---===WSE_1505_00010_0001.djvu===--- Shop Manual 4M5 diesel engine Pub.No.00ELT0085, MARCH 2015 For Colombia ( EURO 4 ) ---===WSE_1505_00010_0001.djvu===--- Shop Manual 4M5 diesel engine Pub.No.00ELT0085, MARCH 2015 For Colombia ( EURO 4 ) ---===WSE_1505_00010_0002.djvu===--- GROUP INDEX GENERAL ........................................ ENGINE ............................................ LUBRICATION . ................................ FUEL AND ENGINE CONTROL ...... ENGINE CONTROL SYSTEM ......... COOLING ......................................... INTAKE AND EXHAUST.................. TURBOCHARGER CONTROL SYSTEM ........................................... EMISSION CONTROL ..................... EXHAUST GAS RECIRCULATION SYSTEM AND DIESEL PARTICULATE FILTER ........ FOREWORD This Shop Manual is published for the information and guidance of personnel responsible for maintenance of Mitsubishi Fuso CANTER series truck, and includes pro- cedures for adjustment and maintenance services. We earnestly look forward to seeing that this manual is made full use of in order to perform correct services with no wastage. For more details, please consult your nearest authorized Mitsubishi Fuso dealer or distributors. Kindly note that the specifications and maintenance ser- vice figures are subject to change without prior notice in line with improvement which will be effected from time to time in the future. MARCH 2015 Applicable models (engine) 4M50T5 ( EURO 4 ) ©2015 Mitsubishi Fuso Truck & Bus Corporation Printed in Japan ---===WSE_1505_00010_0003.djvu===--- This Shop Manual contains the information classified into the following groups. If any system or equipment has two or more variations with significantly different construction, the variations are handled as different groups. These groups are identified by different alphabets preceded by the same number. 1. ENGINE volume (Pub.No. 00ELT0085) 2. CHASSIS volume (Pub.No. 00ELT0086) 3. ELECTRICAL volume (Pub.No. 00ELT0087) Group No. Group subject 00 GENERAL 11 ENGINE 12 LUBRICATION 13 FUEL AND ENGINE CONTROL 13E ENGINE CONTROL SYSTEM 14 COOLING 15 INTAKE AND EXHAUST 15E TURBOCHARGER CONTROL SYSTEM 17 EMISSION CONTROL 17E EXHAUST GAS RECIRCULATION SYSTEM AND DIESEL PARTICULATE FILTER Group No. Group subject 00 GENERAL 21 CLUTCH 22 MANUAL TRANSMISSION 25 PROPELLER SHAFT 26 FRONT AXLE 27 REAR AXLE 31 WHEEL, TIRE 33 FRONT SUSPENSION 34 REAR SUSPENSION 35 BRAKE 36 PARKING BRAKE 37 STEERING 41 BUMPER AND FRAME 42 CAB MOUNTING, TILT 43 DOOR 51 EXTERIOR 52 INTERIOR 55 HEATER, VENTILATION Group No. Group subject 54 ELECTRICAL ---===WSE_1505_00010_0004.djvu===--- 00-1 GROUP 00 GENERAL VEHICLE MODEL CODING SYSTEM ................................................ 00-2 EQUIPMENT TYPE CODES LIST .. .................................................... 00-3 POWER TRAIN TABLE . ..................................................................... 00-4 HOW TO READ THIS MANUAL ......................................................... 00-6 CHASSIS NUMBER, ENGINE NUMBER AND VEHICLE IDENTIFICATION NUMBER ............................................. 00-14 PRECAUTIONS FOR MAINTENANCE OPERATION 1. General Precautions ................................................................... 00-16 2. Handling of Battery..................................................................... 00-19 3. Handling of Sensors, Relays and Electronic Control Units ......... 00-19 4. Handling Precautions for Electric Circuits .................................. 00-20 5. Service Precautions for Alternators ............................................ 00-23 6. Intermittent Faults ...................................................................... 00-24 7. Precautions for Arc Welding ....................................................... 00-25 8. Precautions When Repainting .................................................... 00-25 JACKING UP THE VEHICLE ............................................................ 00-26 DIAGNOSIS CODES 1. Diagnosis Codes ........................................................................ 00-28 2. Access and Clearing of Stored Diagnosis Code.......................... 00-28 TABLE OF STANDARD TIGHTENING TORQUES 1. Tightening Torques..................................................................... 00-32 2. Table of Standard Tightening Torque .......................................... 00-32 ---===WSE_1505_00010_0005.djvu===--- 00-2 1 Basic vehicle type F Cab-over engine truck 2 Load capacity, drive system E 2tonclassandover,4 2 3 Cab type 8 Wide cab 4 Vehicle variations, Suspension 5 Rigid axle Light duty vehicle (G.V.M. 7000 kg or more) 5 Engine D 4M50T 6 Wheelbase E 3350 mm G 3850 mm H 4710 mm 7 Chassis arrangement for use None Standard use Z Wide frame Rear tire arrangement, Payload 6 Rear double Payload 3000 kg to 4000 kg 8 Vehicle specification S With turbocharger 9 Steering position L Left-hand drive vehicle 1 7 4 35 2 9 8 6 FE85DE 10 11 VEHICLE MODEL CODING SYSTEM ---===WSE_1505_00010_0006.djvu===--- 00 00-3 Component Name plate marking Code description Engine 4M50T5 4 M 5 0 T 5 Power version number Turbocharged Order of development within same series Order of development among different series Diesel engine No. of cylinders (4) Clutch C5W33 C 5 W 33 Disc OD Facing material (W: Woven) Load capacity (in tonnes) of main model Initial letter of the clutch Transmission M035S6 M 035 S 6 Forward speeds Type of mesh (S: Synchromesh) Load capacity (in tonnes) of main model Initial letter of the transmission Propeller shaft P3 P 3 Load capacity (in tonnes) of main model Initial letter of the propeller shaft Front axle F350T F 350 T Vehicle type (T: Truck) Load capacity of main model Initial letter of the front axle Rear axle R035T R 03 5 T Vehicle type (T: Truck) Order of development within same series Load capacity (in tonnes) of main model Initial letter of the rear axle Reduction and differential D035H D 03 5 H Tooth profile (H: Hypoid gear) Order of development within same series Load capacity (in tonnes) of main model Initial letter of the reduction & differential EQUIPMENT TYPE CODES LIST ---===WSE_1505_00010_0007.djvu===--- 00-4 Vehicle model Engine Clutch Transmission Propeller shaft Rear axle Reduction & Differential FE85DE6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H FE85DG6SLGP 4M50T5 C5W33 M036S6 P3 R035T D035H FE85DHZSLGP 4M50T5 C5W33 M036S6 P3 R035T D035H POWER TRAIN TABLE ---===WSE_1505_00010_0008.djvu===--- MEMO 00-5 00 ---===WSE_1505_00010_0009.djvu===--- 00-6 This manual consists of the following parts: Specifications Structure and Operation Troubleshooting Circuits Electrical Equipment Installation Positions Inspection of Electrical Equipment On-vehicle Inspection and Adjustment Service procedures Connector configuration chart On-vehicle Inspection and Adjustment Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de- scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for looseness, play, backlash, crack, damage, etc. Service procedures Procedures for servicing components and parts off the vehicle are described centering on key points in their re- moval, installation, disassembly, reassembly, inspection, etc. Inspection Check items subject to "acceptable/unacceptable" judgement on the basis of service standards are all given. Some routine visual checks and cleaning of some reused parts are not described but must always be included in actual service work. Caution This service manual contains important cautionary instructions and supplementary information under the following four headings which identify the nature of the instructions and information: Terms and Units Front and rear The forward running direction of the vehicle is referred to as the front and the reverse running direction is referred to as the rear. Left and right Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and right. Standard value Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clear- ance between two parts when assembled, and the standard value for an assembly part, as the case may be. Limit When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must be replaced or repaired. DANGER Precautions that should be taken in handling potentially dangerous substances such as battery fluid and coolant additives. WARNING Precautionary instructions, which, if not observed, could result in serious injury or death. CAUTION Precautionary instructions, which, if not observed, could result in damage to or de- struction of equipment or parts. NOTE Suggestions or supplementary information for more efficient use of equipment or better understanding. HOW TO READ THIS MANUAL ---===WSE_1505_00010_0010.djvu===--- 00 00-7 Tightening torque Values are directly specified for out-of-standard tightening torques for bolts and nuts. Where there is no specified figure for tightening torque, follow the table covering standard tightening torques. (Values for standard tightening torques are based on thread size and material.) When the item is to be tightened in a wet state, "wet" is indicated. Where there is no indication, read it as dry. Units Tightening torques and other parameters are given in SI* units with metric units added in brackets { }. *SI: Le Système International d'Unités Unit SI unit {metric unit} Conversion factor Force N {kgf} 9.80665 N {1 kgf} Moment of force N·m {kgf·m} 9.80665 N·m {1 kgf·m} Pressure Positive pressure kPa {kgf/cm 2 } 98.0665 kPa {1 kgf/cm 2 } Vacuum pressure kPa {mmHg} 0.133322 kPa {1 mmHg} Pa {mmH 2 O} 9.80665 Pa {1 mmH 2 O} Volume dm 3 {L} 1dm 3 {1 L} Heat quantity J {kcal} 4186.05 J {1 kcal} Heat flow W {kcal/h} 1.16279 W {1 kcal/h} Power kW {PS} 0.7355 kW {1 PS} Example: 390 N·m {40 kgf·m} Metric unit SI unit ---===WSE_1505_00010_0011.djvu===--- 00-8 Illustrated Parts Breakdown and Service Procedures Symbol Denotation Application Remarks Tightening torque Parts not tightened to standard torques (standard torques specified where neces- sary for servicing) Specified values shown in table See Table of Standard Tightening Torques for parts for which no tightening torques are speci- fied. Locating pin Parts to be positioned for installation Non-reusable parts Parts not to be reused Lubricant and/or sealant Parts to be coated with lubricant or sealant for assembly or installation Necessary lubricant and/or sealant, quantity re- quired, etc. are specified in table. Special tool Parts for which special tools are required for service operation Tool name/shape and part number are shown in table. *a Associated part Parts associated with those removed/disas- sembled for servicing HOW TO READ THIS MANUAL ---===WSE_1505_00010_0012.djvu===--- 00 00-9 ---===WSE_1505_00010_0013.djvu===--- 00-10 How to Read Circuits (Electrical) HOW TO READ THIS MANUAL ---===WSE_1505_00010_0014.djvu===--- 00 00-11 1.1 Index number: to Index numbers are used as reference numbers for electrical circuits. Each electrical circuit has been assigned its own index number. 1.2 Key number: A01 to Z99 Key numbers indicate electrical equipment installation locations. The installation location of an electrical equip- ment can be easily found using its key number shown in a circuit diagram. All of the electrical equipment installation locations are listed in Gr54-10. 1.3 Part name 1.4 Connector type (type indication) A list of the connectors used is included in Gr54-14. 1.5 Connector terminal number 1.6 Major harness division Major harness divisions are shown. 1.7 Wiring variations between different specifications Variations in wiring/circuit between different vehicle specifications are clearly indicated as shown. 1.8 Circuit number, wire diameter, wire color 1.9 Code number: #001 to #999 Code numbers are reference numbers to find individual electrical equipment inspection procedures. The inspec- tion procedure for an electrical equipment can be found using its code number shown in a circuit diagram. 1.10Grounding point: [1] to [99] Locations where wires are grounded to the vehicle. All of the grounding points are listed in . 1.11 Harness connection The arrow in the wiring diagram indicates where harnesses are connected, and NOT the flow of electricity. 100 999 130 ---===WSE_1505_00010_0015.djvu===--- 00-12 Wire color Wire color Base color + tracer BB l a c k BW Black/ white BY Black/ yellow BR Black/red BG Black/ green BL Black/ blue BO Black/ orange BP Black/ pink BV Black/ violet BBr Black/ brown Br Brown BrW Brown/ white BrB Brown/ black BrY Brown/ yellow BrR Brown/ red BrG Brown/ green BrL Brown/ blue BrGr Brown/ gray BrV Brown/ Violet GG r e e n GW Green/ white GR Green/ red GY Green/ yellow GB Green/ black GL Green/ blue GO Green/ orange GGr Green/ gray GBr Green/ brown GV Green/ violet Gr, Gy Gray GrL, GyL Gray/ blue GrR, GyR Gray/ red GrB, GyB Gray/ black GrG, GyG Gray/ green GrW, GyW Gray/ white GrY Gray/ yellow GrG Gray/ green GrBr Gray/ brown LB l u e LW Blue/ white LR Blue/red LY Blue/ yellow LB Blue/ black LO Blue/ orange LG Blue/ green LGr Blue/gray LBr Blue/ brown Lg Light green LgR Light green/ red LgY Light green/ yellow LgB Light green/ black LgW Light green/ white O Orange OL Orange/ blue OB Orange/ black OG Orange/ green PP i n k P B Pink/ black PG Pink/ green PL Pink/ blue PW Pink/ white PGr Pink/gray PV Pink/ violet Pu Purple RR e d RW Red/ white RB Red/ black RY Red/ yellow RG Red/ green RL Red/blue RO Red/ orange RBr Red/ brown Rgr Red/ Gray Sb Sky blue V Violet VY Violet/yel- low VW Violet/ white VR Violet/red VG Violet/ green VGr Violet/ gray VB Violet/ black WW h i t e WR White/ red WB White/ black WL White/ blue WG White/ green WO White/ orange WV White/ violet WBr White/ brown WY White/ yellow Y Yellow YR Yellow/ red YB Yellow/ black YG Yellow/ green YL Yellow/ blue YW Yellow/ white YO Yellow/ orange YP Yellow/ pink YV Yellow/ violet YGr Yellow/ gray YBr Yellow/ brown HOW TO READ THIS MANUAL ---===WSE_1505_00010_0016.djvu===--- MEMO 00-13 00 ---===WSE_1505_00010_0017.djvu===--- 00-14 Serial chassis and engine numbers are assigned to the vehicles and engines in manufacturing sequence. Every vehicle and engine has its own number. These numbers are required for registration and related inspection of the vehicle. Chassis number Engine number An engine name plate indicates the following item. Engine model CHASSIS NUMBER, ENGINE NUMBER AND VIHICLE IDENTIFICATION NUMBER ---===WSE_1505_00010_0018.djvu===--- 00 00-15 Vehicle identification number (V.I.N.) The nameplate shows the following. Vehicle identification number (VIN) Maximum permitted laden mass of the vehicle Maximum permitted laden mass of the combination Maximum permitted load mass for 1st axle Maximum permitted load mass for 2nd axle The meanings of VIN are listed below. Example: (1) Geographic area J: Asia (Japan) (2) Country L: Japan (3) Manufacture C: Mitsubishi Fuso Truck & Bus (4) GVW & Brake type B: 3.5 t < GVW ≦ 12 t/Hydraulic (5) Model C: FE84P D: FE85P 1: FE85D (6) Series (wheel base) E:3.2to3.49m G:3.8 to 4.09 m H:4.1 to 4.39 m (7) Cab type 6: Cab over (8) Engine type J: 3.907 L, Diesel 3: 4.899 L, Diesel (9) Check digit (10) Model year F: 15M/Y G: 16M/Y (11) Plant K: Kawasaki (12) Plant Sequential Number 3 4 5 JC L FK (1) (2) (3) (10)(11) (12) BCE6J (4) (5) (6) (7) (8) (9) ---===WSE_1505_00010_0019.djvu===--- 00-16 1. General Precautions Before performing service operations, inquire into the customer's complaints and ascertain the condition by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently. Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or dis- assembled. Then, follow the service procedure given in this manual. Perform service operations on a level surface. Before starting, take the following preparatory steps: To prevent soiling and damage, place covers over the seats, trim and floor in the cab and over the paintwork of the body. Prepare all the general and special tools necessary for the job. WARNING Special tools must be used wherever specified in this man- ual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage. After manually tilting the cab, be sure to engage the stopper with the lock lever to secure the cab stay in a rigid state. Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions. Identify the weight of the item being lifted. Use the cable that is strong enough to support the weight. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0019.djvu===--- 00-16 1. General Precautions Before performing service operations, inquire into the customer's complaints and ascertain the condition by checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently. Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be removed or dis- assembled. Then, follow the service procedure given in this manual. Perform service operations on a level surface. Before starting, take the following preparatory steps: To prevent soiling and damage, place covers over the seats, trim and floor in the cab and over the paintwork of the body. Prepare all the general and special tools necessary for the job. WARNING Special tools must be used wherever specified in this man- ual. Do not attempt to use other tools since they could cause injuries and/or vehicle damage. After manually tilting the cab, be sure to engage the stopper with the lock lever to secure the cab stay in a rigid state. Take extreme care when removing/installing heavy items such as engine, transmission and axle. When lifting heavy items using a cable etc., observe the following precautions. Identify the weight of the item being lifted. Use the cable that is strong enough to support the weight. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0020.djvu===--- 00 00-17 If lifting eyes are not provided on the item being lifted, tie a ca- ble around the item taking into account the item's center of gravity. Do not allow anyone to pass or stay under a lifted item which may possibly fall. Never work in shoes that have oily soles. When working with a partner or in a group, use pre-arranged sig- nals and pay constant attention to safety. Be careful not to touch switches and levers unintentionally. Inspect for oil leakage etc. before washing the vehicle. If the or- der is reversed, any oil leakage or fault that may exist could go unnoticed during inspection. Prepare replacement parts ready for installation. ---===WSE_1505_00010_0021.djvu===--- 00-18 Oil seals, packings, O-rings and other rubber parts, gaskets, and split pins must be replaced with new ones after removal. Use only genuine MITSUBISHI replacement parts. When disassembling parts, visually check them for wear, cracks, damage, deformation, deterioration, rust, corrosion, defective ro- tation, fatigue, clogging and any other possible defect. To facilitate correct reassembly of parts, make alignment marks on them before disassembly and arrange disassembled parts neatly. Make punch marks and other alignment marks where they will not detract from parts' functionality and appearance. After removing parts from the vehicle, cover the area to keep it free of dust. CAUTION Be careful not to mix up identical parts, similar parts and parts that have left/right alignments. Keep new replacement parts and original (removed) parts separately. Apply the specified oil or grease to U-seals, oil seals, dust seals and bearings before reassembly. Always use the specified oils and greases when performing in- spection or replacement. Immediately wipe away any excess oil or grease with a rag. Wear safety goggles when using a grinder or welder. Wear gloves when necessary, and watch out for sharp edges and oth- er items that might wound your hands. