhaul. Always arrange the disassembled parts in order and protect them from dust. Before installation, thoroughly clean and dry each part and then apply hypoid gear oil to it.
Page 533: Problem Symptoms Table
29 2 DIFFERENTIAL DIFFERENTIAL SYSTEM (SH 2) 290AD 0 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspect Area See page...
Page 534 29 3 DIFFERENTIAL DIFFERENTIAL OIL (SH 2) DIFFERENTIAL OIL (SH 2) 2907M 02 REPLACEMENT DRAIN DIFFERENTIAL OIL ADD DIFFERENTIAL OIL Filler Plug Oil type: Hypoid gear oil API GL 5 Recommended oil viscosity: SAE 90 Capacity: 5.2 liters (5.5 US qts, 4.8 Imp. qts) Torque for drain and filler plugs: 50 N m (5 0 kgf cm, 37 ft lbf) Drain Plug...
Page 535 29 4 DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL (SH 2) REAR DIFFERENTIAL CARRIER OIL SEAL (SH 2) 290A9 0 COMPONENTS Rear Differential Dust Reflector Rear Drive Pinion Lock Nut 435 (4,440, 32 ) 74.5 (760, 58) z Drive Differential Carrier Oil Seal Rear Drive Pinion Companion Flange N·m (kgf·cm, ft·lbf) : Specified torque z Non reusable part...
Page 536 29 5 DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL (SH 2) 2907O 02 REPLACEMENT DRAIN DIFFERENTIAL OIL (See page 29 3) DISCONNECT PROPELLER SHAFT ASSY Place matchmarks on the flanges. Remove the 4 nuts and 4 washers, and disconnect the rear propeller shaft. Matchmarks D3255 REMOVE REAR DRIVE PINION COMPANION FLANGE...
Page 537 29 6 DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL (SH 2) INSTALL REAR DIFFERENTIAL CARRIER OIL SEAL Apply MP grease to the lip of a new oil seal. Using a brass bar and hammer, tap in the oil seal. Oil seal drive in depth: 0 mm (0 in.) D32555 INSTALL REAR DRIVE PINION COMPANION FLANGE SUB ASSY REAR...
Page 538 29 7 DIFFERENTIAL REAR DIFFERENTIAL CARRIER OIL SEAL (SH 2) INSTALL PROPELLER SHAFT ASSY Align the matchmarks and connect the propeller shaft to the companion flange with the 4 bolts, 4 washers and 4 nuts. Tighten the nuts (see pub No. S YXZE05A, page 30 4 or 30 ADD DIFFERENTIAL OIL (See page 29 3)
Page 539 29 8 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) DIFFERENTIAL CARRIER ASSY REAR (SH 2) 290AA 0 COMPONENTS Rear Axle Shaft RH Rear Axle Shaft RH 96.6 (985, 7 ) z Gasket 60 (6 0, 44) Filler Plug 50 (5 0, 37) z Gasket 52 (530, 38) z L Gasket...
Page 540 29 9 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Pilot Bearing Outer Race Retainer Pilot Bearing Outer Race 22 (225, 6) Rear Differential Bearing Adjust Side Bearing Cap Nut Lock Side Bearing Cap 22 (225, 6) 2 0 (2, 40, 55) Pilot Bearing Outer Race Retainer 2 0 (2, 50, 55)
Page 541 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Thrust Washer Rear Differential Bearing Adjust Nut Rear Differential Case RH Side Bearing Inner Race Differential Side Gear Differential Pinion Thrust Washer Thrust Washer Side Bearing Inner Race Side Bearing Outer Race 90 ( ,950, 4 ) Differential Spider Rear Differential Ring Gear 90 ( ,950, 4 )
Page 542 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) 290AB 0 OVERHAUL DRAIN DIFFERENTIAL OIL (See page 29 3) REMOVE REAR AXLE SHAFT (See pub No. S YXZE05A, page 30 72 or 30 75) REMOVE PROPELLER SHAFT ASSY (See pub No. S YXZE05A, page 30 4 or 30 REMOVE REAR DIFFERENTIAL CARRIER ASSY Using a jack, support the differential carrier.