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0022.djvu===--- 00 00-19 2. Handling of Battery 2.1 Handling of battery cable Before working on the electrical system, disconnect the (--) bat- tery cable to prevent short circuits. CAUTION Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. (Semiconductor components may otherwise be damaged.) Disconnect the (--) battery cable, then insulate the (--) termi- nal of the battery and (--) battery cable with insulating tape or the like. If the (--) battery cable is not disconnected, battery voltage will remain constantly applied to the B terminal, inviting danger of electric shock. 3. Handling of Sensors, Relays and Electronic Control Units Carefully handle sensors relays, and other items that are sensi- tive to shock and heat. Do not remove or paint the cover of any control unit. When separating connectors, grasp the connectors themselves rather than the harnesses. To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them to- gether until they click. Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or equivalent.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them. ---===WSE_1505_00010_0022.djvu===--- 00 00-19 2. Handling of Battery 2.1 Handling of battery cable Before working on the electrical system, disconnect the (--) bat- tery cable to prevent short circuits. CAUTION Make sure that the starter switch and lighting switches are OFF before disconnecting or connecting battery cable. (Semiconductor components may otherwise be damaged.) Disconnect the (--) battery cable, then insulate the (--) termi- nal of the battery and (--) battery cable with insulating tape or the like. If the (--) battery cable is not disconnected, battery voltage will remain constantly applied to the B terminal, inviting danger of electric shock. 3. Handling of Sensors, Relays and Electronic Control Units Carefully handle sensors relays, and other items that are sensi- tive to shock and heat. Do not remove or paint the cover of any control unit. When separating connectors, grasp the connectors themselves rather than the harnesses. To separate locking connectors, first push them in the direction of the arrows. To reconnect locking connectors, push them to- gether until they click. Before washing the vehicle, cover electrical parts to keep them dry. (Use plastic sheets or equivalent.) Keep water away from harness connectors and sensors and immediately wipe off any water that gets on them. ---===WSE_1505_00010_0023.djvu===--- 00-20 When applying a voltage to a part for inspection purposes, check that the (+) and (--) cables are connected properly then gradually increase the voltage from zero. Do not exceed the specified voltage. Remember that control units and sensors do not necessarily op- erate on the battery voltage. 4. Handling Precautions for Electric Circuits CAUTION Do not pierce wire insulation with test probes or alligator clips when performing electrical inspections. Doing so can, particularly with the chassis harness, hasten corrosion. 4.1 Inspection of harnesses (1) Inspections with connectors fitted together (1.1) Waterproof connectors Connect an inspection harness and connector A between the connectors B of the circuit to be inspected. Perform the inspec- tion by applying a test probe C to the connectors of the inspec- tion harness. Do not insert the test probe C into the wire-entry sides of the waterproof connectors since this would damage their waterproof seals and lead to rust. (1.2) Non-waterproof connectors Perform the inspection by inserting a test probe C into the wire- entry sides of the connectors. An extra-narrow probe is required for control unit connectors, which are smaller than other types of connector. Do not force a regular-size probe into control unit connectors since this would cause damage. (2) Inspections with connectors separated (2.1) Inspections on female terminals Perform the inspection by carefully inserting a test probe into the terminals. Do not force the test probe into the terminals since this could deform them and cause poor connections. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0024.djvu===--- 00 00-21 (2.2) Inspections on male terminals Perform the inspection by applying test probes directly to the pins. CAUTION . Be careful not to short-circuit pins together with the test probes. With control unit connectors, short-circuiting of pins can cause damage to the control unit's internal circuit- ry. When using a multimeter to check continuity, do not allow the test probes to touch the wrong terminals. 4.2 Inspection of connectors (1) Visual inspection Check that the connectors are fitted together securely. Check whether wires have been separated from their terminals due to pulling of the harness. Check that male and female terminals fit together tightly. ---===WSE_1505_00010_0025.djvu===--- 00-22 Check for defective connections caused by loose terminals, by rust on terminals, or by contamination of terminals by foreign substances. (2) Checking for loose terminals If connector terminal retainers become damaged, male and fe- male terminals may not mate with each other when the connec- tor bodies are fitted together. To check for such terminals, gently pull each wire and see whether any terminals slip out of their connector housings. 4.3 Inspections when a fuse blows Remove the fuse, then measure the resistance between ground and the fuse's load side. Next, close the switch of each circuit connected to the fuse. If the resistance measurement between any switch and ground is zero, there is a short circuit between the switch and the load. If the resistance measurement is not zero, the circuit is not cur- rently short-circuited; the fuse probably blew due to a momen- tary short circuit. The main causes of short circuits are as follows: Harnesses trapped between chassis parts Harness insulation damage due to friction or heat Moisture in connectors or circuitry Human error (accidental short-circuiting of components) 4.4 Inspection of chassis ground A special ground bolt is used to tighten a ground terminal. When servicing the ground point, be sure to follow the procedures de- scribed below: When reinstalling the ground bolt Tighten the ground bolt to the specified torque. When relocating the ground point A special ground bolt must be used. Spot-weld a nut to a frame and tighten the ground bolt to the specified torque. Be sure to apply touch-up paint to the welded point. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0026.djvu===--- 00 00-23 5. Service Precautions for Alternators When servicing alternators, observe the following precautions: Never reverse the polarity of battery connections. If the polarity of the battery connections were to be reversed, a large current would flow from the battery to the alternator, damaging the diodes and regulator. Never disconnect the battery cables with the engine running. Disconnection of the battery cables during engine operation would cause a surge voltage, leading to deterioration of the di- odes and regulator. Never perform inspections using a high-voltage multimeter. The use of a high-voltage multimeter could damage the diodes and regulator. Keep alternators dry. Water on alternators can cause internal short circuits and dam- age. Never operate an alternator with the B and L terminals short-cir- cuited. Operation with the B and L terminals connected together would damage the diode trio. ---===WSE_1505_00010_0027.djvu===--- 00-24 Disconnect the battery cables before quick-charging the battery with a quick charger. Unless the battery cables are disconnected, quick-charging can damage the diodes and regulator. 6. Intermittent Faults An intermittent fault typically occurs only under certain operating conditions. Once these conditions have been identified, the cause of the intermittent fault can be ascertained easily. First, ask the customer about the vehicle operating conditions and weather conditions under which the fault occurs. Also ask about the frequency with which the fault occurs and about the fault symptoms. Then, reproduce the fault based on this information. In accordance with the conditions under which the fault occurs, determine whether the fault is caused by vibration, heat or other factors. if vibration is a possible factor, see if the fault can be re- produced by performing the following checks on individual con- nectors and other parts: Gently move connectors up and down and to left and right. Gently move wiring harnesses up and down and to left and right. Gently wiggle sensors and other devices by hand. Gently wiggle wiring harnesses on suspension systems and other moving parts. Connectors and other parts to be checked are those included or given as likely fault locations in inspection procedures corre- sponding to diagnosis codes and/or fault symptoms. PRECAUTIONS FOR MAINTENANCE OPERATION ---===WSE_1505_00010_0028.djvu===--- 00 00-25 7. Precautions for Arc Welding When arc welding is performed, current from the welder flows to ground via the vehicle's metal parts. Unless ap- propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (--) cable of the welder is connected, might be largely damaged. Current flows backward as shown below. 7.1 From battery (--) cable To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery's (--) cable. 7.2 Procedure Turn the starter switch to the LOCK position. Disconnect the battery's (--) cable. Cover all parts of the vehicle that may be damaged by welding sparks. Connect the welder's (--) cable to the vehicle as close as possi- ble to the area being welded. Do not connect the welder's (--) ca- ble to the cab if the frame is being welded, and vice versa. Set the welding current in accordance with the part being weld- ed. 8. Precautions When Repainting When repainting, cover the following electronic control components with a masking material. If paint get on these components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti- lation holes. Engine electronic control unit and other electronic control units Sensors ---===WSE_1505_00010_0028.djvu===--- 00 00-25 7. Precautions for Arc Welding When arc welding is performed, current from the welder flows to ground via the vehicle's metal parts. Unless ap- propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses. And any electrical device near the point on the vehicle to which the (--) cable of the welder is connected, might be largely damaged. Current flows backward as shown below. 7.1 From battery (--) cable To prevent damage to the battery and to electrical devices that are connected directly to the battery, it is essential to disconnect the battery's (--) cable. 7.2 Procedure Turn the starter switch to the LOCK position. Disconnect the battery's (--) cable. Cover all parts of the vehicle that may be damaged by welding sparks. Connect the welder's (--) cable to the vehicle as close as possi- ble to the area being welded. Do not connect the welder's (--) ca- ble to the cab if the frame is being welded, and vice versa. Set the welding current in accordance with the part being weld- ed. 8. Precautions When Repainting When repainting, cover the following electronic control components with a masking material. If paint get on these components, functional reliability could be deteriorated as a result of the poor connection of connectors, internal circuit failure caused by heat build-up due to poor heat dissipation, erroneous sensor values due to clogged venti- lation holes. Engine electronic control unit and other electronic control units Sensors ---===WSE_1505_00010_0029.djvu===--- 00-26 <Front of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the front of the vehicle with a bottle jack or garage jack. 3 Support the front of the vehicle frame on jack stands. WARNING Chock the wheels firmly to prevent the vehicle from rolling away. Do not attempt to remove the chocks until the operation is completed. It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the front of the vehicle frame on jack stands. Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed. JACKING UP THE VEHICLE ---===WSE_1505_00010_0030.djvu===--- 00 00-27 <Rear of Vehicle> Jacking up procedure 1 Place chocks against the rear wheels. 2 Jack up the rear of the vehicle using a bottle jack or garage jack as illustrated above. 3 Support the vehicle frame on jack stands on both sides. WARNING Chock the wheels firmly to prevent the vehicle from rolling away. Do not attempt to remove the chocks until the operation is completed. It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition- ally support the vehicle frame on jack stands on both sides. Never attempt to remove the bottle jack, garage jack, or jack stands until the operation is completed. ---===WSE_1505_00010_0031.djvu===--- 00-28 1. Diagnosis Codes The diagnosis code indicates the faulty location(s) of the vehicle. Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo- cation(s). Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed. Using a Multi-Use Tester Flashing of a warning lamp on meter cluster The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in- dividual systems. 1.1 Systems and diagnosis code displaying methods 1.2 Types of diagnosis codes (1) Present diagnosis code Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code. The fault warning lamp is lit at the same time. (2) Past diagnosis code Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec- tronic control unit. With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re- pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory of the electronic control unit. The warning lamp is not lit because the indicated fault is not present one. 2. Access and Clearing of Stored Diagnosis Code 2.1 Using Multi-Use Tester (1) Connecting Multi-Use Tester Special tools Warning lamp System Diagnosis code displaying methods Reference Gr Multi-Use Tester Flashing of warning lamp Engine control system Common rail OO 13E Turbocharger control function 15E Exhaust gas recirculation control function 17E Preheating control, starter continuous energizing preventing function 54 Mark Tool name and shape Part No. Application Multi-Use Tester-III SOFTWARE DISC FMS-E14-1 or higher (Multi-Use Tes- ter-III version) Data transmission between V.C.I and PC V.C.I. MH062927 Data transmission between electronic control unit and PC DIAGNOSIS CODES ---===WSE_1505_00010_0031.djvu===--- 00-28 1. Diagnosis Codes The diagnosis code indicates the faulty location(s) of the vehicle. Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo- cation(s). Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed. Using a Multi-Use Tester Flashing of a warning lamp on meter cluster The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in- dividual systems. 1.1 Systems and diagnosis code displaying methods 1.2 Types of diagnosis codes (1) Present diagnosis code Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code. The fault warning lamp is lit at the same time. (2) Past diagnosis code Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec- tronic control unit. With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re- pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory of the electronic control unit. The warning lamp is not lit because the indicated fault is not present one. 2. Access and Clearing of Stored Diagnosis Code 2.1 Using Multi-Use Tester (1) Connecting Multi-Use Tester Special tools Warning lamp System Diagnosis code displaying methods Reference Gr Multi-Use Tester Flashing of warning lamp Engine control system Common rail OO 13E Turbocharger control function 15E Exhaust gas recirculation control function 17E Preheating control, starter continuous energizing preventing function 54 Mark Tool name and shape Part No. Application Multi-Use Tester-III SOFTWARE DISC FMS-E14-1 or higher (Multi-Use Tes- ter-III version) Data transmission between V.C.I and PC V.C.I. MH062927 Data transmission between electronic control unit and PC DIAGNOSIS CODES ---===WSE_1505_00010_0031.djvu===--- 00-28 1. Diagnosis Codes The diagnosis code indicates the faulty location(s) of the vehicle. Reading the diagnosis code(s) and performing the corresponding remedy (troubleshooting) repairs the faulty lo- cation(s). Diagnosis codes can be displayed in the following two methods. Select either of them according to the system to be diagnosed. Using a Multi-Use Tester Flashing of a warning lamp on meter cluster The table below indicates the systems for which diagnosis codes can be displayed and the methods usable for in- dividual systems. 1.1 Systems and diagnosis code displaying methods 1.2 Types of diagnosis codes (1) Present diagnosis code Fault developed in the vehicle after the starter switch is set to ON is indicated by corresponding diagnosis code. The fault warning lamp is lit at the same time. (2) Past diagnosis code Past fault developed in the vehicle is indicated by corresponding diagnosis code stored in the memory of the elec- tronic control unit. With the vehicle restored to its normal condition or the starter switch turned from OFF to ON after inspection or re- pair against present diagnosis codes, the present diagnosis code is stored as past diagnosis codes in the memory of the electronic control unit. The warning lamp is not lit because the indicated fault is not present one. 2. Access and Clearing of Stored Diagnosis Code 2.1 Using Multi-Use Tester (1) Connecting Multi-Use Tester Special tools Warning lamp System Diagnosis code displaying methods Reference Gr Multi-Use Tester Flashing of warning lamp Engine control system Common rail OO 13E Turbocharger control function 15E Exhaust gas recirculation control function 17E Preheating control, starter continuous energizing preventing function 54 Mark Tool name and shape Part No. Application Multi-Use Tester-III SOFTWARE DISC FMS-E14-1 or higher (Multi-Use Tes- ter-III version) Data transmission between V.C.I and PC V.C.I. MH062927 Data transmission between electronic control unit and PC DIAGNOSIS CODES ---===WSE_1505_00010_0032.djvu===--- 00 00-29 <Preparation for system inspection> Move the starter switch to the LOCK position. Connect installed PC, , -A and as illustrat- ed. Connect the Multi-Use Tester connector on the vehicle with the connector of -A. Multi-Use Tester har- ness E A: For inspection and drive recorder B: For drive recorder C: Drive recorder har- ness D: Cigar plug harness MH063659 A: MH063661 B: MH063663 C: MH063665 D: MH063666 Power supply to V.C.I. and communi- cation with electronic control unit Multi-Use Tester test harness D (used for extension) MH062951 Multi-Use Tester test harness E extension USB cable MH063668 Communication between V.C.I. and PC Mark Tool name and shape Part No. Application ---===WSE_1505_00010_0033.djvu===--- 00-30 <Preparation for inspection using the drive recorder function> Move the starter switch to the LOCK position. Connect installed PC, , -A, -B, -C, -D and as illustrated. Connect the Multi-Use Tester connector on the vehicle with the connector of -B. <To extend the cable> Use to extend the cable if -A is not long enough such as when using Multi-Use Tester outside the vehicle. (2) Access of diagnosis code Set the starter switch to ON. Operate the Multi-Use Tester for a display of necessary diagnosis code stored in the memory of the electronic control unit and identify the location of the fault. (3) Clearing of diagnosis code Set the starter switch to ON (the engine not to be started). Operate the Multi-Use Tester to delete all the diagnosis codes stored in the memory of the electronic control unit. 2.2 Use of Blinking Warning Lamp for Diagnosis Code Using the diagnosis and memory clear switches, display diagnosis codes. CAUTION Opening the memory clear switch followed by its reconnection will erase the stored diagnosis codes from the memory. To avoid inadver- tently erasing necessary codes, be sure to read well the procedure de- scribed below before handling diag- nosis codes. DIAGNOSIS CODES ---===WSE_1505_00010_0034.djvu===--- 00 00-31 (1) Reading diagnosis codes To read a diagnosis code, observe how may times the warning lamp flashes and how long each illumination lasts. The duration of illumination differs between the first and second digits. Second digit: 1.2 sec. First digit: 0.4 sec. A diagnosis code consists of the flashing of second digit and the flashing of first digit in that order. If a diagnosis code has "0" in the second digit, only the first digit will be displayed. The diagnosis code 01 will be displayed if the system is normal. The same diagnosis code will be displayed 3 times in a row be- fore moving to the display of the next code. After the last diagnosis code is displayed, the first code will be displayed again 3 times in a row and then the subsequent codes. This will be repeated. (2) Present diagnosis codes Turn the starter switch ON. Remove the diagnosis switch. Present diagnosis codes will be displayed by flashing of the warning lamp. When the diagnosis switch is connected, electronic control unit will stop (terminate) displaying diagnosis codes. (3) Present and past diagnosis codes Turn the starter switch to the ON position. Open the diagnosis switch. Present diagnosis codes will be displayed by flashing of the warning lamp. Open the memory clear switch. Present and past diagnosis codes will be displayed by flashing of the warning lamp. Turn the starter switch to the OFF position and connect the memory clear switch and diagnosis switch to terminate the diag- nosis code displaying mode. (4) Erasing diagnosis codes Turn the starter switch to the ON position (do not start the en- gine). Open the memory clear switch and reconnect it; all diagnosis codes stored in electronic control unit memory will be erased. To cancel diagnosis code erasure after opening the memory clear switch, turn the starter switch to the OFF position and then reconnect the memory clear switch. ---===WSE_1505_00010_0035.djvu===--- 00-32 1. Tightening Torques Tightening torques are roughly classified into the following two categories: Fasteners used in a location denoted by "wet" should always be tightened in a wet condition (lubricated with en- gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition. 2. Table of Standard Tightening Torque Threads and bearing surfaces shall be dry (tightened in a dry condition). If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt. Automotive screws refer to coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with nominal diameter of 10 mm or larger. (1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m}) Tightening torque Definition Availability of torque specifica- tions in text How to determine tightening torque Standard tightening torque Tightening torque determined according to thread size and material of bolts and nuts None Locate a bolt or nut correspond- ing to actual part in the following standard tightening torque table. Specified tightening torque Tightening torque of bolts and nuts other than those defined in "Standard tightening torque", or that of bolts and nuts not identified in the following tables Provided Tightening torque is shown in the text. Strength 4T 7T 8T (stud) (stud) (stud) Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Nominal diameter mm M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- 5to7 {0.5 to 0.7} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- 8to12 {0.8 to 1.2} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.6 to 2.4} -- 19to28 {1.9 to 2.9} -- M10 18to27 {1.8 to 2.8} 17to25 {1.7 to 2.5} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} 45to60 {4.6 to 6.1} 37to55 {3.8 to 5.6} M12 34to50 {3.5 to 5.1} 31to45 {3.2 to 4.6} 70to90 {7.1 to 9.2} 65to85 {6.6 to 8.7} 80 to 105 {8.2 to 11} 75to95 {7.6 to 9.7} M14 60to80 {6.1 to 8.2} 55to75 {5.6 to 7.6} 110 to 150 {11 to 15} 100 to 140 {10 to 14} 130 to 170 {13 to 17} 120 to 160 {12 to 16} M16 90 to 120 {9.2 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 22} 160 to 210 {16 to 21} 200 to 260 {20 to 27} 190 to 240 {19 to 24} M18 130 to 170 {13 to 17} 120 to 150 {12 to 15} 250 to 330 {25 to 34} 220 to 290 {22 to 30} 290 to 380 {30 to 39} 250 to 340 {25 to 35} M20 180 to 240 {18 to 24} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} 400 to 530 {41 to 54} 360 to 480 {37 to 49} M22 250 to 330 {25 to 34} 230 to 300 {23 to 31} 460 to 620 {47 to 63} 420 to 560 {43 to 57} 540 to 720 {55 to 73} 490 to 650 {50 to 66} M24 320 to 430 {33 to 44} 290 to 380 {30 to 39} 600 to 810 {61 to 83} 540 to 720 {55 to 73} 700 to 940 {71 to 96} 620 to 830 {63 to 85} TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1505_00010_0035.djvu===--- 00-32 1. Tightening Torques Tightening torques are roughly classified into the following two categories: Fasteners used in a location denoted by "wet" should always be tightened in a wet condition (lubricated with en- gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition. 2. Table of Standard Tightening Torque Threads and bearing surfaces shall be dry (tightened in a dry condition). If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt. Automotive screws refer to coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with nominal diameter of 10 mm or larger. (1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m}) Tightening torque Definition Availability of torque specifica- tions in text How to determine tightening torque Standard tightening torque Tightening torque determined according to thread size and material of bolts and nuts None Locate a bolt or nut correspond- ing to actual part in the following standard tightening torque table. Specified tightening torque Tightening torque of bolts and nuts other than those defined in "Standard tightening torque", or that of bolts and nuts not identified in the following tables Provided Tightening torque is shown in the text. Strength 4T 7T 8T (stud) (stud) (stud) Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Nominal diameter mm M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- 5to7 {0.5 to 0.7} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- 8to12 {0.8 to 1.2} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.6 to 2.4} -- 19to28 {1.9 to 2.9} -- M10 18to27 {1.8 to 2.8} 17to25 {1.7 to 2.5} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} 45to60 {4.6 to 6.1} 37to55 {3.8 to 5.6} M12 34to50 {3.5 to 5.1} 31to45 {3.2 to 4.6} 70to90 {7.1 to 9.2} 65to85 {6.6 to 8.7} 80 to 105 {8.2 to 11} 75to95 {7.6 to 9.7} M14 60to80 {6.1 to 8.2} 55to75 {5.6 to 7.6} 110 to 150 {11 to 15} 100 to 140 {10 to 14} 130 to 170 {13 to 17} 120 to 160 {12 to 16} M16 90 to 120 {9.2 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 22} 160 to 210 {16 to 21} 200 to 260 {20 to 27} 190 to 240 {19 to 24} M18 130 to 170 {13 to 17} 120 to 150 {12 to 15} 250 to 330 {25 to 34} 220 to 290 {22 to 30} 290 to 380 {30 to 39} 250 to 340 {25 to 35} M20 180 to 240 {18 to 24} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} 400 to 530 {41 to 54} 360 to 480 {37 to 49} M22 250 to 330 {25 to 34} 230 to 300 {23 to 31} 460 to 620 {47 to 63} 420 to 560 {43 to 57} 540 to 720 {55 to 73} 490 to 650 {50 to 66} M24 320 to 430 {33 to 44} 290 to 380 {30 to 39} 600 to 810 {61 to 83} 540 to 720 {55 to 73} 700 to 940 {71 to 96} 620 to 830 {63 to 85} TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1505_00010_0035.djvu===--- 00-32 1. Tightening Torques Tightening torques are roughly classified into the following two categories: Fasteners used in a location denoted by "wet" should always be tightened in a wet condition (lubricated with en- gine oil or grease). Any other fasteners than those so specified should be tightened in a dry condition. 2. Table of Standard Tightening Torque Threads and bearing surfaces shall be dry (tightened in a dry condition). If the mating nut and bolt (or stud bolt) are different in level of strength, tighten them to the torque specified for the bolt. Automotive screws refer to coarse screw thread with nominal diameter of 3 to 8 mm or fine screw thread with nominal diameter of 10 mm or larger. (1) Hexagon head bolts and stud bolts (Unit: N·m {kgf·m}) Tightening torque Definition Availability of torque specifica- tions in text How to determine tightening torque Standard tightening torque Tightening torque determined according to thread size and material of bolts and nuts None Locate a bolt or nut correspond- ing to actual part in the following standard tightening torque table. Specified tightening torque Tightening torque of bolts and nuts other than those defined in "Standard tightening torque", or that of bolts and nuts not identified in the following tables Provided Tightening torque is shown in the text. Strength 4T 7T 8T (stud) (stud) (stud) Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Nominal diameter mm M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- 5to7 {0.5 to 0.7} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- 8to12 {0.8 to 1.2} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.6 to 2.4} -- 19to28 {1.9 to 2.9} -- M10 18to27 {1.8 to 2.8} 17to25 {1.7 to 2.5} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} 45to60 {4.6 to 6.1} 37to55 {3.8 to 5.6} M12 34to50 {3.5 to 5.1} 31to45 {3.2 to 4.6} 70to90 {7.1 to 9.2} 65to85 {6.6 to 8.7} 80 to 105 {8.2 to 11} 75to95 {7.6 to 9.7} M14 60to80 {6.1 to 8.2} 55to75 {5.6 to 7.6} 110 to 150 {11 to 15} 100 to 140 {10 to 14} 130 to 170 {13 to 17} 120 to 160 {12 to 16} M16 90 to 120 {9.2 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 22} 160 to 210 {16 to 21} 200 to 260 {20 to 27} 190 to 240 {19 to 24} M18 130 to 170 {13 to 17} 120 to 150 {12 to 15} 250 to 330 {25 to 34} 220 to 290 {22 to 30} 290 to 380 {30 to 39} 250 to 340 {25 to 35} M20 180 to 240 {18 to 24} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} 400 to 530 {41 to 54} 360 to 480 {37 to 49} M22 250 to 330 {25 to 34} 230 to 300 {23 to 31} 460 to 620 {47 to 63} 420 to 560 {43 to 57} 540 to 720 {55 to 73} 490 to 650 {50 to 66} M24 320 to 430 {33 to 44} 290 to 380 {30 to 39} 600 to 810 {61 to 83} 540 to 720 {55 to 73} 700 to 940 {71 to 96} 620 to 830 {63 to 85} TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1505_00010_0036.djvu===--- 00 00-33 (2) Hexagon flange bolts (Unit: N·m {kgf·m}) Strength 8.8 (Nut 4T) 8.8 (Nut 6T) Automotive screw thread Nominal diameter mm M10 18to27 {1.8 to 2.8} 45to60 {4.6 to 6.1} M12 34to50 {3.5. to 5.1} 80 to 105 {8.2 to 11} M14 60to80 {6.1 to 8.2} 130 to 170 {13 to 17} Strength 4T 7T 8T Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Nominal diameter mm M6 4to6 {0.4 to 0.6} -- 8to12 {0.8 to 1.2} -- 10to14 {1.0 to 1.4} -- M8 10to15 {1.0 to 1.5} -- 19to28 {1.9 to 2.9} -- 22to33 {2.2 to 3.4} -- M10 21to31 {2.1 to 3.2} 20to29 {2.0 to 3.0} 45to55 {4.6 to 5.6} 37to54 {3.8 to 5.5} 50to65 {5.1 to 6.6} 50to60 {5.1 to 6.1} M12 38to56 {3.9 to 5.7} 35to51 {3.6 to 5.2} 80 to 105 {8.2 to 11} 70to95 {7.1 to 9.7} 90 to 120 {9.2 to 12} 85 to 110 {8.7 to 11} Strength 8.8 (Nut 4T) 8.8 Automotive screw thread Nominal diameter mm M10 21to31 {2.1 to 3.2} 50to65 {5.1 to 6.6} M12 38to56 {3.9 to 5.7} 90 to 120 {9.2 to 12} ---===WSE_1505_00010_0037.djvu===--- 00-34 (3) Hexagon nuts (Unit: N·m {kgf·m}) (4) Hexagon flange nuts (Unit: N·m {kgf·m}) (5) Tightening torques of general flare nuts (Unit: N·m {kgf·m}) Strength 4T 6T (Bolt 7T) 6T (Bolt 8T) Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Automotive screw thread Coarse screw thread Nominal diameter mm M5 2to3 {0.2 to 0.3} -- 4to6 {0.4 to 0.6} -- 5to7 {0.5 to 0.7} -- M6 4to6 {0.4 to 0.6} -- 7to10 {0.7 to 1.0} -- 8to12 {0.8 to 1.2} -- M8 9to13 {0.9 to 1.3} -- 16to24 {1.6 to 2.4} -- 19to28 {1.9 to 2.9} -- M10 18to27 {1.8 to 2.8} 17to25 {1.7 to 2.5} 34to50 {3.5 to 5.1} 32to48 {3.3 to 4.9} 45to60 {4.6 to 6.1} 37to55 {3.8 to 5.6} M12 34to50 {3.5 to 5.1} 31to45 {3.2 to 4.6} 70to90 {7.1 to 9.2} 65to85 {6.6 to 8.7} 80 to 105 {8.2 to 11} 75to95 {7.6 to 9.7} M14 60to80 {6.1 to 8.2} 55to75 {5.6 to 7.6} 110 to 150 {11 to 15} 100 to 140 {10 to 14} 130 to 170 {13 to 17} 120 to 160 {12 to 16} M16 90 to 120 {9.2 to 12} 90 to 110 {9 to 11} 170 to 220 {17 to 22} 160 to 210 {16 to 21} 200 to 260 {20 to 27} 190 to 240 {19 to 24} M18 130 to 170 {13 to 17} 120 to 150 {12 to 15} 250 to 330 {25 to 34} 220 to 290 {22 to 30} 290 to 380 {30 to 39} 250 to 340 {25 to 35} M20 180 to 240 {18 to 24} 170 to 220 {17 to 22} 340 to 460 {35 to 47} 310 to 410 {32 to 42} 400 to 530 {41 to 54} 360 to 480 {37 to 49} M22 250 to 330 {25 to 34} 230 to 300 {23 to 31} 460 to 620 {47 to 63} 420 to 560 {43 to 57} 540 to 720 {55 to 73} 490 to 650 {50 to 66} M24 320 to 430 {33 to 44} 290 to 380 {30 to 39} 600 to 810 {61 to 83} 540 to 720 {55 to 73} 700 to 940 {71 to 96} 620 to 830 {63 to 85} Strength 4T Automotive screw thread Coarse screw thread Nominal diameter mm M6 4to6 {0.4 to 0.6} -- M8 10to15 {1.0 to 1.5} -- M10 21to31 {2.1 to 3.2} 20to29 {2.0 to 3.0} M12 38to56 {3.9 to 5.7} 35to51 {3.6 to 5.2} Pipe diameter mm φ4.76 φ6.35 φ8 φ10 φ12 φ15 Tightening torque 17 {1.7} 25 {2.6} 39 {4.0} 59 {6.0} 88 {9.0} 98 {10} TABLE OF STANDARD TIGHTENING TORQUES ---===WSE_1505_00010_0038.djvu===--- 00 00-35 (6) Tightening torques of nylon tubes for general air piping (DIN) (Unit: N·m {kgf·m}) (7) Tightening torques of nylon tubes for general air piping (SAE) (Unit: N·m {kgf·m}) Nominal diameter wall thickness mm 6 1 10 1.25 12 1.5 15 1.5 Tightening torque 20 {2.0 } 34 {3.5 } 49 {5.0 } 54 {5.5 } Nominal diameter in. 1/4 3/8 1/2 5/8 Tightening torque 13 {1.3 } 29 {3.0 } 49 {5.0 } 64 {6.5 } +6 0 +0.6 0 +10 0 +1.0 0 +10 0 +1.0 0 +5 0 +0.5 0 +4 0 +0.4 0 +5 0 +0.5 0 +5 0 +0.5 0 +5 0 +0.5 0 ---===WSE_1505_00010_0039.djvu===--- 11-1 GROUP 11 ENGINE SPECIFICATIONS .................................. 11-2 STRUCTURE AND OPERATION 1. Exploded View ................................. 11-3 2. Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame ........ 11-4 3. Valve Mechanism ............................. 11-5 4. Connecting Rod............................... 11-6 5. Piston .............................................. 11-6 6. Timing Gears ................................... 11-7 7. Flywheel .......................................... 11-7 8. Balance Shafts ................................. 11-8 9. Crankcase and Main Bearings ......... 11-9 10.Oil Seals .........................................11-11 TROUBLESHOOTING ......................... 11-12 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measuring Compression Pressure ........................................ 11-14 2. Inspection and Adjustment of Valve Clearances..................................... 11-16 ENGINE REMOVAL AND INSTALLATION .................................... 11-18 ROCKER COVER ................................ 11-22 ROCKERS AND CAMSHAFTS ........... 11-24 CYLINDER HEAD AND VALVE MECHANISM........................................ 11-36 PISTONS, CONNECTING ROD AND CYLINDER LINERS ............................. 11-50 FLYWHEEL .......................................... 11-64 FRONT CASE ...................................... 11-68 TIMING GEARS AND BALANCE SHAFTS................................................ 11-72 CRANKSHAFT AND CRANKCASE .... 11-80 BALANCE SHAFT BUSHINGS ........... 11-88 ---===WSE_1505_00010_0040.djvu===--- 11-2 Item Specifications Engine model 4M50T5 Type 4-cylinder, in-line, water-cooled, 4-cycle diesel engine Combustion chamber Direct injection type Valve mechanism Double overhead camshaft (DOHC) Maximum output kW {PS} / rpm 132 {180} / 2700 Maximum torque N·m {kgf·m} / rpm 530 {54} / 1600 Bore × stroke mm φ114 × 120 Total displacement cm 3 {L} 4899 {4.899} Compression ratio 17.0 SPECIFICATIONS ---===WSE_1505_00010_0041.djvu===--- 11 11-3 1. Exploded View STRUCTURE AND OPERATION ---===WSE_1505_00010_0041.djvu===--- 11 11-3 1. Exploded View STRUCTURE AND OPERATION ---===WSE_1505_00010_0042.djvu===--- 11-4 2. Cylinder Head, Cylinder Head Gasket, Camshaft and Camshaft Frame The camshaft is supported at its jour- nals from below by the cylinder head and retained from above by the cam- shaft frame. The upper and lower camshaft bear- ings are identical, but cannot be inter- changed when they are reinstalled. The exhaust camshaft and the intake camshaft have identical gears but dif- ferent cams. The thirteen shortest bolts and four shorter bolts fasten the camshaft frame onto the cylinder head. The two long bolts fasten the camshaft frame to the front case. 2.1 Cylinder head gasket Select and use a cylinder head gasket of a thickness that can accommodate the piston projection. The size (thickness) class of the gas- ket can be identified by the shape of the notches and size mark cut on the edge of each gasket. STRUCTURE AND OPERATION ---===WSE_1505_00010_0043.djvu===--- 11 11-5 3. Valve Mechanism The short rockers and the long rockers are installed differently, as shown in the illustration. Each valve has an inner valve spring and an outer valve spring. ---===WSE_1505_00010_0044.djvu===--- 11-6 4. Connecting Rod Weight mark: "C" to "G" (with "G" as the maximum) 5. Piston Each piston must be mated with a cyl- inder in the upper crankcase that has the same size mark as the piston. The pistons are marked with either "A" or "B", where "B" stands for the larger and "A" for the smaller of the two avail- able diameters. The pistons have been made light- weight by use of a special aluminum alloy, as well as by the reduction of their height. STRUCTURE AND OPERATION ---===WSE_1505_00010_0044.djvu===--- 11-6 4. Connecting Rod Weight mark: "C" to "G" (with "G" as the maximum) 5. Piston Each piston must be mated with a cyl- inder in the upper crankcase that has the same size mark as the piston. The pistons are marked with either "A" or "B", where "B" stands for the larger and "A" for the smaller of the two avail- able diameters. The pistons have been made light- weight by use of a special aluminum alloy, as well as by the reduction of their height. STRUCTURE AND OPERATION ---===WSE_1505_00010_0045.djvu===--- 11 11-7 6. Timing Gears All gears, except the vacuum pump gear, each has timing mark(s) to ensure correct engagement during assem- bly. 7. Flywheel One side of each flywheel ring gear tooth is chamfered to facilitate the engagement of the starter pinion. ---===WSE_1505_00010_0045.djvu===--- 11 11-7 6. Timing Gears All gears, except the vacuum pump gear, each has timing mark(s) to ensure correct engagement during assem- bly. 7. Flywheel One side of each flywheel ring gear tooth is chamfered to facilitate the engagement of the starter pinion. ---===WSE_1505_00010_0046.djvu===--- 11-8 8. Balance Shafts The balance shaft RH and balance shaft LH are mounted in the upper crankcase on the right and left sides of the crankshaft. The balance shafts reduce the vibration of the engine caused by the rotation of the crankshaft. The balance shaft RH and balance shaft LH are both driven by timing gears. Each balance shaft is held in the up- per crankcase by way of three balance shaft bushings. The balance shaft LH has a locating hole to enable correct installation. 