Page 543 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Place matchmarks on the bearing cap and differential car- rier. Remove the 4 bolts, 2 bearing caps and 2 adjusting nuts. Remove the differential case together with the bearing outer races from the carrier. Matchmarks C60238 HINT:...
Page 544 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) REMOVE SIDE BEARING INNER RACE Using SST, remove the 2 inner races from the differential case. 09950 60020, (0995 00680), 09950 400 (09957 040 0), 09950 00020, 09950 00030 If reusing the bearings, arrange them so that the right bearing and left bearing can be distinguished.
Page 545 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Remove the 4 pinion gear thrust washers, 4 pinion gears and spider. Remove the 4 side gear thrust washers and side gear. C60247 REMOVE PILOT BEARING INNER RACE Using a snap ring expander, remove the snap ring. Using a grinder, make a groove to the inner race.
Page 546 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Remove the lock nut and companion flange. D32576 REMOVE REAR DIFFERENTIAL CARRIER OIL SEAL Using SST, remove the oil seal. 09308 00 0 D32577 REMOVE DIFFERENTIAL DRIVE PINION Using a press, press out the drive pinion from the drive pinion cage.
Page 547 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) REMOVE FRONT BEARING OUTER RACE Using a brass bar and hammer, tap out the bearing oil seal. Using a brass bar and hammer, tap out the bearing outer race. NOTICE: Do not damage the inner surface of the cage. D32579 REMOVE REAR BEARING OUTER RACE Using a brass bar and hammer, tap out the bearing outer...
Page 548 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Using a snap ring expander, install a new snap ring in the groove on the drive pinion tip. NOTICE: Use a cloth or similar object as a cover, at the time of snap ring installation, to prevent the snap ring from flying off.
Page 549 29−18 DIFFERENTIAL − DIFFERENTIAL CARRIER ASSY REAR (SH12) Using a torque wrench, measure the preload at the lock nut part. Preload: New bearing 1.47 to 1.96 N·m (15 to 20 kgf·cm, 13 to 17 in.·lbf) Reused bearing 0.98 to 1.47 N·m (10 to 15 kgf·cm, 9 to 13 in.·lbf) NOTICE: When either bearing is new, use the preload for a new bear- ing.
Page 550 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Using a chisel and hammer, caulk the lock nut positively at the shaft groove (2 places). D33027 INSPECT SPIDER BEARING Using a micrometer, measure the outer diameter of the spider. Using a caliper gauge, measure the inner diameter of the pinion.
Page 551 29 20 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) INSTALL REAR DIFFERENTIAL SPIDER Install the thrust washer on the slide gear. C60270 Install the 4 pinion gears and 4 thrust washers to the spi- der. Install the spider with the pinion gears to the LH case. C60247 ADJUST DIFFERENTIAL SIDE GEAR BACKLASH Using a dial gauge, measure the side gear backlash.
Page 552 29−21 DIFFERENTIAL − DIFFERENTIAL CARRIER ASSY REAR (SH12) INSTALL DIFFERENTIAL RING GEAR Align the matchmarks on the ring gear and differential. Using a press, fix the differential. Apply sealant to the threads of the 16 bolts and install them. Sealant: Part No.
Page 553 29 22 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) The conical distance is the basic dimension when the tooth contact of the drive pinion and the ring gear is ad- justed. Setting them in this dimension makes the tooth contact best. Additionally, because of machine proces- sing, dimension of the error when manufactured against the standard dimension is stamped on the tip of the pin- ion.
Page 554 29 23 DIFFERENTIAL DIFFERENTIAL CARRIER ASSY REAR (SH 2) Align the matchmarks on the cap and carrier. Temporarily install the side bearing caps with the bolt. HINT: If the bearing cap does not tightly fit the carrier, the adjusting nuts may not be properly threaded. Reinstall the adjusting nuts if necessary.
Page 555 29−24 DIFFERENTIAL − DIFFERENTIAL CARRIER ASSY REAR (SH12) INSPECT TOOTH CONTACT BETWEEN RING GEAR AND DRIVE PINION Coat 3 or 4 teeth at 3 different positions on the ring gear with red lead. Turn the companion flange in both directions to inspect the ring gear for proper tooth contact.
Page 556 29−25 DIFFERENTIAL − DIFFERENTIAL CARRIER ASSY REAR (SH12) MEASURE TOTAL PRELOAD Using a torque wrench, measure the total preload. HINT: Total preload = Drive pinion preload + Side bearing preload. Side bearing preload (new bearing): Reduction Ratio Standard 4.875 0.31 to 0.40 N·m (3.1 to 4.1 kgf·cm, 2.7 to 3.5 in.·lbf) 5.125 0.29 to 0.38 N·m (3.0 to 3.9 kgf·cm, 2.6 to 3.3 in.·lbf) C60338...
Page 557 29−26 DIFFERENTIAL − DIFFERENTIAL CARRIER ASSY REAR (SH12) INSTALL REAR DIFFERENTIAL BEARING ADJUSTING NUT LOCK Install 2 new nut locks on the bearing caps. Torque: 22 N·m (225 kgf·cm, 16 ft·lbf) C60285 INSTALL REAR DIFFERENTIAL CARRIER ASSY Seal Packing Clean the contact surface of the differential case and rear axle housing.
Page 558 BRAKE VACUUM PUMP ASSY ....COMPONENTS ......REPLACEMENT .
Page 559 32 1 BRAKE VACUUM PUMP ASSY VACUUM PUMP ASSY 3218R 01 COMPONENTS Oil Level Gage Sub assy Oil Pump Separator Sub assy 13 (133, 10) 55 (561, 41) Bracket 55 (561, 41) 13 (133, 10) 29 (296, 21) Clip z O Ring Vacuum Pump Assy z Gasket 55 (561, 41)
Page 560 32 2 BRAKE VACUUM PUMP ASSY 3218S 01 REPLACEMENT REMOVE OIL SEPARATOR SUB ASSY Remove the wire harness clamp. Remove the 2 bolts and bracket. F48589 Disengage the 3 clips and disconnect the 3 hoses. Remove the 2 bolts and separator. F48590 REMOVE FUEL PIPE Remove the nut and clamp.
Page 561 32 3 BRAKE VACUUM PUMP ASSY REMOVE OIL LEVEL GAGE SUB ASSY Remove the nut and gage. F48593 REMOVE NOZZLE LEAKAGE PIPE NO. 3 Remove the bolt. 2 union bolts, 2 gaskets and leakage pipe. F48594 REMOVE VACUUM PIPE Remove the bolt and clamp. Disengage the clip and disconnect the vacuum hose from the vacuum pipe.
Page 562 32 4 BRAKE VACUUM PUMP ASSY INSTALL VACUUM PIPE Install the pipe with 2 new gaskets and the union bolt. Torque: 13 N m (133 kgf cm, 10 ft lbf) INSTALL NOZZLE LEAKAGE PIPE NO. 3 Install the leakage pipe No. 3 with 2 new gaskets and the 2 union bolts. Torque: 13 N m (133 kgf cm, 10 ft lbf) INSTALL OIL LEVEL GAGE SUB ASSY Install the gage with the nut.
Page 563: On Vehicle Inspection
32 5 BRAKE ABS & TRACTION ACTUATOR ASSY ABS & TRACTION ACTUATOR ASSY 3218U 01 ON VEHICLE INSPECTION BRAKE ACTUATOR INSPECTION Prepare for the inspection. Connect the hand held tester (with 24 V VIM) to the DLC3 and start the engine. NOTICE: Be sure to use the 24 V VIM, because the hand held tester will be damaged if you do not use the 24 V VIM.
Page 564 32 6 BRAKE ABS & TRACTION ACTUATOR ASSY 3218V 01 COMPONENTS 22 (224, 16)* 24 (245, 18) Connector 14 (143, 10)* 15 (153, 11) 29 (296, 21) ABS & Traction Actuator Assy 5.4 (55, 48 in. lbf) Brake Actuator Bracket No. 1 N m (kgf cm, ft lbf) : Specified torque * For use with SST...