8.1 Reduction of vertical vibration (secondary vibration element) When the piston moves up and down, vertical vibrations are generated at the top dead center (TDC) and bottom dead center (BDC) due to inertia. The balance shaft LH and the balance shaft RH rotate so that their weight portions are at the bottom positions when a piston is at TDC and at the top positions when the piston is at BDC, i.e., the weight portions are always on the opposite side to the piston head. This creates centrifugal forces in the balance shaft RH and balance shaft LH, the total of which is equal in amount to the inertia force that the pis- ton creates when it is at TDC or BDC. These centrifugal forces in the bal- ance shafts cancel out the inertia forc- es resulting from piston's movements and reduce the amount of vertical vi- bration. The balance shafts also reduce the moment created around the crank- shaft (which constitutes secondary vi- bration elements) when the engine is running in the middle-to-high speed range. STRUCTURE AND OPERATION ---===WSE_1505_00010_0047.djvu===--- 11 11-9 9. Crankcase and Main Bearings 9.1 Crankcase The crankcase is a two-piece type consisting of an upper crankcase and a lower crankcase, which hold the crankshaft in between. Cylinder liners are inserted into the cylinder bores in the upper crankcase. An water jacket is formed in the walls of these cylinders to cool them down. The main cap bolts and the bolts that fasten the upper and lower crankcas- es together are tightened using a spe- cial method. ---===WSE_1505_00010_0048.djvu===--- 11-10 The upper crankcase is marked with a size mark ("1" or "2") to be used as a reference in selecting cylinder liners. The first to forth size marks from the front of the engine correspond to the No. 1 to No. 4 cylinders. 9.2 Main bearing The upper main bearings have oil holes through which engine oil is sup- plied to the crankshaft journals. An oil groove is provided in the No. 1 lower bearing. 9.3 Thrust plates Two upper and lower thrust plate pairs are installed on both sides of the up- per and lower main bearings at the rearmost journal of the crankshaft. Select the thrust plates of a thickness that can accommodate the crankshaft end play. The thrust plates each have two oil grooves, which assures their minimum friction against the crank- shaft journal. STRUCTURE AND OPERATION ---===WSE_1505_00010_0049.djvu===--- 11 11-11 10. Oil Seals 10.1Front oil seal The front oil seal is fitted in the front case, and prevents oil from leaking by contact of its lip with the front oil seal slinger. The front oil seal slinger is press-fitted onto the fan shaft. 10.2Rear oil seal The rear oil seal is fitted in the crank- case assembly, and prevents oil from leaking by contact of its lip with the rear oil seal slinger. The rear oil seal slinger is press-fitted onto the rear end of the crankshaft. ---===WSE_1505_00010_0050.djvu===--- 11-12 Symptoms Reference Gr Possible causes Cylinder head and valve mechanism Incorrect valve clearance OO Defective cylinder head gasket OO Worn valve and valve seat; carbon deposits OO Weakened valve spring OO Defective rocker shaft and camshaft frame O Poor lubrication of rocker shaft and camshaft frame O Timing gears Incorrect backlash in timing gears O Poor lubrication of timing gears and idler shaft O Camshaft Excessive end play in camshaft O Worn camshaft O Pistons and connecting rods Worn/damaged piston ring groove(s) OO Worn/damaged piston ring(s) OO Worn piston pin and connecting rod small end O Crankshaft Excessive end play in crankshaft O Incorrectly fitted crankshaft O Worn/damaged crankshaft pins and connecting rod bear- ings O Worn/damaged crankshaft journals and main bearings O Fuel system Defective supply pump O O Gr13E Faulty fuel spray from injector OO Gr13A Air- or water-trapped in fuel system O Irregular fuel (kerosene, heavy oil, bio-fuel, etc.) is used O Cooling system Malfunctioning cooling system components O Gr14 Loose/damaged belts O Intake and exhaust system Clogged air cleaner OO Gr15 Malfunctioning turbocharger OO Clogged muffler OO Incorrect oil viscosity O Gr12 Incorrectly fitted piping and hoses O Defective/incorrectly fitted alternator and other auxiliaries O TROUBLESHOOTING ---===WSE_1505_00010_0051.djvu===--- MEMO 11-13 11 ---===WSE_1505_00010_0052.djvu===--- 11-14 1. Measuring Compression Pressure Service standards Special tools (Unit: mm) A drop in compression pressure can be used as a guide to determine when the engine should be overhauled. Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor- mal as the parts wear down. Before the compression measurement, confirm that the engine oil, starter, and battery are in normal condition. Place the vehicle in the following conditions. Warm up the engine until the coolant temperature reaches approximately 80 to 90°C. Turn off the lights and auxiliaries. Place the transmission in neutral. Place the steering wheel in the straight-ahead position. Remove the fuse (M9) to prevent fuel from being injected when the engine is cranked by the starter. CAUTION When cranking the engine, never shut off the power to the engine electronic control unit by disconnecting the engine electronic control unit connector or the like. If the engine is cranked while shutting off the power to the engine electronic control unit, the electronic control unit cannot control the supply pump and this may cause failure to the pump. Location Maintenance item Standard value Limit Remedy -- Compression pressure Each cylinder (at 250 rpm) 3100 kPa {32 kgf/cm 2 } 2400 kPa {24 kgf/cm 2 } Inspect Cylinder-to-cylinder pres- sure difference -- 500 kPa {5 kgf/cm 2 } or less Inspect Mark Tool name and shape Part No. Application Compression gauge adapter MH063853 Measuring compression pressure AB C M14 × 1.5 58 φ7.2 ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0052.djvu===--- 11-14 1. Measuring Compression Pressure Service standards Special tools (Unit: mm) A drop in compression pressure can be used as a guide to determine when the engine should be overhauled. Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor- mal as the parts wear down. Before the compression measurement, confirm that the engine oil, starter, and battery are in normal condition. Place the vehicle in the following conditions. Warm up the engine until the coolant temperature reaches approximately 80 to 90°C. Turn off the lights and auxiliaries. Place the transmission in neutral. Place the steering wheel in the straight-ahead position. Remove the fuse (M9) to prevent fuel from being injected when the engine is cranked by the starter. CAUTION When cranking the engine, never shut off the power to the engine electronic control unit by disconnecting the engine electronic control unit connector or the like. If the engine is cranked while shutting off the power to the engine electronic control unit, the electronic control unit cannot control the supply pump and this may cause failure to the pump. Location Maintenance item Standard value Limit Remedy -- Compression pressure Each cylinder (at 250 rpm) 3100 kPa {32 kgf/cm 2 } 2400 kPa {24 kgf/cm 2 } Inspect Cylinder-to-cylinder pres- sure difference -- 500 kPa {5 kgf/cm 2 } or less Inspect Mark Tool name and shape Part No. Application Compression gauge adapter MH063853 Measuring compression pressure AB C M14 × 1.5 58 φ7.2 ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0053.djvu===--- 11 11-15 Disconnect the injector connector and remove all injectors. Cover the injector mounting holes with shop towels. After crank- ing the engine by the starter, check that no foreign substances are deposited on the shop towels. If there are deposits (such as engine oil or coolant) on the shop towels, the following may be the cause: Deposits of engine oil alone can mean a defective piston ring seal; the piston rings must be inspected. Deposits of both engine oil and coolant can mean cracks in the cylinders; the crankcase must be replaced. WARNING When coolant and engine oil deposits are evident, cranking the engine could be dangerous as these substances, heat- ed to high temperatures, will blow out from the injector mounting holes. Make sure to stay away from the injector mounting holes when the engine is being cranked. Attach the gasket and to one of the injector mounting holes. Then, connect a compression gauge to . Crank the engine and measure the compression pressure for all the cylinders one after another. Determine the compression pressure difference between the cylinders. If the compression pressure is below the limit or the cylinder-to- cylinder pressure differences is not within the limit, pour a small amount of engine oil into the corresponding injector mounting hole and remeasure the compression pressure. If the compression pressure increases, the piston rings and cylinder surfaces may be badly worn or otherwise damaged. If the compression pressure remains unchanged, there may be seizure in the valves, the valves may be incorrectly seated or the cylinder head gasket may be defective. Install the injector after inspection. (See Gr13.) ---===WSE_1505_00010_0054.djvu===--- 11-16 2. Inspection and Adjustment of Valve Clearances Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Special tools Valve clearances should be checked and adjusted as follows while the engine is still cold. [Inspection] Remove the rocker cover. Bring the No. 1 or No. 4 cylinder piston to the top dead center (TDC) on the compression stroke by the following procedure: Hook onto the grooves in the fan pulley. Turn the fan pulley in the illustrated direction to align the point- er with the "I, IV" or "1" to "4" mark on the flywheel. This will place either the No. 1 or No. 4 cylinder piston at TDC on the compression stroke. The cylinder in which the rocker arms for both the intake and exhaust valves can be pushed down by hand by the valve clearance amounts has its piston at TDC. Rotate the engine by one full turn to switch the TDCs of the No. 1 and No. 4 cylinder pistons. With the No. 1 or No. 4 cylinder piston at TDC, measure the clearance of the valves marked with a circle in the table below. Location Maintenance item Standard value Limit Remedy -- Valve clearance (when cold) Intake valve 0.4 -- Adjust Exhaust valve 0.5 -- Mark Parts to be tightened Tightening torque Remarks -- Lock nut (adjusting screw stopping) 20.6 {2.1} -- Mark Tool name and shape Part No. Application Cranking handle MH063704 Turning the fan pulley Cylinder No. 1 2 3 4 Valve INEXINEXINEXINEX No. 1 cylinder piston at TDC on compression stroke OOO-- --O-- -- No. 4 cylinder piston at TDC on compression stroke -- -- --OO--OO ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0055.djvu===--- 11 11-17 The feeler gauge cannot be inserted under the adjusting screw pad without carrying out the above step, as the pad will block the feeler gauge as shown in the illustration. To insert the feeler gauge under the adjusting screw pad, push the pad at the bottom on one side with a flat-blade screwdriver or a similar tool. Insert the feeler gauge into the small space cre- ated under the other side of the pad, as shown in the illustration. The feeler gauge must have a slight drag when taking measure- ments. If the feeler gauge can be moved without any resistance, the measurement will be incorrect. If the measurements are not within the standard value range, adjust the value clearance by the following procedures. [Adjustment] Adjust the valve clearance by loosening the lock nut and rotating the adjusting screw so that the feeler gauge can only be moved with a slight drag. After the adjustment, hold the adjusting screw in place with a screwdriver and tighten the lock nut to the specified torque. Recheck the valve clearance with the feeler gauge, and readjust if the measurements are not within the specified value range. ---===WSE_1505_00010_0056.djvu===--- 11-18 CAUTION Only use hoisting equipment appropriate for the engine and transmission weight (approximately 600 kg). Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (front mounting installation) 69to88{7to9} -- Nut (rear mounting installation) 130 to 170 {13 to 17} -- ENGINE REMOVAL AND INSTALLATION ---===WSE_1505_00010_0057.djvu===--- 11 11-19 Special tools Work before removal Preparing for engine removal: Installation of engine front hanger and flange bolt Install , and on the engine. Mark Tool name and shape Part No. Application Engine front hanger MH063636 Removal and installation of engine Flange bolt MF140429 MF140433 MF140421 Installation of engine front hanger Engine rear hanger MH063711 Removal and installation of engine ---===WSE_1505_00010_0058.djvu===--- 11-20 Removal procedure Removal: Engine and transmission Hook the wire rope on and hitch the chain block to . Then, pull all the slack out of the slings by a crane. CAUTION The slings must be strong enough to hang the engine and transmission assembly (weighing approximately 600 kg). Be sure to keep the slings away from the exhaust gas recir- culation pipes. Make sure that all harnesses and pipes are disconnected. Lift the engine and transmission assembly slowing. Take care not to bump the assembly against the frame and cab. CAUTION When lifting the engine and transmission assembly, do not incline it larger than 40°. ENGINE REMOVAL AND INSTALLATION ---===WSE_1505_00010_0059.djvu===--- MEMO 11-21 11 ---===WSE_1505_00010_0060.djvu===--- 11-22 ROCKER COVER ---===WSE_1505_00010_0061.djvu===--- 11 11-23 Disassembly sequence WARNING Fuel is highly combustible. Keep fire and heat away. Wipe off the leaked fuel. It may cause a fire. CAUTION Be careful not to hit the injectors with a tool or any other hard object during removal. Do not allow dust to enter the injectors or injection pipes. Otherwise, faulty injection may result. After confirming that no water, oil or any other substance is accumulated in the injector mounting hole, remove the injector. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Be sure to tighten the injector mounting bolts to the specified torque. If they are over-tightened, the injec- tors may be deformed, resulting in faulty injection. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Mark Parts to be tightened Tightening torque Remarks Bolt (cover installation) 23.2 {2.4} -- Bolt (rocker cover installation) Bolt (PCV pipe installation) Injection pipe (union nut installation) 30.4 to 35 {3.1 to 3.6} -- Bolt (injector installation) 5.2 to 7.2 {0.53 to 0.73} -- Bolt (cylinder sensor installation) 8 {0.82} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required 1 Oil filler cap 2 Grommet 3 Spacer 4 Insulator 5 Cover 6-- 7 Snap ring 8 Fuel return hose 9 Injection pipe 10 Bolt (with hexagonal hole) 11 Injector 12 O-ring 13 Tip gasket 14 PCV pipe 15-- 16 Cylinder sensor 17 Rocker cover 18 Rocker cover gasket A 19 Rocker cover gasket B : Non-reusable parts PCV: Positive Crankcase Ventilation ---===WSE_1505_00010_0061.djvu===--- 11 11-23 Disassembly sequence WARNING Fuel is highly combustible. Keep fire and heat away. Wipe off the leaked fuel. It may cause a fire. CAUTION Be careful not to hit the injectors with a tool or any other hard object during removal. Do not allow dust to enter the injectors or injection pipes. Otherwise, faulty injection may result. After confirming that no water, oil or any other substance is accumulated in the injector mounting hole, remove the injector. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Be sure to tighten the injector mounting bolts to the specified torque. If they are over-tightened, the injec- tors may be deformed, resulting in faulty injection. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Mark Parts to be tightened Tightening torque Remarks Bolt (cover installation) 23.2 {2.4} -- Bolt (rocker cover installation) Bolt (PCV pipe installation) Injection pipe (union nut installation) 30.4 to 35 {3.1 to 3.6} -- Bolt (injector installation) 5.2 to 7.2 {0.53 to 0.73} -- Bolt (cylinder sensor installation) 8 {0.82} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required 1 Oil filler cap 2 Grommet 3 Spacer 4 Insulator 5 Cover 6-- 7 Snap ring 8 Fuel return hose 9 Injection pipe 10 Bolt (with hexagonal hole) 11 Injector 12 O-ring 13 Tip gasket 14 PCV pipe 15-- 16 Cylinder sensor 17 Rocker cover 18 Rocker cover gasket A 19 Rocker cover gasket B : Non-reusable parts PCV: Positive Crankcase Ventilation ---===WSE_1505_00010_0062.djvu===--- 11-24 Disassembly sequence 1 Exhaust rocker shaft (See later sections.) 2 Intake rocker shaft (See later sections.) 3 Camshaft frame 4 Gasket 5 O-ring 6 Upper camshaft bearing 7 Packing 8 Intake camshaft (See later sections.) 9 Exhaust camshaft (See later sections.) 10 Lower camshaft bearing * a: Head idler gear : Locating pin : Non-reusable parts CAUTION The camshaft frame and cylinder head are manufactured as a matched set. Never replace the camshaft frame or the cylinder head individually. Do not change the upper and lower camshaft bearing combinations. Do not interchange the position of an upper and lower camshaft bearing set with that of another. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy -- Head idler gear-to-camshaft gear backlash 0.080 to 0.126 0.3 Replace -- Camshaft end play 0.10 to 0.20 0.3 Replace 6,8,10 Camshaft bearing-to-intake camshaft clearance 0.07 to 0.12 0.16 Replace 6,9,10 Camshaft bearing-to-exhaust camshaft clearance 0.07 to 0.12 0.16 Replace 6, 10 Camshaft bearing span (when free) -- 35.5 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0062.djvu===--- 11-24 Disassembly sequence 1 Exhaust rocker shaft (See later sections.) 