Page 565 32 7 BRAKE ABS & TRACTION ACTUATOR ASSY 3218W 01 REPLACEMENT REMOVE BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY REMOVE BRAKE MASTER CYLINDER RESERVOIR STRAINER DRAIN BRAKE FLUID NOTICE: Wash brake fluid off immediately if it adheres to any painted surface. DISCONNECT BATTERY NEGATIVE TERMINAL REMOVE ABS &...
Page 566 32 8 BRAKE ABS & TRACTION ACTUATOR ASSY INSTALL BRAKE MASTER CYLINDER RESERVOIR FILLER CAP ASSY CONNECT BATTERY NEGATIVE TERMINAL CHECK ACTUATOR WITH HAND HELD TESTER (See page 32 5)
Page 567 32 9 BRAKE LOAD SENSING VALVE ASSY LOAD SENSING VALVE ASSY 3218T 01 ON VEHICLE INSPECTION SET REAR AXLE LOAD HINT: If the vehicle unladen weight exceeds the specification, set it by following step 5. Rear axle load (including vehicle weight): Model Front axle load kg (lb) XZU305R TQMMWQ3...
Page 568 32 10 BRAKE LOAD SENSING VALVE ASSY IF VEHICLE UNLADEN WEIGHT EXCEEDS SPECIFI- Example 1 CATION, SET IT BY FOLLOWING STEPS kPa (kgf/ cm psi) Make a graph of rear axle load and brake fluid pressure as shown in example 1 or 2, using the applicable data of A B C point data table.
Page 569 32 11 BRAKE LOAD SENSING VALVE ASSY A, B, C point data table: Model (lb) (kg/ cm , psi) (lb) (kg/ cm , psi) (lb) (kg/ cm , psi) 2,179 8,300 2,555 12,900 XZU305R TQMMWQ3 (2,185) (5.1, 73) (4,803) (84.9, 1,204) (5,633) (132, 1,871) 1,121...
Page 570 32 12 BRAKE LOAD SENSING VALVE ASSY IF NECESSARY, CHECK VALVE BODY Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the piston moves down about 1 mm (0.039 in.). Even at this time, the piston should not make contact with or move the load sensing spring.
Page 571: Parking Brake
PARKING BRAKE PARKING BRAKE SYSTEM ....PROBLEM SYMPTOMS TABLE ... . . PARKING BRAKE CABLE ASSY NO.2 .
Page 572: Parking Brake System
PARKING BRAKE PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM 330HJ 0 PROBLEM SYMPTOMS TABLE Use the table below to help determine the cause of the problem. The numbers indicate likely causes of the problem in descending order. Check each part in order. Repair or replace parts as necessary. Symptom Suspected Area See Page...
Page 573 33 2 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.2 PARKING BRAKE CABLE ASSY NO.2 330HK 0 COMPONENTS Parking Brake Lever Assy 5.0 (5 , 44 in. lbf) Control Bracket No. 9 Parking Brake Switch Assy 8 ( 84, 3) Control Bracket No. 7 8 ( 84, 3) 7.0 (7 , 62 in.
Page 574 33 3 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.2 330HL 0 REPLACEMENT REMOVE SHIFT LEVER KNOB SUB ASSY REMOVE SHIFTING HOLE COVER SUB ASSY REMOVE PARKING BRAKE HOLE COVER REMOVE SHIFT LEVER BOOT COVER REMOVE PARKING BRAKE CABLE ASSY NO.2 Loosen the lock nut and disconnect the cable No.
Page 575 33 4 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.2 Remove the parking brake cable No. 2 to each cable bracket with the bolt or nut, as shown in the illustration. F48572 INSTALL PARKING BRAKE CABLE ASSY NO.2 Connect the parking brake cable No. 2 to the parking brake cable No.
Page 576 33 5 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.2 Insert the flange to the bracket w/ frame by installing the Bracket nut. w/ Frame Insert the parking brake cable No. 2 into the room interior. Mount the cable grommet into the floor panel. Torque: 8 N m ( 84 kgf cm, 3 ft lbf) Flange F48568...
Page 577 33 6 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3 PARKING BRAKE CABLE ASSY NO.3 HINT: COMPONENTS: See page 33 2. 330HM 0 REPLACEMENT REMOVE PROPELLER SHAFT ASSY (2 JOINT TYPE) REMOVE PROPELLER INTERMEDIATE SHAFT ASSY REMOVE PARKING BRAKE DRUM SUB ASSY REMOVE PARKING BRAKE SHOE RETURN TENSION SPRING REMOVE PARKING BRAKE SHOE ADJUSTER SUB ASSY REMOVE PARKING BRAKE SHOE ASSY RH OR CENTER NO.2...
Page 578 33 7 PARKING BRAKE PARKING BRAKE CABLE ASSY NO.3 Disconnect the parking brake cable No. 3. Remove the bolt and clamp from the parking brake shoe back plate. Disconnect the parking brake cable No. 3 from the parking brake shoe back plate. Remove the inner wire spring, E ring, collar and dust seal from the cable No.
Page 579 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION SYSTEM (M550) ....... . 41 1 PROBLEM SYMPTOMS TABLE .
Page 580 41 1 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION SYSTEM (M550) MANUAL TRANSMISSION SYSTEM (M550) 410D4 02 PROBLEM SYMPTOMS TABLE Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause of the problem. Check each part in order. If necessary, replace these parts. Symptom Suspected Area See Page...
Page 581 41 2 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION OIL (M550) MANUAL TRANSMISSION OIL (M550) 410D5 02 REPLACEMENT REPLACE MANUAL TRANSMISSION OIL Loosen the filler plug. Oil Level 0 to 5 mm Remove the drain plug. (0 to 0.20 in.) HINT: Use a container to catch the transmission oil. Remove the filler plug.
Page 582 41 3 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION UNIT ASSY (M550) MANUAL TRANSMISSION UNIT ASSY (M550) 410GF 01 REPLACEMENT DISCONNECT BATTERY NEGATIVE TERMINAL DRAIN MANUAL TRANSMISSION OIL (See page 41 2) REMOVE ENGINE SIDE COVER SUB ASSY LH REMOVE ENGINE SIDE COVER SUB ASSY RH REMOVE EXHAUST PIPE ASSY CENTER (See page 15 2) REMOVE EXHAUST PIPE ASSY FRONT (See page 15 2) REMOVE PROPELLER SHAFT ASSY...
Page 583 41 4 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION UNIT ASSY (M550) REMOVE ENGINE MOUNTING BRACKET NO.3 Using a transmission jack, support the transmission unit. Remove the nut. D32616 Remove the 4 bolts and mounting bracket together with the insulator. D33020 REMOVE ENGINE MOUNTING BRACKET NO.1 HINT: Use the same procedure discribed for the No.
Page 584 41 5 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION UNIT ASSY (M550) INSTALL ENGINE MOUNTING BRACKET NO.1 Install the nut. Torque: 64 N m (650 kgf cm, 47 ft lbf) D32616 Install the mounting bracket with the 4 bolts. Torque: 57 N m (581 kgf cm, 42 ft lbf) D33020 INSTALL ENGINE MOUNTING BRACKET NO.3 HINT:...
Page 585 41 6 MANUAL TRANSMISSION/TRANSAXLE MANUAL TRANSMISSION UNIT ASSY (M550) CONNECT SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY Connect the 2 control cables to the levers with the 2 nuts. Torque: 12 N m (122 kgf cm, 9 ft lbf) Install the 2 control cables to the bracket with 2 new clips. D32613 D32614 D32725...
Page 586: Remove Transmission
41 7 MANUAL TRANSMISSION/TRANSAXLE TRANSMISSION REAR BEARING RETAINER OIL SEAL (M550) TRANSMISSION REAR BEARING RETAINER OIL SEAL (M550) 410D7 02 REPLACEMENT REMOVE PROPELLER SHAFT ASSY B type propeller shaft (See pub No. S1 YXZE05A, page 30 6 or 30 22) LE type propeller shaft (See pub No.
Page 587 41 8 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) 410GG 01 REPLACEMENT REMOVE SHIFT LEVER KNOB SUB ASSY REMOVE PARKING BRAKE HOLE COVER Remove the 2 screws and parking brake hole cover. REMOVE SHIFTING HOLE COVER SUB ASSY AND SHIFT LEVER BOOT COVER Remove the 3 clips, shifting hole cover and shift lever boot cover.