2 Intake rocker shaft (See later sections.) 3 Camshaft frame 4 Gasket 5 O-ring 6 Upper camshaft bearing 7 Packing 8 Intake camshaft (See later sections.) 9 Exhaust camshaft (See later sections.) 10 Lower camshaft bearing * a: Head idler gear : Locating pin : Non-reusable parts CAUTION The camshaft frame and cylinder head are manufactured as a matched set. Never replace the camshaft frame or the cylinder head individually. Do not change the upper and lower camshaft bearing combinations. Do not interchange the position of an upper and lower camshaft bearing set with that of another. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy -- Head idler gear-to-camshaft gear backlash 0.080 to 0.126 0.3 Replace -- Camshaft end play 0.10 to 0.20 0.3 Replace 6,8,10 Camshaft bearing-to-intake camshaft clearance 0.07 to 0.12 0.16 Replace 6,9,10 Camshaft bearing-to-exhaust camshaft clearance 0.07 to 0.12 0.16 Replace 6, 10 Camshaft bearing span (when free) -- 35.5 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0062.djvu===--- 11-24 Disassembly sequence 1 Exhaust rocker shaft (See later sections.) 2 Intake rocker shaft (See later sections.) 3 Camshaft frame 4 Gasket 5 O-ring 6 Upper camshaft bearing 7 Packing 8 Intake camshaft (See later sections.) 9 Exhaust camshaft (See later sections.) 10 Lower camshaft bearing * a: Head idler gear : Locating pin : Non-reusable parts CAUTION The camshaft frame and cylinder head are manufactured as a matched set. Never replace the camshaft frame or the cylinder head individually. Do not change the upper and lower camshaft bearing combinations. Do not interchange the position of an upper and lower camshaft bearing set with that of another. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Location Maintenance item Standard value Limit Remedy -- Head idler gear-to-camshaft gear backlash 0.080 to 0.126 0.3 Replace -- Camshaft end play 0.10 to 0.20 0.3 Replace 6,8,10 Camshaft bearing-to-intake camshaft clearance 0.07 to 0.12 0.16 Replace 6,9,10 Camshaft bearing-to-exhaust camshaft clearance 0.07 to 0.12 0.16 Replace 6, 10 Camshaft bearing span (when free) -- 35.5 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0063.djvu===--- 11 11-25 Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Work before removal Inspection: Head idler gear-to-camshaft gear backlash Measure the backlash at three or more locations for each pair of gears. If any of the measurements exceeds the specified limit, replace the defective part(s). Inspection: Camshaft end play If the end play exceeds the specified limit, replace the defective part(s). Mark Parts to be tightened Tightening torque Remarks Bolt (rocker shaft installation: 10 places) 27 {2.8} Wet Bolt (camshaft frame installation: 13 places) Bolt (camshaft installation: 2 places) 23.5 {2.4} -- Bolt (camshaft frame installation: 4 places) 23.2 {2.4} -- Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads and seat Engine oil As required Camshaft bearing inner surface Camshaft journals and cams Cylinder head mounting surface of camshaft frame ThreeBond 1217H As required Entire periphery of packing Mark Tool name and shape Part No. Application Rocker shaft set tool MH063861 Installation of rocker shaft ---===WSE_1505_00010_0064.djvu===--- 11-26 Releasing valve spring tension Before removing the bolts in the next process, loosen the adjust- ing screws on the rockers whose valve springs are compressed (due to the cams lifting these rockers). This operation is neces- sary to release the tension in the valve springs, thus preventing other parts from undue forces when the bolts are removed. Removal procedure Removal: Rocker shafts and camshaft frame Loosen the rocker shaft installation bolts (10 places) and the camshaft frame installation bolts (13 places) in several passes in the order indicated in the illustration (1 to 23). Then, remove the rocker shafts and the camshaft frame. Inspection procedure Inspection: Camshaft bearing free span CAUTION Do not force the bearings open. If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Camshaft bearing-to-camshaft clearance If the measurement is not within the standard value range, re- place the defective part(s). ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0064.djvu===--- 11-26 Releasing valve spring tension Before removing the bolts in the next process, loosen the adjust- ing screws on the rockers whose valve springs are compressed (due to the cams lifting these rockers). This operation is neces- sary to release the tension in the valve springs, thus preventing other parts from undue forces when the bolts are removed. Removal procedure Removal: Rocker shafts and camshaft frame Loosen the rocker shaft installation bolts (10 places) and the camshaft frame installation bolts (13 places) in several passes in the order indicated in the illustration (1 to 23). Then, remove the rocker shafts and the camshaft frame. Inspection procedure Inspection: Camshaft bearing free span CAUTION Do not force the bearings open. If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Camshaft bearing-to-camshaft clearance If the measurement is not within the standard value range, re- place the defective part(s). ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0065.djvu===--- 11 11-27 Installation procedure Installation: Camshaft Install the upper camshaft bearing on the camshaft frame and the lower camshaft bearing on the cylinder head by fitting their lugs into the notches in the camshaft frame and cylinder head. Place the No. 1 cylinder piston at the top dead center on the compression stroke. Align the mating marks on the camshaft gears with those on the camshaft frame when installing the camshafts. NOTE Each camshaft gear also has mating mark "L" or "R" for alignment with the head idler gear. This mark may not be exactly aligned with that on the head idler gear, as the posi- tion that the head idler gear takes when it is installed may make it impossible to align them. Such a misalignment does not lead to any undesirable consequences. Installation: Rocker shafts and camshaft frame Clean the sealant application surfaces on each part. Apply sealant to the entire periphery of the four packings evenly and without any breaks. Apply sealant to the camshaft frame evenly and without any breaks. Mount the camshaft frame and packing on the cylinder head within three minutes of applying the sealant, being careful not to dislodge the sealant in the process. CAUTION Do not run the engine within one hour of installing the rock- er shafts and camshaft frame. ---===WSE_1505_00010_0066.djvu===--- 11-28 Install on the rocker shafts to prevent the rocker arms from moving away from each other. Set the rocker shafts to the camshaft frame and then remove . Tighten the bolts (1 to 23) to the specified torque in the order in- dicated in the illustration. CAUTION Reapply sealant to the areas specified above if any of the bolts is loosened or removed after the rocker shafts and camshaft frame are installed. ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0067.djvu===--- MEMO 11-29 11 ---===WSE_1505_00010_0068.djvu===--- 11-30 Rocker Shafts and Rockers Disassembly sequence Although the above illustration includes only the construction of the rockers on the exhaust rocker shaft, the rock- ers on the intake rocker shaft also has the same construction. Assembly sequence Follow the disassembly sequence in reverse. CAUTION The short rockers and long rockers must be installed alternately. Be aware that the order of installation for the intake rockers is different from the order of installation for the exhaust rockers. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 2, 6, 8,9 Rocker bushing-to-rocker shaft clearance 0.01 to 0.08 0.12 Replace 3, 7 Rocker (roller) radial play 0.038 to 0.100 -- Replace Mark Parts to be tightened Tightening torque Remarks Lock nut (adjusting screw stopping) 20.6 {2.1} -- Mark Points of application Specified lubricant and/or sealant Quantity Rocker bushing inner surface Engine oil As required 1 Adjusting screw 2 Rocker bushing 3 Short rocker 4 Rocker shaft spring 5 Adjusting screw 6 Rocker bushing 7 Long rocker 8 Exhaust rocker shaft 9 Intake rocker shaft : Hole for camshaft frame locating pin : Non-reusable parts ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0068.djvu===--- 11-30 Rocker Shafts and Rockers Disassembly sequence Although the above illustration includes only the construction of the rockers on the exhaust rocker shaft, the rock- ers on the intake rocker shaft also has the same construction. Assembly sequence Follow the disassembly sequence in reverse. CAUTION The short rockers and long rockers must be installed alternately. Be aware that the order of installation for the intake rockers is different from the order of installation for the exhaust rockers. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 2, 6, 8,9 Rocker bushing-to-rocker shaft clearance 0.01 to 0.08 0.12 Replace 3, 7 Rocker (roller) radial play 0.038 to 0.100 -- Replace Mark Parts to be tightened Tightening torque Remarks Lock nut (adjusting screw stopping) 20.6 {2.1} -- Mark Points of application Specified lubricant and/or sealant Quantity Rocker bushing inner surface Engine oil As required 1 Adjusting screw 2 Rocker bushing 3 Short rocker 4 Rocker shaft spring 5 Adjusting screw 6 Rocker bushing 7 Long rocker 8 Exhaust rocker shaft 9 Intake rocker shaft : Hole for camshaft frame locating pin : Non-reusable parts ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0068.djvu===--- 11-30 Rocker Shafts and Rockers Disassembly sequence Although the above illustration includes only the construction of the rockers on the exhaust rocker shaft, the rock- ers on the intake rocker shaft also has the same construction. Assembly sequence Follow the disassembly sequence in reverse. CAUTION The short rockers and long rockers must be installed alternately. Be aware that the order of installation for the intake rockers is different from the order of installation for the exhaust rockers. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 2, 6, 8,9 Rocker bushing-to-rocker shaft clearance 0.01 to 0.08 0.12 Replace 3, 7 Rocker (roller) radial play 0.038 to 0.100 -- Replace Mark Parts to be tightened Tightening torque Remarks Lock nut (adjusting screw stopping) 20.6 {2.1} -- Mark Points of application Specified lubricant and/or sealant Quantity Rocker bushing inner surface Engine oil As required 1 Adjusting screw 2 Rocker bushing 3 Short rocker 4 Rocker shaft spring 5 Adjusting screw 6 Rocker bushing 7 Long rocker 8 Exhaust rocker shaft 9 Intake rocker shaft : Hole for camshaft frame locating pin : Non-reusable parts ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0069.djvu===--- 11 11-31 Special tools (Unit: mm) Inspection procedure Inspection: Rocker (roller) radial clearance Replace the rocker if the radial play measurement is not within the standard value range. Inspection: Rocker bushing-to-rocker shaft clearance Replace the bushing if the measurement exceeds the specified limit. Replacement of rocker bushing [Removal] Mark Tool name and shape Part No. Application Rocker bushing puller MH062536 Removal and installation of rocker bushing AB φ24.5 φ22 ---===WSE_1505_00010_0070.djvu===--- 11-32 [Installation] Press-fit each rocker bushing in the rocker with its ends facing in the illustrated directions. ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0071.djvu===--- MEMO 11-33 11 ---===WSE_1505_00010_0072.djvu===--- 11-34 Camshafts Disassembly sequence 1 Intake camshaft gear 2 Key 3 Intake camshaft 4 Exhaust camshaft gear 5 Key 6 Exhaust camshaft * a: Sensor plate : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION The exhaust camshaft gear has the sensor plate. Do not mistake it for the intake camshaft gear. If the gears are incorrectly installed, en- gine malfunction will occur. Service standards (Unit: mm) Removal procedure Removal: Camshaft gears Remove the camshaft gear by pushing on the camshaft using a press. CAUTION Do not use a hammer to remove the camshaft gear. Be sure to use a press for this purpose. Location Maintenance item Standard value Limit Remedy 1, 3, 4, 6 Camshaft gear-to-camshaft interference 0.007 to 0.041 -- Replace 3 Intake camshaft Cam lift Cams for long rockers Lobe height: 42.219 Base circle diameter: 35.009 7.21 7.16 Replace Cams for short rockers Lobe height:44.281 Base circle diameter: 35.012 9.269 9.219 Bend 0.01 0.03 Replace 6 Exhaust camshaft Cam lift Cams for long rockers Lobe height: 42.279 Base circle diameter: 35.095 7.184 7.134 Replace Cams for short rockers Lobe height: 44.359 Base circle diameter: 35.117 9.242 9.192 Bend 0.01 0.03 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0072.djvu===--- 11-34 Camshafts Disassembly sequence 1 Intake camshaft gear 2 Key 3 Intake camshaft 4 Exhaust camshaft gear 5 Key 6 Exhaust camshaft * a: Sensor plate : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION The exhaust camshaft gear has the sensor plate. Do not mistake it for the intake camshaft gear. If the gears are incorrectly installed, en- gine malfunction will occur. Service standards (Unit: mm) Removal procedure Removal: Camshaft gears Remove the camshaft gear by pushing on the camshaft using a press. CAUTION Do not use a hammer to remove the camshaft gear. Be sure to use a press for this purpose. Location Maintenance item Standard value Limit Remedy 1, 3, 4, 6 Camshaft gear-to-camshaft interference 0.007 to 0.041 -- Replace 3 Intake camshaft Cam lift Cams for long rockers Lobe height: 42.219 Base circle diameter: 35.009 7.21 7.16 Replace Cams for short rockers Lobe height:44.281 Base circle diameter: 35.012 9.269 9.219 Bend 0.01 0.03 Replace 6 Exhaust camshaft Cam lift Cams for long rockers Lobe height: 42.279 Base circle diameter: 35.095 7.184 7.134 Replace Cams for short rockers Lobe height: 44.359 Base circle diameter: 35.117 9.242 9.192 Bend 0.01 0.03 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0072.djvu===--- 11-34 Camshafts Disassembly sequence 1 Intake camshaft gear 2 Key 3 Intake camshaft 4 Exhaust camshaft gear 5 Key 6 Exhaust camshaft * a: Sensor plate : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION The exhaust camshaft gear has the sensor plate. Do not mistake it for the intake camshaft gear. If the gears are incorrectly installed, en- gine malfunction will occur. Service standards (Unit: mm) Removal procedure Removal: Camshaft gears Remove the camshaft gear by pushing on the camshaft using a press. CAUTION Do not use a hammer to remove the camshaft gear. Be sure to use a press for this purpose. Location Maintenance item Standard value Limit Remedy 1, 3, 4, 6 Camshaft gear-to-camshaft interference 0.007 to 0.041 -- Replace 3 Intake camshaft Cam lift Cams for long rockers Lobe height: 42.219 Base circle diameter: 35.009 7.21 7.16 Replace Cams for short rockers Lobe height:44.281 Base circle diameter: 35.012 9.269 9.219 Bend 0.01 0.03 Replace 6 Exhaust camshaft Cam lift Cams for long rockers Lobe height: 42.279 Base circle diameter: 35.095 7.184 7.134 Replace Cams for short rockers Lobe height: 44.359 Base circle diameter: 35.117 9.242 9.192 Bend 0.01 0.03 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0072.djvu===--- 11-34 Camshafts Disassembly sequence 1 Intake camshaft gear 2 Key 3 Intake camshaft 4 Exhaust camshaft gear 5 Key 6 Exhaust camshaft * a: Sensor plate : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION The exhaust camshaft gear has the sensor plate. Do not mistake it for the intake camshaft gear. If the gears are incorrectly installed, en- gine malfunction will occur. Service standards (Unit: mm) Removal procedure Removal: Camshaft gears Remove the camshaft gear by pushing on the camshaft using a press. CAUTION Do not use a hammer to remove the camshaft gear. Be sure to use a press for this purpose. Location Maintenance item Standard value Limit Remedy 1, 3, 4, 6 Camshaft gear-to-camshaft interference 0.007 to 0.041 -- Replace 3 Intake camshaft Cam lift Cams for long rockers Lobe height: 42.219 Base circle diameter: 35.009 7.21 7.16 Replace Cams for short rockers Lobe height:44.281 Base circle diameter: 35.012 9.269 9.219 Bend 0.01 0.03 Replace 6 Exhaust camshaft Cam lift Cams for long rockers Lobe height: 42.279 Base circle diameter: 35.095 7.184 7.134 Replace Cams for short rockers Lobe height: 44.359 Base circle diameter: 35.117 9.242 9.192 Bend 0.01 0.03 Replace ROCKERS AND CAMSHAFTS ---===WSE_1505_00010_0073.djvu===--- 11 11-35 Inspection procedure Inspection: Camshaft gear-to-camshaft interference If the measurement is not within the standard value range, re- place the defective part(s). Inspection: Camshaft (1) Cam lift Replace the camshaft if the difference between the cam lobe height and base circle diameter measurements is less than the specified limit. The cams for the long rockers (L) are different from the cams for the short rockers (S). (2) Bend Place supports under the journals at the ends of the camshaft and measure the bend of the camshaft at the central journal. The amount of camshaft bend is obtained by giving the camshaft one turn and dividing the dial gauge reading by two. If the measurement exceeds the specified limit, replace the cam- shaft. Installation procedure Installation: Camshaft gears Heat the camshaft gears to approximately 150°C with a gas burner. WARNING You may burn yourself if you touch the heated gear. Install the camshaft gear on the camshaft with a mating mark ("R" or "L") facing in the illustrated direction. Press the gear until its end comes in close contact with the flange on the camshaft. ---===WSE_1505_00010_0073.djvu===--- 11 11-35 Inspection procedure Inspection: Camshaft gear-to-camshaft interference If the measurement is not within the standard value range, re- place the defective part(s). Inspection: Camshaft (1) Cam lift Replace the camshaft if the difference between the cam lobe height and base circle diameter measurements is less than the specified limit. The cams for the long rockers (L) are different from the cams for the short rockers (S). (2) Bend Place supports under the journals at the ends of the camshaft and measure the bend of the camshaft at the central journal. The amount of camshaft bend is obtained by giving the camshaft one turn and dividing the dial gauge reading by two. If the measurement exceeds the specified limit, replace the cam- shaft. Installation procedure Installation: Camshaft gears Heat the camshaft gears to approximately 150°C with a gas burner. WARNING You may burn yourself if you touch the heated gear. Install the camshaft gear on the camshaft with a mating mark ("R" or "L") facing in the illustrated direction. Press the gear until its end comes in close contact with the flange on the camshaft. ---===WSE_1505_00010_0074.djvu===--- 11-36 CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0075.djvu===--- 11 11-37 Disassembly sequence CAUTION Be careful not to damage the glow plugs and injectors when placing the cylinder head on the worktable, as they are protruding out of the bottom of the cylinder head. Assembly sequence Follow the disassembly sequence in reverse. CAUTION The cylinder head bolts are tightened using the torque-turned method. Any cylinder head bolt that has three marks indicating that the bolt has been tightened three times already must be replaced with a new one. Do not forget to install the thrust plate. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Head idler gear end play 0.1 to 0.2 0.3 Replace 3, 4 Head idler shaft-to-head idler gear bushing clearance 0.01 to 0.05 0.1 Replace 5, * a Head idler gear-to-idler gear backlash 0.103 to 0.158 0.3 Replace Mark Parts to be tightened Tightening torque Remarks Cylinder head bolt 147 {15} + 90° Wet Reusable up to 3 times Nut (connection plate installation) 1.0 to 1.5 {0.1 to 0.15} -- Glow plug 19.6 to 24.5 {2 to 2.5} -- Bolt (head idler shaft installation) 54.9 {5.6} Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt (head idler gear installation) threads and seating sur- face under head Engine oil As required Head idler shaft outer peripheral surface Cylinder head bolt threads Top surfaces of joints between upper crankcase and front case ThreeBond 1207C As required 1 Connection plates 2 Glow plug 3 Head idler shaft 4 Head idler gear bushing 5 Head idler gear 6 Thrust plate 7 Cylinder head bolt 8 Cylinder head (See later sections.) 9 Cylinder head gasket * a: Idler gear * b: Upper crankcase * c: Front case : Locating pin : Non-reusable parts ---===WSE_1505_00010_0075.djvu===--- 11 11-37 Disassembly sequence CAUTION Be careful not to damage the glow plugs and injectors when placing the cylinder head on the worktable, as they are protruding out of the bottom of the cylinder head. Assembly sequence Follow the disassembly sequence in reverse. CAUTION The cylinder head bolts are tightened using the torque-turned method. Any cylinder head bolt that has three marks indicating that the bolt has been tightened three times already must be replaced with a new one. Do not forget to install the thrust plate. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Head idler gear end play 0.1 to 0.2 0.3 Replace 3, 4 Head idler shaft-to-head idler gear bushing clearance 0.01 to 0.05 0.1 Replace 5, * a Head idler gear-to-idler gear backlash 0.103 to 0.158 0.3 Replace Mark Parts to be tightened Tightening torque Remarks Cylinder head bolt 147 {15} + 90° Wet Reusable up to 3 times Nut (connection plate installation) 1.0 to 1.5 {0.1 to 0.15} -- Glow plug 19.6 to 24.5 {2 to 2.5} -- Bolt (head idler shaft installation) 54.9 {5.6} Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt (head idler gear installation) threads and seating sur- face under head Engine oil As required Head idler shaft outer peripheral surface Cylinder head bolt threads Top surfaces of joints between upper crankcase and front case ThreeBond 1207C As required 1 Connection plates 2 Glow plug 3 Head idler shaft 4 Head idler gear bushing 5 Head idler gear 6 Thrust plate 7 Cylinder head bolt 8 Cylinder head (See later sections.) 9 Cylinder head gasket * a: Idler gear * b: Upper crankcase * c: Front case : Locating pin : Non-reusable parts ---===WSE_1505_00010_0076.djvu===--- 11-38 Special tools (Unit: mm) Work before removal Inspection: Head idler gear-to-idler gear backlash If the measurement exceeds the specified limit, replace the de- fective part(s). Inspection: Head idler gear end play If the measurement exceeds the specified limit, replace the de- fective part(s). Removal procedure Removal: Cylinder head Loosen the cylinder head bolts (1 to 18) in several passes in the order indicated in the illustration and remove the cylinder head. Removal: Cylinder head gasket CAUTION When removing the cylinder head gasket, be careful not to scratch the cylinder head, the upper crankcase and the front case. Mark Tool name and shape Part No. Application Idler gear bushing puller MH061779 Removal and installation of idler gear bushing AB φ32 φ35 CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0076.djvu===--- 11-38 Special tools (Unit: mm) Work before removal Inspection: Head idler gear-to-idler gear backlash If the measurement exceeds the specified limit, replace the de- fective part(s). Inspection: Head idler gear end play If the measurement exceeds the specified limit, replace the de- fective part(s). Removal procedure Removal: Cylinder head Loosen the cylinder head bolts (1 to 18) in several passes in the order indicated in the illustration and remove the cylinder head. Removal: Cylinder head gasket CAUTION When removing the cylinder head gasket, be careful not to scratch the cylinder head, the upper crankcase and the front case. Mark Tool name and shape Part No. Application Idler gear bushing puller MH061779 Removal and installation of idler gear bushing AB φ32 φ35 CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0077.djvu===--- 11 11-39 Inspection procedure Inspection: Head idler shaft-to-head idler gear bushing clearance Replace the bushing if the measurement exceeds the specified limit. Replacement of head idler gear bushing [Removal] [Installation] Position the bushing on the head idler gear with their ends fac- ing the illustrated directions and their oil holes on the same line. Using , press the bushing into the head idler gear until it is flush with the lower edge of the chamfer on the head idler gear. Remeasure the clearance between the bushing and head idler shaft. Ream the bushing if the measurement is less than the standard value. Installation procedure Installation: Cylinder head CAUTION Before fitting the cylinder head bolts, check the punch marks on each bolt's head. Do not use the bolt if there are three punch marks. The punch marks indicate the number of times each bolt has been tightened using the torque-turn tightening meth- od. Any bolt that already has three punch marks must be re- placed. ---===WSE_1505_00010_0077.djvu===--- 11 11-39 Inspection procedure Inspection: Head idler shaft-to-head idler gear bushing clearance Replace the bushing if the measurement exceeds the specified limit. Replacement of head idler gear bushing [Removal] [Installation] Position the bushing on the head idler gear with their ends fac- ing the illustrated directions and their oil holes on the same line. Using , press the bushing into the head idler gear until it is flush with the lower edge of the chamfer on the head idler gear. Remeasure the clearance between the bushing and head idler shaft. Ream the bushing if the measurement is less than the standard value. Installation procedure Installation: Cylinder head CAUTION Before fitting the cylinder head bolts, check the punch marks on each bolt's head. Do not use the bolt if there are three punch marks. The punch marks indicate the number of times each bolt has been tightened using the torque-turn tightening meth- od. Any bolt that already has three punch marks must be re- placed. ---===WSE_1505_00010_0078.djvu===--- 11-40 The cylinder head gasket comes in three sizes. Choose the gas- ket appropriate for the cylinder head by the following procedure. Measure the amount of piston projection for every cylinder. (See "PISTONS, CONNECTING RODS AND CYLINDER LINERS" section.) Select a cylinder head gasket with the appropriate thickness for the average of the piston projection measurements from the table below. If any of the piston projection measurements is more than 0.05 mm larger than the average value, then use the gasket one class higher than that class (A→B, B→C). Unit: mm The size class of the cylinder head gasket can be determined from the size mark or the shape of the notches cut on the gasket edge. CAUTION Replacement of the piston or connecting rod alters the pis- ton projection. Always measure the amount of piston pro- jection after either or both of them are replaced. Clean the sealant application surfaces of each part. Apply sealant to the top surfaces of the joints between the upper crankcase and front case (at two places). Install the cylinder head and its gasket on the upper crankcase within three minutes of applying the sealant, being careful not to dislodge the sealant. CAUTION Be careful not to damage the cylinder head gasket. Other- wise, coolant or oil may leak out, or engine power reduction due to noise may result. Do not run the engine within one hour of mounting the cyl- inderhead. If any cylinder head bolts are loosened or re- moved, be sure to reapply sealant to the surfaces specified above. Tighten the cylinder head bolts (1 to 18) to a torque of 147 N·m {15 kgf·m} (wet) in the order indicated in the illustration. Then, tighten them further by 90° in the same order. After tightening each bolt, make a punch mark on the head of the bolt to indicate the number of times that it has been used. CAUTION Cylinder head bolts that have been tightened using the torque-turn method must never be additionally tightened af- ter the final angular tightening. Piston projection Cylinder head gasket Size Thickness when tightened --0.088 to --0.027 "A" 0.75 ± 0.04 --0.027 to 0.033 "B" 0.80 ± 0.04 0.033 to 0.094 "C" 0.85 ± 0.04 CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0079.djvu===--- MEMO 11-41 11 ---===WSE_1505_00010_0080.djvu===--- 11-42 Cylinder Head Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. CAUTION When an intake valve or exhaust valve have been removed, make sure to replace the valve stem seal. 1 Valve cotter 2 Upper retainer 3 Outer valve spring 4 Inner valve spring 5 Valve stem seal 6 Exhaust valve 7 Intake valve 8 Exhaust valve guide 9 Intake valve guide 10 Exhaust valve seat 11 Intake valve seat 12 Sealing cap (diameter: 22 mm) 13 Sealing cap (diameter: 30 mm) 14 Sealing cap (diameter: 40 mm) 15 Tapered plug 16 Stud (short) 17 Stud (long) 18 Cylinder head : Non-reusable parts CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0080.djvu===--- 11-42 Cylinder Head Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. CAUTION When an intake valve or exhaust valve have been removed, make sure to replace the valve stem seal. 1 Valve cotter 2 Upper retainer 3 Outer valve spring 4 Inner valve spring 5 Valve stem seal 6 Exhaust valve 7 Intake valve 8 Exhaust valve guide 9 Intake valve guide 10 Exhaust valve seat 11 Intake valve seat 12 Sealing cap (diameter: 22 mm) 13 Sealing cap (diameter: 30 mm) 14 Sealing cap (diameter: 40 mm) 15 Tapered plug 16 Stud (short) 17 Stud (long) 18 Cylinder head : Non-reusable parts CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0080.djvu===--- 11-42 Cylinder Head Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. CAUTION When an intake valve or exhaust valve have been removed, make sure to replace the valve stem seal. 1 Valve cotter 2 Upper retainer 3 Outer valve spring 4 Inner valve spring 5 Valve stem seal 6 Exhaust valve 7 Intake valve 8 Exhaust valve guide 9 Intake valve guide 10 Exhaust valve seat 11 Intake valve seat 12 Sealing cap (diameter: 22 mm) 13 Sealing cap (diameter: 30 mm) 14 Sealing cap (diameter: 40 mm) 15 Tapered plug 16 Stud (short) 17 Stud (long) 18 Cylinder head : Non-reusable parts CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0081.djvu===--- 11 11-43 Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 3 Outer valve spring Free length 87.8 83.4 Replace Installed load (57 in installed length) 360±18N {36.7 ± 1.8 kgf} -- Squareness -- 2.0 4 Inner valve spring Free length 78.8 74.9 Replace Installed load (52.3 in installed length) 168±8.3N {17.1 ± 0.85 kgf} 2.0 Squareness -- -- 6 Exhaust valve Stem outside diameter φ8 φ7.85 Replace Sinkage from cylinder head bottom surface 1.5 ± 0.25 2.0 Replace Valve margin 1.5 1.2 Replace Seat angle 45° ± 15' -- Reface 6, 8 Exhaust valve stem-to-valve guide clearance 0.07 to 0.10 0.2 Replace 7 Intake valve Stem outside diameter φ8 φ7.85 Replace Sinkage from cylinder head bottom surface 1.5 ± 0.25 2.0 Replace Valve margin 1.5 1.2 Replace Seat angle 45° ± 15' -- Reface 7, 9 Intake valve stem-to-valve guide clearance 0.03 to 0.06 0.2 Replace 10 Exhaust valve seat width 2.5 ± 0.2 3.5 Replace 11 Intake valve seat width 2±0.2 2.8 Replace 18 Cylinder head Bottom surface distortion 0.05 0.2 Correct or replace Height from top surface to bot- tom surface 107 ± 0.05 106.5 Replace Valve seat hole diameter φ38 -- Mark Parts to be tightened Tightening torque Remarks Tapered plug 14 {1.4} -- Stud 20 {2.0} -- Mark Points of application Specified lubricant and/or sealant Quantity Lip of valve stem seal Engine oil As required Valve stem and valve end --0.060 --0.075 --0.025 --0.040 +0.025 0 ---===WSE_1505_00010_0082.djvu===--- 11-44 Special tools (Unit: mm) Mark Tool name and shape Part No. Application Valve lifter MH061668 Removal and installation of valve cot- ters Valve lifter seat MH061772 Valve lifter hook MH061679 Valve stem seal installer MH063607 Installation of valve stem seals Valve lapper 30091-07500 Lapping valves and valve seats Valve guide remover 31391-10500 Removal of valve guides Valve guide installer MH063604 Installation of valve guides Caulking tool body 31391-13100 Installation of valve seat Installer ring MH063605 A φ38 ABC φ26.5 φ14.7 φ8 AB φ8 φ12 ABC φ25.5 φ13 29 A φ8 B φ38 CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0083.djvu===--- 11 11-45 Removal procedure Removal: Valve cotters Remove the valve cotters by evenly compressing the valve springs. Inspection procedure Inspection: Valves If the valve has been replaced with a new one due to the result of the following inspections, make sure to lap the valve and valve seat. (1) Stem outside diameter Replace the valve if the stem's outside diameter is below the lim- it or is severely worn. (2) Valve seat angle Reface the valve if the measured value is not within the standard value range. (3) Valve margin Replace the valve if the measured value exceeds the specified limit. Refacing Limit grinding to a necessary minimum. If the valve margin is below the limit after grinding, replace the valve. After grinding, make sure to lap the valve and valve seat. Inspection: Valve stem-to-valve guide clearance If the clearance exceeds the specified limit, replace the defective part(s). ---===WSE_1505_00010_0083.djvu===--- 11 11-45 Removal procedure Removal: Valve cotters Remove the valve cotters by evenly compressing the valve springs. Inspection procedure Inspection: Valves If the valve has been replaced with a new one due to the result of the following inspections, make sure to lap the valve and valve seat. (1) Stem outside diameter Replace the valve if the stem's outside diameter is below the lim- it or is severely worn. (2) Valve seat angle Reface the valve if the measured value is not within the standard value range. (3) Valve margin Replace the valve if the measured value exceeds the specified limit. Refacing Limit grinding to a necessary minimum. If the valve margin is below the limit after grinding, replace the valve. After grinding, make sure to lap the valve and valve seat. Inspection: Valve stem-to-valve guide clearance If the clearance exceeds the specified limit, replace the defective part(s). ---===WSE_1505_00010_0084.djvu===--- 11-46 Replacement of valve guides [Removal] [Installation] Install the valve guide until sits snugly on the cylinder head. CAUTION The valve guides have a specified amount of depth. Make sure to use to achieve the specified depth. Exhaust valve guides are longer than intake valve guides. Make sure to install the correct type of guide in each loca- tion. Inspection: Contact between valve and valve seat Before starting inspection, check that the valve and valve guide are intact. Apply an even coat of red lead to the valve contact surface of the valve seat. Strike the valve once against the valve seat. Do not rotate the valve during this operation. If the red lead deposited on the valve indicates a poor contact pattern, take either of the following corrective actions. Lapping Perform lapping according to the following procedure. Apply a thin coat of lapping compound to the seat contact sur- face of the valve. CAUTION Do not put any compound on the stem of the valve. Start with an intermediate-grit compound (120 to 150 grit) and finish with a fine-grit compound (200 grit or more). Adding a small amount of engine oil to the lapping com- pound can facilitate even application. Corrective action Minor defect Lapping Serious defect Reface or replace valve and valve seat CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0085.djvu===--- 11 11-47 Strike the valve several times against the valve seat while rotat- ing the valve a little at a time. Wash away the compound with diesel fuel. Apply engine oil to the valve contact surface of the valve seat and rub in the valve and seat well. Inspect the contact pattern of the valve and valve seat again. If the contact pattern is still defective, replace the valve seat. Inspection: Valve seats If a valve is corrected or replaced with a new one as a result of the following inspection, make sure to lap the valve seat and valve. (1) Valve seat width If the measurement exceeds the limit, reface or replace the valve seat. (2) Valve sinkage from cylinder head bottom surface Measure the sinkage with the valve seat in intimate contact. If the measurement exceeds the limit, adjust or replace the de- fective part(s). Refacing the valve seat Grind the valve seat using a valve seat cutter or valve seat grinder. After grinding, place a piece of sandpaper approximately #400 between the cutter and valve seat and grind the valve seat light- ly. Use a 15° or 75° cutter to cut the valve seat to a width within the standard range. If the valve seat cannot be refaced, replace the valve seat. CAUTION Make sure that the valve seat refacing does not cause the valve sinkage to exceed the specified limit. After refacing, lap the valve and valve seat. ---===WSE_1505_00010_0086.djvu===--- 11-48 Replacement of valve seat [Removal] The valve seats are installed by expansion fitting. To remove a valve seat, grind inside the metal stock to reduce the wall thick- ness, then remove the valve seat at room temperature. [Inspection] Check that the diameter of the valve seat hole in the cylinder head conform with the standard value. Replace the cylinder head if the measurement deviates from the standard value. [Installation] Chill the valve seat thoroughly by immersing in it in liquid nitro- gen. Install the valve seat in the cylinder head using and , with the chamfered edge of toward the valve seat. Turn over so that its chamfered edge is toward , and calk the valve seat. Lap the valve seat and valve. Inspection: Cylinder head bottom surface distortion If the distortion exceeds the specified limit, rectify it using a sur- face grinder. CAUTION When griding the cylinder head bottom surface, make sure that the height of the cylinder head (from the top surface to the bottom surface) is not reduced to a valve below the specified limit. CYLINDER HEAD AND VALVE MECHANISM ---===WSE_1505_00010_0087.djvu===--- 11 11-49 Installation procedure Installation: Sealing caps Drive the sealing caps into the cylinder head to the specified depth. Installation: Valve stem seal Apply engine oil to the lip of the valve stem seal. Install the valve stem seal until sits snugly on the cylinder head. CAUTION After installing the valve stem seal, check that its spring is not deformed or damaged. Installation: Valve cotter To install the valve cotter, follow the removal procedure. (See " Removal: Valve cotters".) ---===WSE_1505_00010_0088.djvu===--- 11-50 Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later sections.) 5 Cylinder liner * a: Upper crankcase * b: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Piston projection from upper crankcase top surface (av- erage value) --0.088 to 0.094 -- Replace -- Connecting rod end play 0.15 to 0.45 0.6 Replace 1, 3 Connecting rod bearing span when free -- 69.5 Replace 1, 3, * b Connecting rod bearing-to-crankshaft oil clearance 0.034 to 0.093 0.2 4, 5 Piston-to-cylinder liner clearance 0.181 to 0.201 -- Replace 5 Cylinder liner Flange projection above crankcase top surface 0.01 to 0.07 -- Replace Bore diameter φ114 to 114.02 φ114.25 Difference in flange projec- tion from neighboring cylin- der liner 0.04 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (connecting rod cap installation) 29 {3.0} + 90° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required Connecting rod bearing inside surface Upper crankcase contact surface of cylinder liner Piston outside surface Cylinder liner wall surface PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0088.djvu===--- 11-50 Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later sections.) 5 Cylinder liner * a: Upper crankcase * b: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Piston projection from upper crankcase top surface (av- erage value) --0.088 to 0.094 -- Replace -- Connecting rod end play 0.15 to 0.45 0.6 Replace 1, 3 Connecting rod bearing span when free -- 69.5 Replace 1, 3, * b Connecting rod bearing-to-crankshaft oil clearance 0.034 to 0.093 0.2 4, 5 Piston-to-cylinder liner clearance 0.181 to 0.201 -- Replace 5 Cylinder liner Flange projection above crankcase top surface 0.01 to 0.07 -- Replace Bore diameter φ114 to 114.02 φ114.25 Difference in flange projec- tion from neighboring cylin- der liner 0.04 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (connecting rod cap installation) 29 {3.0} + 90° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required Connecting rod bearing inside surface Upper crankcase contact surface of cylinder liner Piston outside surface Cylinder liner wall surface PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0088.djvu===--- 11-50 Disassembly sequence 1 Lower connecting rod bearing 2 Connecting rod cap 3 Upper connecting rod bearing 4 Piston and connecting rod (See later sections.) 5 Cylinder liner * a: Upper crankcase * b: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Piston projection from upper crankcase top surface (av- erage value) --0.088 to 0.094 -- Replace -- Connecting rod end play 0.15 to 0.45 0.6 Replace 1, 3 Connecting rod bearing span when free -- 69.5 Replace 1, 3, * b Connecting rod bearing-to-crankshaft oil clearance 0.034 to 0.093 0.2 4, 5 Piston-to-cylinder liner clearance 0.181 to 0.201 -- Replace 5 Cylinder liner Flange projection above crankcase top surface 0.01 to 0.07 -- Replace Bore diameter φ114 to 114.02 φ114.25 Difference in flange projec- tion from neighboring cylin- der liner 0.04 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (connecting rod cap installation) 29 {3.0} + 90° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required Connecting rod bearing inside surface Upper crankcase contact surface of cylinder liner Piston outside surface Cylinder liner wall surface PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0089.djvu===--- 11 11-51 Special tools (Unit: mm) Work before removal Retaining cylinder liners The cylinder liners slips out of the upper crankcase easily when the upper crankcase is turned over or the crankshaft is rotated with pistons inside liners. To prevent this from happening, retain the flange of each cylinder liner in position with a bolt and wash- er. Mark Tool name and shape Part No. Application Piston guide clamp MH063432 Installation of piston and connecting rod assembly Piston guide lever MH061658 Cylinder liner extractor MH062537 Removal of cylinder liner Cylinder liner installer MH063606 Installation of cylinder liner Adapter MH063433 Measurement of cylinder liner flange projection above upper crankcase top surface and difference in flange pro- jection between neighboring cylinder liners Bolt MF130625 Washer MH005012 A φ113.5 AB 40 M14×2 ---===WSE_1505_00010_0090.djvu===--- 11-52 Inspection: Piston projection from upper crankcase top sur- face CAUTION The amount of piston projection affects engine perfor- mance and must therefore be inspected without fail. Set the piston at the top dead center. Mark reference points A (five points in total) on the top surface of the upper crankcase as shown in the illustration. Using each of the marks as a zero point, measure the amount of piston projec- tion relative to the zero point (height of measurement point B -- height of reference point A). Make the measurements at the two measurement points B for each cylinder (eight points in total) using the reference point A nearest to each measurement point, and calculate the average value of all the measurements. If the average value is out of the standard value range, check the clearances between all relevant parts. Select and use a cylinder head gasket that can accommodate the average piston projection (average value of the eight mea- surements). (See the CYLINDER HEAD section.) Inspection: Connecting rod end play Measure the end play for every connecting rod. If any measurement exceeds the specified limit, replace the de- fective part(s). Inspection: Difference in flange projection between neigh- boring cylinder liners Install on the upper crankcase so that it is not lying on top of any part of the flanges. Tighten to a torque of 49 N·m {5 kgf·m}. Measure the amount of projection of the cylinder liner flange above the upper crankcase top surface. If the measurement is not within the standard value range, in- spect the state of installation of the cylinder liner and then re- place the defective part(s). CAUTION Insufficient projection of the flange can lead to a reduced pressure around the bore of the cylinder head gasket, caus- ing gas leakage. PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0091.djvu===--- 11 11-53 Inspection procedure Inspection: Connecting rod bearing span when free CAUTION Do not attempt to manually expand the bearings. If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Connecting rod bearing-to-crankshaft oil clear- ance Fit the lower bearing to the connecting rod cap and the upper bearing to the connecting rod, then tighten the bolts to a torque of 29 N·m {3.0 kgf·m}. Measure the inside diameter of the bearing and the diameter of the crankshaft pin. If the clearance exceeds the limit, replace the defective part(s). If a bearing has to be replaced with an undersized one, machine the crankshaft pin to the specified undersize diameter. (See the CRANKSHAFT section.) Inspection: Piston-to-cylinder liner clearance If the measurement is not within the standard value range, re- place the defective part(s). A: Cylinder bore measurement (in direction of crankshaft axis) B: Cylinder bore measurement (in direction perpendicular to crankshaft axis) C: Piston diameter measurement (in direction perpendicular to piston pin hole) ---===WSE_1505_00010_0092.djvu===--- 11-54 Replacement of cylinder liner [Removal] [Installation] When replacing cylinder liners, select the cylinder liners which correspond to the size marks on the crankcase and the piston. CAUTION Make sure to use pistons and cylinder liners of the same size. Failure to do so may result in seizures in the engine. Apply a thin coat of engine oil to the surfaces surrounding the cylinder liner of the upper crankcase (the shaded areas in the il- lustration). Insert the cylinder liner into the upper crankcase by pushing down on by hand slowly and evenly. CAUTION Handle the cylinder liner extremely carefully, as its wall is relatively thin and can be easily damaged. Upper crankcase size mark Cylinder liner size mark Piston size mark "1" "1A" "A" "1B" "2A" "2" "2B" "B" PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0093.djvu===--- 11 11-55 Installation procedure Installation: Connecting rod bearings CAUTION Do not reverse the positions of the lower bearing and the upper bearing (with oil hole) when installing, as this may cause seizure in the engine. Installation: Piston and connecting rod Check that the piston ring end gaps are in their correct positions. A: 1st compression ring gap B: 2nd compression ring gap C: Oil ring gap D: Oil ring expander spring gap " ": Front mark on piston Check that the pistons and the cylinder liners have identical size marks ("A" or "B"). Install the pistons in the cylinder liners. Be careful not to scratch the inner surface of the liner and the crankshaft pins. Face the front mark " " of the piston toward the front of the en- gine. Using the adjusting bolt of , adjust the inside diameter of such that it matches the piston's skirt diameter. Remove the tools from the piston and apply engine oil to the fol- lowing parts before reinstalling the tools around the piston rings: Outside surface of piston Inside surface of Inside surface of cylinder liner ---===WSE_1505_00010_0094.djvu===--- 11-56 After installing the piston and connecting rod assembly, align the mating marks on the connecting rod and connecting rod cap and tighten the bolts alternately in the following manner. First tighten the bolt to a torque of 29 N·m {3.0 kgf·m}. Tighten the bolt further by turning it clockwise by 90°. PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0095.djvu===--- MEMO 11-57 11 ---===WSE_1505_00010_0096.djvu===--- 11-58 Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod 8 Piston : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 1 to 3 Piston ring end gap 1st compression ring 0.3 to 0.45 1.5 Replace 2nd compression ring 0.4 to 0.55 Oil ring 0.3 to 0.5 1to3,8 Piston ring side clearance in piston groove 1st compression ring 0.02 to 0.10 0.2 Replace 2nd compression ring 0.065 to 0.105 0.15 Oil ring 0.025 to 0.065 5, 6 Piston pin-to-connecting rod bushing clearance 0.020 to 0.055 0.1 Replace 5, 8 Piston pin-to-piston clearance 0.004 to 0.022 0.05 Replace 7 Connecting rod Bend -- 0.05 Replace Twist -- 0.1 Mark Points of application Specified lubricant and/or sealant Quantity Piston pin outside surface Engine oil As required Connecting rod bushing outside surface Connecting rod bushing fitting surface of connecting rod PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0096.djvu===--- 11-58 Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod 8 Piston : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 1 to 3 Piston ring end gap 1st compression ring 0.3 to 0.45 1.5 Replace 2nd compression ring 0.4 to 0.55 Oil ring 0.3 to 0.5 1to3,8 Piston ring side clearance in piston groove 1st compression ring 0.02 to 0.10 0.2 Replace 2nd compression ring 0.065 to 0.105 0.15 Oil ring 0.025 to 0.065 5, 6 Piston pin-to-connecting rod bushing clearance 0.020 to 0.055 0.1 Replace 5, 8 Piston pin-to-piston clearance 0.004 to 0.022 0.05 Replace 7 Connecting rod Bend -- 0.05 Replace Twist -- 0.1 Mark Points of application Specified lubricant and/or sealant Quantity Piston pin outside surface Engine oil As required Connecting rod bushing outside surface Connecting rod bushing fitting surface of connecting rod PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0096.djvu===--- 11-58 Piston and Connecting Rod Disassembly sequence 1 1st compression ring 2 2nd compression ring 3 Oil ring 4 Snap ring 5 Piston pin 6 Connecting rod bushing 7 Connecting rod 8 Piston : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 1 to 3 Piston ring end gap 1st compression ring 0.3 to 0.45 1.5 Replace 2nd compression ring 0.4 to 0.55 Oil ring 0.3 to 0.5 1to3,8 Piston ring side clearance in piston groove 1st compression ring 0.02 to 0.10 0.2 Replace 2nd compression ring 0.065 to 0.105 0.15 Oil ring 0.025 to 0.065 5, 6 Piston pin-to-connecting rod bushing clearance 0.020 to 0.055 0.1 Replace 5, 8 Piston pin-to-piston clearance 0.004 to 0.022 0.05 Replace 7 Connecting rod Bend -- 0.05 Replace Twist -- 0.1 Mark Points of application Specified lubricant and/or sealant Quantity Piston pin outside surface Engine oil As required Connecting rod bushing outside surface Connecting rod bushing fitting surface of connecting rod PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0097.djvu===--- 11 11-59 Special tools Removal procedure Removal: Piston ring Removal: Piston pin Remove the piston pin by striking it with a rod and hammer. If the piston pin is difficult to remove, first heat the piston in hot water or with a piston heater. Inspection procedure Inspection: Piston ring end gap Using the crown of a piston, push the piston ring horizontally into a cylinder in the cylinder liner until it reaches the lower part of the cylinder liner, where there is relatively small wear. Taking care not to move the piston ring, measure the end gap. If any of the rings has a gap exceeding the specified limit, re- place all the piston rings as a set. Mark Tool name and shape Part No. Application Piston ring tool MH060014 Removal and installation of piston rings Connecting rod bushing puller kit MH062225 Removal and installation of connect- ing rod bushings ---===WSE_1505_00010_0097.djvu===--- 11 11-59 Special tools Removal procedure Removal: Piston ring Removal: Piston pin Remove the piston pin by striking it with a rod and hammer. If the piston pin is difficult to remove, first heat the piston in hot water or with a piston heater. Inspection procedure Inspection: Piston ring end gap Using the crown of a piston, push the piston ring horizontally into a cylinder in the cylinder liner until it reaches the lower part of the cylinder liner, where there is relatively small wear. Taking care not to move the piston ring, measure the end gap. If any of the rings has a gap exceeding the specified limit, re- place all the piston rings as a set. Mark Tool name and shape Part No. Application Piston ring tool MH060014 Removal and installation of piston rings Connecting rod bushing puller kit MH062225 Removal and installation of connect- ing rod bushings ---===WSE_1505_00010_0098.djvu===--- 11-60 Inspection: Piston ring side clearance in piston groove Remove any carbon deposits from the ring groove in the piston before measurement. Measure the side clearance of each ring around the piston's en- tire periphery. If any of the measurements exceeds the specified limit, replace the defective part(s). If any of the piston rings is defective, re- place all the rings on the piston as a set. Inspection: Piston pin-to-piston clearance If the measurement exceeds the specified limit, replace the de- fective part(s). Inspection: Piston pin-to-connecting rod bushing clearance If any of the measurements exceeds the specified limit, replace the bushing. Replacement of connecting rod bushing Replace the connecting rod bushing using . [Removal] Remove the upper bearing (if fitted) from the big end of the con- necting rod. Mount the connecting rod on the base and lock it in position with the bracket and plate. Fit collar A over the puller with its ends facing in the illustrated di- rections. Then, slowly apply a pressure of approximately 49 kN {5000 kgf} to the puller with a press to force out the connecting rod bushing. PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0099.djvu===--- 11 11-61 [Installation] Apply engine oil to the outside surface of the connecting rod bushing and the bushing fitting surface of the connecting rod. Fit collar B, the bushing, and collar A over the puller in the illus- trated directions and lock this arrangement together with the nut. Align the oil holes in the connecting rod bushing and the con- necting rod. Then, use a press to slowly apply a pressure of ap- proximately 49 kN {5000 kgf} to the puller until the bushing is forced into place. After press-fitting the connecting rod bushing, measure the clearance between the piston pin and connecting rod bushing. If the measurement is less than the standard clearance range, ream the bushing. Inspection: Connecting rod bend and twist Mount the connecting rod on the connecting rod aligner. Also mount the connecting rod bearings, piston pin, and connecting rod cap to create the same conditions as are expected when the connecting rod is mounted on a crankshaft. Tighten the bolts of the connecting rod bearing cap to a torque of 29 N·m {3.0 kgf·m } . Measure the extent of bend and twist in the connecting rod. If either measurement exceeds the specified limit, replace the connecting rod. ---===WSE_1505_00010_0100.djvu===--- 11-62 Installation procedure Installation: Piston and connecting rod Install pistons and connecting rods as follows when replacing them. All connecting rods used in the same engine must be of the same weight size mark. Weight mark: "C" to "G" Apply engine oil to the piston pin, and assemble the piston and connecting rod with their marks facing in the illustrated direc- tions. " ": Front mark on piston "F" : Front mark on connecting rod If the piston pin is difficult to insert, heat the piston in hot water or with a piston heater Installation: Piston rings With the manufacturer's marks (found near the piston ring end gaps) facing up, install the piston rings so that the end gap of each ring is positioned as illustrated. A: 1st compression ring end gap B: 2nd compression ring end gap C: Oil ring end gap D: Oil ring's expander spring end gap " ": Front mark on piston The manufacturer's marks are present only on the 1st and 2nd compression rings. PISTONS, CONNECTING ROD AND CYLINDER LINERS ---===WSE_1505_00010_0101.djvu===--- MEMO 11-63 11 ---===WSE_1505_00010_0102.djvu===--- 11-64 Disassembly sequence 1 Plate 2 Bearing 3 Ring gear 4 Flywheel * a: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 4 Flywheel Friction surface runout (when fitted) -- 0.2 Rectify or replace Friction surface height 19.5 18.5 Replace Friction surface distortion 0.05 0.2 Rectify or replace Friction surface parallelism 0.1 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (flywheel assembly installation) 58 {5.9} + 40° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required FLYWHEEL ---===WSE_1505_00010_0102.djvu===--- 11-64 Disassembly sequence 1 Plate 2 Bearing 3 Ring gear 4 Flywheel * a: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 