Page 588 41 9 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Remove the bolt and bracket. D32625 Remove the bolt and clamp. D32626 Remove the 2 bolts and clamp. D32627 Remove the nut and clamp. D32628 Remove the bolt and clamp. D32629...
Page 589 41 10 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Remove the clamp. D32631 Remove the bolt and clamp. D32632 Remove the 2 bolts and bracket. D32633 Remove the 2 clips and disconnect the select cable and shift cable. D33084 Remove the nut and disconnect the shift cable from the control lever.
Page 590 41 11 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Remove the nut and disconnect the select cable from the select lever. D32636 INSTALL SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY Install the shift cable to the shift lever with the nut. Torque: 18 N m (184 kgf cm, 13 ft lbf) D32635 Install the select cable to the select lever with the nut.
Page 591 41 12 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Install the brackets and clamps, as shown in the illustra- tion. D32729 Install the clamp with the 2 bolts. Torque: 18 N m (184 kgf cm, 13 ft lbf) D32633 Install the bolt and clamp.
Page 592 41 13 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Install the clamp. D32631 Install the clamp with the bolt. Torque: 18 N m (184 kgf cm, 13 ft lbf) D32629 Install the clamp with the nut. Torque: 18 N m (184 kgf cm, 13 ft lbf) D32628 Install the clamp with the 2 bolts.
Page 593 41 14 MANUAL TRANSMISSION/TRANSAXLE SHIFT AND SELECT TRANSMISSION CONTROL CABLE ASSY (M550) Install the bracket with the bolt. Torque: 18 N m (184 kgf cm, 13 ft lbf) D32625 Connect the shift cable, select cable and grommets with 2 new clips. NOTICE: Be sure to install the grommet.
Page 594 41 15 MANUAL TRANSMISSION/TRANSAXLE SPEEDOMETER DRIVEN (MTM) GEAR SUB ASSY (M550) SPEEDOMETER DRIVEN (MTM) GEAR SUB ASSY (M550) 410GH 01 REPLACEMENT REMOVE SPEEDOMETER DRIVEN (MTM) GEAR SUB ASSY Disconnect the connector. Remove the bolt, speedometer lock plate and speedome- ter driven gear D32718 Remove the clip from the speedometer sleeve.
Page 595 CLUTCH CLUTCH UNIT (N04C TF) ....COMPONENTS ......OVERHAUL .
Page 596 42 1 CLUTCH CLUTCH UNIT (N04C TF) CLUTCH UNIT (N04C TF) 42066 02 COMPONENTS Flywheel Sub assy Pilot Bearing Clutch Disc Assy Clutch Cover Assy 43.1 (439, 32) Clutch Release Bearing Clip Release Fork Sub assy 47.1 (480, 35) Clutch Release Fork Boot N·m (kgf·cm, ft·lbf) : Specified torque Apply Release Hub Grease D33089...
Page 597 42 2 CLUTCH CLUTCH UNIT (N04C TF) 42067 02 OVERHAUL REMOVE MANUAL TRANSMISSION UNIT ASSY (See page 41 3) REMOVE CLUTCH RELEASE BEARING ASSY REMOVE CLUTCH RELEASE FORK BOOT REMOVE CLUTCH RELEASE FORK SUB ASSY D33094 REMOVE CLUTCH COVER ASSY Matchmarks Place matchmarks on the clutch cover and flywheel.
Page 598 42 3 CLUTCH CLUTCH UNIT (N04C TF) INSPECT CLUTCH DISC ASSY Using a vernier caliper, measure the rivet head depth. Minimum rivet head depth: 0.3 mm (0.012 in.) If necessary, replace the clutch disc assy. Depth C93886 Using a dial indicator, measure the disc runout. Maximum runout: 1.0 mm (0.039 in.) If necessary, replace the clutch disc assy.
Page 599 42 4 CLUTCH CLUTCH UNIT (N04C TF) INSTALL PILOT BEARING Using SST and a hammer, tap in a new pilot bearing. 09304 20 2 HINT: After assembling the input shaft bearing to the hub, make sure that it rotates smoothly. D33090 INSTALL CLUTCH DISC ASSY Flywheel Side...
Page 600 42 5 CLUTCH CLUTCH UNIT (N04C TF) INSTALL CLUTCH RELEASE FORK SUB ASSY Apply release hub grease to the contact of the release fork and hub, the contact of release fork and push rod and the release fork pivot points. Grease: Part No.
Page 601: Power Steering
POWER STEERING VANE PUMP ASSY (N04C TF) ... . COMPONENTS ......OVERHAUL .
Page 602 51 1 POWER STEERING VANE PUMP ASSY (N04C TF) VANE PUMP ASSY (N04C TF) 510IN 01 COMPONENTS Oil Pump to Gear Box Tube Hose Support Bracket No. 1 44 (449, 32) 18 (184, 13) 18 (184, 13) Oil Reservoir to Pump Hose No.
Page 603: Drain Coolant
51 2 POWER STEERING VANE PUMP ASSY (N04C TF) 510IO 01 OVERHAUL DRAIN COOLANT DISCONNECT RADIATOR OUTLET HOSE Loosen the clamp and disconnect the radiator outlet hose from the radiator. A97041 REMOVE RADIATOR PIPE Remove the 2 bolts and radiator pipe. Remove O ring from the radiator pipe.
Page 604 51 3 POWER STEERING VANE PUMP ASSY (N04C TF) DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.2 Slide the clip and disconnect the oil reservoir to pump hose from the power steering suction port union. A97045 REMOVE POWER STEERING SUCTION PORT UNION Remove the sensor harness clamp from the power steer- ing suction port union.
Page 605 51 4 POWER STEERING VANE PUMP ASSY (N04C TF) NOTICE: Do not twist the sensor harness. CONNECT OIL RESERVOIR TO PUMP HOSE NO.2 Connect the oil reservoir to pump hose to the power steer- ing suction port union. Install the clip. A97045 INSTALL OIL PUMP TO GEAR BOX TUBE Install the oil pump to gear box tube to the timing gear...
Page 606 51 5 POWER STEERING VANE PUMP ASSY (N04C TF) CONNECT RADIATOR OUTLET HOSE Connect the radiator outlet hose to the radiator. Tighten the clamp. A97041 ADD ENGINE COOLANT (See page 16 3) ADD POWER STEERING FLUID BLEED AIR FROM POWER STEERING FLUID CHECK AMOUNT OF POWER STEERING FLUID CHECK FOR LEAKAGE OF POWER STEERING FLUID...
Page 607: Heater & Air Conditioner
HEATER & AIR CONDITIONER REFRIGERANT LINE (N04C TF) ..55 1 COMPONENTS ......55 1 V COOLER BELT (N04C TF) .
Page 608 55 1 HEATER & AIR CONDITIONER REFRIGERANT LINE (N04C TF) REFRIGERANT LINE (N04C TF) 551EG 02 COMPONENTS 5.4 (55, 48 in. lbf) 8.0 (81, 71 in. lbf) 5.4 (55, 48 in. lbf) 14 (142, 10) Liquid Tube B 33 (336, 24) 5.4 (55, 48 in.
Page 609 55 2 HEATER & AIR CONDITIONER V COOLER BELT (N04C TF) V COOLER BELT (N04C TF) 551EK 02 REPLACEMENT REMOVE V COOLER BELT Adjusting Bolt Loosen the idler pulley bolt. Idler Pulley Bolt Loosen the adjusting bolt and remove the belt. A/C Compressor I41874 INSTALL V COOLER BELT...
Page 610 55 3 HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY (N04C TF) COOLER COMPRESSOR ASSY (N04C TF) 551EH 02 COMPONENTS 25 (256, 18) Magnet Clutch Rotor Earth Wire z Snap Ring Magnet Clutch Hub Magnet Clutch Compressor Assy z Snap Ring Magnet Clutch Washer 18 (183, 13) N m (kgf cm ft lbf) : Specified torque...
Page 611 55 4 HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY (N04C TF) 551EI 03 REPLACEMENT DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM (See Pub. No. S1 YXZE05A on page 55 14) REMOVE V COOLER BELT (See page 55 2) REMOVE COOLER REFRIGERANT DISCHARGE HOSE NO.2 Remove the bolt and disconnect the hose.
Page 612 55 5 HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY (N04C TF) Using snap ring pliers, remove the snap ring and magnet clutch rotor. I41881 Using a screwdriver, disengage the clamp. HINT: Tape the screwdriver tip before use. Remove the screw and earth wire. Clamp I41882 Using snap ring pliers, remove the snap ring and magnet...
Page 613 55 6 HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY (N04C TF) NOTICE: The snap ring should be installed so that its beveled side R Shape faces up. Snap Ring Stator Compressor E59459 Install the earth wire with the screw. Connect the clamp. Clamp I41882 Using snap ring pliers, install the magnet clutch rotor with...
Page 614 55 7 HEATER & AIR CONDITIONER COOLER COMPRESSOR ASSY (N04C TF) INSPECT MAGNETIC CLUTCH CLEARANCE Set the dial indicator to the pressure plate of the magnetic clutch. Connect the magnetic clutch lead wire to the battery’s positive terminal. Check the clearance between the pressure plate and ro- Dial Indicator tor when connecting the battery’s negative terminal to the lead wire.
Page 615 55 8 HEATER & AIR CONDITIONER COOLER CONDENSOR ASSY (N04C TF) COOLER CONDENSOR ASSY (N04C TF) 551EJ 02 COMPONENTS 5.4 (55, 48 in. lbf) w/ Receiver Condensor Assy (Sub Condensor) Fender Side Apron RH 19.5 (199, 14) Condensor Bracket 30(306,22) 8.0 (82, 70 in.
Page 616 WIRING POWER SOURCE ......LOCATION ....... REFER TO DUTRO WORKSHOP MANUAL (Pub.
Page 617 WIRING POWER SOURCE POWER SOURCE 6805B 0 LOCATION R/B No. 2 STARTER Relay Turn Signal Flasher Assy R/B No. 3 Integration Relay* Integration Relay* * : Standard Body : Wide Body R/B No. and J/B No. I4 945...
Page 618 68 2 WIRING POWER SOURCE R/B No. and J/B No. 2 3 4 5 6 7 22 23 24 25 26 27 28 FUSE HEAD (RH) RADIO 7.5 A ECU+B 7.5 A 22: ECU IG 0 A* P ACC DOME 5 A* 5 A* AIR BAG...
Page 619 68 3 WIRING POWER SOURCE R/B No. 2 FUSE MAIN3 60 A : IGN MAIN2 60 A 2: GLOW 00 A 80 A* 3: ABS 40 A* 00 A* 50 A* 30 A 4: HTR 40 A HEAD 50 A 5: E FAN 30 A 6: MAIN4...
Page 620: Alphabetical Index
ALPHABETICAL INDEX...
Page 621 00 2 ALPHABETICAL INDEX (A Page COOLANT (N04C TF) ......16 3 COOLER COMPRESSOR ASSY .
Page 622: Generator Assy (N04C Tf)
00 3 ALPHABETICAL INDEX (E Page HOW TO TROUBLESHOOT ECU CONTROLLED SYSTEMS ..... 01 16 HOW TO USE THIS MANUAL .
Page 623: Replacement
00 4 ALPHABETICAL INDEX (O Page Page OVERHAUL (DIFFERENTIAL CARRIER ASSY P0340/12 (ECD SYSTEM (N04C TF)) ....05 111 REAR (SH12)) ....... . 29 11 P0488/15 (ECD SYSTEM (N04C TF)) .
Page 624 00 5 ALPHABETICAL INDEX (R Page Page REPLACEMENT TERMINALS OF ECU (RADIATOR ASSY (N04C TF)) ....16 10 (EASY & SMOOTH STARTING SYSTEM REPLACEMENT (N04C TF)) .

This manual is also suitable for:

Dutro xzu 345 series Dutro xzu 404 series Dutro xzu 414 series Dutro xzu 424 series Dutro xzu 434 series