4 Flywheel Friction surface runout (when fitted) -- 0.2 Rectify or replace Friction surface height 19.5 18.5 Replace Friction surface distortion 0.05 0.2 Rectify or replace Friction surface parallelism 0.1 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (flywheel assembly installation) 58 {5.9} + 40° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required FLYWHEEL ---===WSE_1505_00010_0102.djvu===--- 11-64 Disassembly sequence 1 Plate 2 Bearing 3 Ring gear 4 Flywheel * a: Crankshaft : Locating pin Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 4 Flywheel Friction surface runout (when fitted) -- 0.2 Rectify or replace Friction surface height 19.5 18.5 Replace Friction surface distortion 0.05 0.2 Rectify or replace Friction surface parallelism 0.1 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (flywheel assembly installation) 58 {5.9} + 40° Wet Mark Points of application Specified lubricant and/or sealant Quantity Bolt threads Engine oil As required FLYWHEEL ---===WSE_1505_00010_0103.djvu===--- 11 11-65 Special tools (Unit: mm) Work before removal Inspection: Flywheel friction surface runout If the runout exceeds the specified limit, check that the bolts are tightened correctly and that there are no abnormalities on the crankshaft mounting surface, then rectify or replace the flywheel. Inspection procedure Inspection: Ring gear Check the ring gear of the flywheel by watching and touching. If there is damage or abnormal wear on it, replace the ring gear following the procedure below. [Removal] Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C, then remove it from the flywheel assembly. WARNING Never touch the heated ring gear, otherwise you may burn yourself. [Installation] Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C. WARNING Never touch the heated ring gear, otherwise you may burn yourself. Fit the ring gear with the side having non-chamfered tooth edges toward the flywheel. Mark Tool name and shape Part No. Application Socket wrench MH062183 Installation of flywheel assembly Magnet base MH062356 ---===WSE_1505_00010_0103.djvu===--- 11 11-65 Special tools (Unit: mm) Work before removal Inspection: Flywheel friction surface runout If the runout exceeds the specified limit, check that the bolts are tightened correctly and that there are no abnormalities on the crankshaft mounting surface, then rectify or replace the flywheel. Inspection procedure Inspection: Ring gear Check the ring gear of the flywheel by watching and touching. If there is damage or abnormal wear on it, replace the ring gear following the procedure below. [Removal] Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C, then remove it from the flywheel assembly. WARNING Never touch the heated ring gear, otherwise you may burn yourself. [Installation] Heat the ring gear evenly with a gas burner or the like until it reaches approximately 200°C. WARNING Never touch the heated ring gear, otherwise you may burn yourself. Fit the ring gear with the side having non-chamfered tooth edges toward the flywheel. Mark Tool name and shape Part No. Application Socket wrench MH062183 Installation of flywheel assembly Magnet base MH062356 ---===WSE_1505_00010_0104.djvu===--- 11-66 Inspection: Flywheel (1) Friction surface height If the height is below the specified limit, replace the flywheel. (2) Friction surface distortion If the measured amount of distortion is above the specified limit, rectify or replace the flywheel assembly. Rectification of friction surface Rectify the friction surface so that its height is not below the specified limit, and it is parallel with surface A with an error not exceeding 0.1 mm. Installation procedure Installation: Flywheel Tighten all the bolts to 58 N·m {5.9 kgf·m} and then additionally tighten them by the following procedure. Rotate the holder of counterclockwise to pretension the in- ternal spring. Fit on the bolt and set so that the rod (extension) is held pressed against it by the spring force. Align a scale mark on the socket with a scale mark on the hold- er. (This point will be the point of reference, or the 0° point.) Starting with this point of reference, turn the socket clockwise with a wrench by 40° (one graduation on the socket scale repre- sents 10°). FLYWHEEL ---===WSE_1505_00010_0105.djvu===--- MEMO 11-67 11 ---===WSE_1505_00010_0106.djvu===--- 11-68 Disassembly sequence CAUTION Do not remove the front oil seal unless defects are evident. Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (power steering oil pipe installation) 29.4 to 39.2 {3 to 4} -- Vacuum pipe 29.4 {3.0} -- Nut (fan pulley installation) 373 {38} -- Eyebolt (oil jet installation) 10 {1.0} -- Bolt (vacuum pump installation) 24 {2.4} -- 1 Power steering oil pipe 2 Power steering oil hose 3 Power steering oil pump (See Gr37.) 4 O-ring 5 Vacuum pipe 6 Vacuum pump (See Gr35.) 7 O-ring 8 Water pump (See Gr14.) 9 Gasket 10 Fan pulley 11 Front oil seal 12-- 13-- 14 Front case 15 Eyebolt 16 Oil jet 17 O-ring 18 Front oil seal slinger : Non-reusable parts FRONT CASE ---===WSE_1505_00010_0106.djvu===--- 11-68 Disassembly sequence CAUTION Do not remove the front oil seal unless defects are evident. Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (power steering oil pipe installation) 29.4 to 39.2 {3 to 4} -- Vacuum pipe 29.4 {3.0} -- Nut (fan pulley installation) 373 {38} -- Eyebolt (oil jet installation) 10 {1.0} -- Bolt (vacuum pump installation) 24 {2.4} -- 1 Power steering oil pipe 2 Power steering oil hose 3 Power steering oil pump (See Gr37.) 4 O-ring 5 Vacuum pipe 6 Vacuum pump (See Gr35.) 7 O-ring 8 Water pump (See Gr14.) 9 Gasket 10 Fan pulley 11 Front oil seal 12-- 13-- 14 Front case 15 Eyebolt 16 Oil jet 17 O-ring 18 Front oil seal slinger : Non-reusable parts FRONT CASE ---===WSE_1505_00010_0106.djvu===--- 11-68 Disassembly sequence CAUTION Do not remove the front oil seal unless defects are evident. Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (power steering oil pipe installation) 29.4 to 39.2 {3 to 4} -- Vacuum pipe 29.4 {3.0} -- Nut (fan pulley installation) 373 {38} -- Eyebolt (oil jet installation) 10 {1.0} -- Bolt (vacuum pump installation) 24 {2.4} -- 1 Power steering oil pipe 2 Power steering oil hose 3 Power steering oil pump (See Gr37.) 4 O-ring 5 Vacuum pipe 6 Vacuum pump (See Gr35.) 7 O-ring 8 Water pump (See Gr14.) 9 Gasket 10 Fan pulley 11 Front oil seal 12-- 13-- 14 Front case 15 Eyebolt 16 Oil jet 17 O-ring 18 Front oil seal slinger : Non-reusable parts FRONT CASE ---===WSE_1505_00010_0107.djvu===--- 11 11-69 Lubricant and/or sealant Special tools (Unit: mm) Removal procedure Removal: Vacuum pump The vacuum pump also serves for positioning the balance shaft LH. Therefore, before removing the vacuum pump, hold the bal- ance shaft in position by the following procedure. Align the pointer A to between the inscribed lines (I and IV or 1 and 4) on the flywheel. (Place No. 1 cylinder piston at the top dead center on compression stroke.) Remove the upper crankcase plug. Mark a screwdriver or the like (φ4.5 mm or less) at a point 40 mm apart from its tip. Insert the screwdriver or the like (φ4.5 mm or less) into the plug hole until it lightly touches the balance shaft LH. CAUTION Do not press the screwdriver hard against the balance shaft LH, as this may damage No. 1 journal of the balance shaft. Put the tip of the screwdriver or the like into the shaft supporting hole at No. 1 journal of the balance shaft. This insertion depth of the screwdriver or the like into the shaft supporting hole should be 5 mm. Remove the vacuum pump with the screwdriver or the like in- serted in the hole. Installation: Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts. Loosen the fan pulley mounting nut while holding . Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Front oil seal lip Front case installation surfaces ThreeBond 1207C or D As required Mark Tool name and shape Part No. Application Holding bar MH062970 Holding of fan pulley AB 114 φ9 ---===WSE_1505_00010_0108.djvu===--- 11-70 Installation procedure Installation: Oil jet When installed, the oil jet must be in contact with the front case and its nozzle must face in the illustrated direction. Installation: Front case Clean the sealant application surfaces of each part. Apply evenly thick beads of sealant to the upper crankcase mounting surface of the front case without any breaks. Mount the front case within three minutes of applying the seal- ant, being careful not to dislodge the sealant. CAUTION Do not run the engine within one hour of installing the front case. If the front case mounting bolts are loosened or removed, be sure to reapply sealant to the front case. Installation: Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts. Tighten the fan pulley mounting nut to the specified torque while holding . Installation: Vacuum pump The vacuum pump also serves as an element holding the bal- ance shaft LH in place. Therefore, before installing the vacuum pump, hold the balance shaft LH in the correct position by the following procedure. Place the No. 1 cylinder piston at the top dead center on com- pression stroke. Remove the upper crankcase plug. Insert a screwdriver or a similar tool into the plug hole until it lightly touches the balance shaft LH. CAUTION Do not press the screwdriver strongly against the balance shaft LH, as this may damage the No. 1 journal of the bal- ance shaft. Turn the balance shaft LH slowly until the screwdriver aligns with the shaft support hole at the No. 1 journal and insert the screwdriver into the hole. Install the vacuum pump. After installing the vacuum pump, remove the screwdriver and reinstall the plug. FRONT CASE ---===WSE_1505_00010_0109.djvu===--- MEMO 11-71 11 ---===WSE_1505_00010_0110.djvu===--- 11-72 TIMING GEARS AND BALANCE SHAFTS ---===WSE_1505_00010_0111.djvu===--- 11 11-73 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Backlash between gears Idler gear and fan shaft 0.09 to 0.14 0.3 Replace Fan shaft and No. 1 idler gear 0.06 to 0.10 0.3 No. 1 idler gear and crankshaft gear 0.11 to 0.13 0.3 No. 1 idler gear and supply pump idler gear 0.12 to 0.15 0.3 Oil pump gear and crankshaft gear 0.12 to 0.15 0.3 Oil pump gear and balance shaft gear RH 0.19 to 0.22 0.3 -- End play of gears and shafts Idler gear 0.10 to 0.20 0.3 Replace Fan shaft 0.07 to 0.19 0.3 No. 1 idler gear 0.15 to 0.25 0.3 Balance shaft RH 0.1 to 0.2 0.3 Balance shaft LH 0.1 to 0.2 0.3 2, 4 Idler gear bushing-to-idler shaft clearance 0.02 to 0.06 0.1 Replace 5, 8 Fan shaft case bushing-to-fan shaft clearance 0.03 to 0.07 0.1 Replace 8, 9 Fan shaft-to-fan gear shaft clearance 0.01 to 0.05 0.1 Replace 11, 13 No. 1 idler gear bushing-to-No. 1 idler shaft clearance 0.03 to 0.07 0.1 Replace 20 Balance shaft RH bend 0.025 0.05 Replace 25 Balance shaft LH bend 0.025 0.05 Replace Mark Parts to be tightened Tightening torque Remarks Bolt (idler shaft installation) 32.3 {3.3} -- Bolt (No. 1 idler shaft installation) 53.9 {5.5} -- Nut (balance shaft gear installation) 96.1 {9.8} Wet Mark Points of application Specified lubricant and/or sealant Quantity Inner surface of every bushing Engine oil As required Outside surface of every shaft O-rings Nut threads Balance shaft journals 1 Thrust plate 2 Idler gear bushing 3 Idler gear 4 Idler shaft 5 Fan shaft case bushing 6 Fan shaft case 7 Thrust plate 8 Fan shaft 9 Fan gear shaft 10 Thrust plate 11 No. 1 idler gear bushing 12 No. 1 idler gear 13 No. 1 idler shaft 14 Oil pump (See Gr12.) 15 O-ring 16 Balance shaft gear RH 17 Thrust spacer 18 Key 19 Thrust plate 20 Balance shaft RH 21 Balance shaft gear LH 22 Thrust spacer 23 Key 24 Thrust plate 25 Balance shaft LH * a: Crankshaft gear * b: Supply pump idler gear : Locating pin : Non-reusable parts ---===WSE_1505_00010_0111.djvu===--- 11 11-73 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Backlash between gears Idler gear and fan shaft 0.09 to 0.14 0.3 Replace Fan shaft and No. 1 idler gear 0.06 to 0.10 0.3 No. 1 idler gear and crankshaft gear 0.11 to 0.13 0.3 No. 1 idler gear and supply pump idler gear 0.12 to 0.15 0.3 Oil pump gear and crankshaft gear 0.12 to 0.15 0.3 Oil pump gear and balance shaft gear RH 0.19 to 0.22 0.3 -- End play of gears and shafts Idler gear 0.10 to 0.20 0.3 Replace Fan shaft 0.07 to 0.19 0.3 No. 1 idler gear 0.15 to 0.25 0.3 Balance shaft RH 0.1 to 0.2 0.3 Balance shaft LH 0.1 to 0.2 0.3 2, 4 Idler gear bushing-to-idler shaft clearance 0.02 to 0.06 0.1 Replace 5, 8 Fan shaft case bushing-to-fan shaft clearance 0.03 to 0.07 0.1 Replace 8, 9 Fan shaft-to-fan gear shaft clearance 0.01 to 0.05 0.1 Replace 11, 13 No. 1 idler gear bushing-to-No. 1 idler shaft clearance 0.03 to 0.07 0.1 Replace 20 Balance shaft RH bend 0.025 0.05 Replace 25 Balance shaft LH bend 0.025 0.05 Replace Mark Parts to be tightened Tightening torque Remarks Bolt (idler shaft installation) 32.3 {3.3} -- Bolt (No. 1 idler shaft installation) 53.9 {5.5} -- Nut (balance shaft gear installation) 96.1 {9.8} Wet Mark Points of application Specified lubricant and/or sealant Quantity Inner surface of every bushing Engine oil As required Outside surface of every shaft O-rings Nut threads Balance shaft journals 1 Thrust plate 2 Idler gear bushing 3 Idler gear 4 Idler shaft 5 Fan shaft case bushing 6 Fan shaft case 7 Thrust plate 8 Fan shaft 9 Fan gear shaft 10 Thrust plate 11 No. 1 idler gear bushing 12 No. 1 idler gear 13 No. 1 idler shaft 14 Oil pump (See Gr12.) 15 O-ring 16 Balance shaft gear RH 17 Thrust spacer 18 Key 19 Thrust plate 20 Balance shaft RH 21 Balance shaft gear LH 22 Thrust spacer 23 Key 24 Thrust plate 25 Balance shaft LH * a: Crankshaft gear * b: Supply pump idler gear : Locating pin : Non-reusable parts ---===WSE_1505_00010_0112.djvu===--- 11-74 Special tools (Unit: mm) Work before removal Inspection: Backlash between gears For each pair of gears, measure the backlash at more than three teeth. If any of the measurements exceeds the specified limit, replace the defective part(s). Inspection: End play of gears and shafts If the measurement exceeds the specified limit, replace the de- fective part(s). Removal procedure Removal: Balance shaft Remove the balance shaft RH by turning its nut counterclock- wise, and the balance shaft LH by turning its nut clockwise. Mark Tool name and shape Part No. Application Idler gear bushing puller MH062540 Removal and installation of idler gear bushing Idler gear bushing puller MH062601 Removal and installation of fan shaft case bushing Idler gear bushing puller MH062541 Removal and installation of No. 1 idler gear bushing AB φ46.5 φ50 AB φ37 φ40 AB φ54.5 φ58 TIMING GEARS AND BALANCE SHAFTS ---===WSE_1505_00010_0112.djvu===--- 11-74 Special tools (Unit: mm) Work before removal Inspection: Backlash between gears For each pair of gears, measure the backlash at more than three teeth. If any of the measurements exceeds the specified limit, replace the defective part(s). Inspection: End play of gears and shafts If the measurement exceeds the specified limit, replace the de- fective part(s). Removal procedure Removal: Balance shaft Remove the balance shaft RH by turning its nut counterclock- wise, and the balance shaft LH by turning its nut clockwise. Mark Tool name and shape Part No. Application Idler gear bushing puller MH062540 Removal and installation of idler gear bushing Idler gear bushing puller MH062601 Removal and installation of fan shaft case bushing Idler gear bushing puller MH062541 Removal and installation of No. 1 idler gear bushing AB φ46.5 φ50 AB φ37 φ40 AB φ54.5 φ58 TIMING GEARS AND BALANCE SHAFTS ---===WSE_1505_00010_0113.djvu===--- 11 11-75 Inspection procedure Inspection: Idler gear bushing-to-idler shaft clearance If the measurement exceeds the specified limit, replace the bushing. Replacement of idler gear bushing [Removal] [Installation] Place the idler gear with its ends facing as illustrated. Press-fit the idler gear bushing until sits snugly on the chamfered end of the idler gear. After press-fitting the bushing, measure the clearance. If the measurement is less than the minimum of the standard value range, ream the idler gear bushing until the clearance falls within the standard value range. Inspection: Fan shaft case bushing-to-fan shaft clearance Replace the fan shaft case bushing if the measurement exceeds the specified limit. Replacement of fan shaft case bushing [Removal] ---===WSE_1505_00010_0114.djvu===--- 11-76 [Installation] Position the fan shaft case with its ends facing in the illustrated directions. Press in the bushing until rests snugly on the chamfered end of the fan shaft case. After press-fitting the bushing, remeasure the clearance be- tween it and the fan shaft. Ream the bushing if the measurement is below the standard val- ue range. Inspection: Fan shaft-to-fan gear shaft clearance Replace the fan shaft if the measurement exceeds the specified limit. Inspection: No. 1 idler gear bushing-to-No. 1 idler shaft clearance Replace the bushing if the measurement exceeds the specified limit. Replacement of No. 1 idler gear bushing [Removal] [Installation] Position the No. 1 idler gear with its ends facing in the illustrated directions. Press in the gear bushing until sits snugly on the cham- fered end of the No. 1 idler gear. After press-fitting the bushing, remeasure the clearance be- tween it and the No. 1 idler shaft. Ream the busing if the measurement is below the standard val- ue range. TIMING GEARS AND BALANCE SHAFTS ---===WSE_1505_00010_0115.djvu===--- 11 11-77 Inspection: Balance shaft bend Place supports under the No. 1 and No. 3 journals of the bal- ance shaft and measure the bend of the balance shaft at the No. 2 journal. The amount of balance shaft bend is obtained by giving the bal- ance shaft one turn and dividing the dial gauge reading by two. If the measurement exceeds the specified limit, replace the bal- ance shaft. Installation procedure Installation: Balance shafts Install all the indicated parts on each balance shaft with their ends facing in the illustrated directions. Tighten the nut for the balance shaft RH by turning it clockwise, and the nut for the balance shaft LH by turning it counterclock- wise. Install the assembled balancer shafts, RH and LH, to the crank- case in the following ways. Procedures for RH and LH shafts are different. Balancer shaft RH: No special positioning or the like is re- quired. Just install the shaft to the crankcase. (Adjustment of balancer shaft timing will be performed when installing the oil pump.) Balancer shaft LH: The gear of the balancer shaft LH is en- gaged with the vacuum pump gear after installing the front case. At that moment, the balancer shaft cannot be rotated and therefore the shaft timing cannot be adjusted. For this reason, the position of the balancer shaft LH must be fixed when installing the shaft. Insert the balancer shaft LH into the crankcase and then do as follows: Remove the plug on the upper crankcase. Prepare a Philips screwdriver with 4.5 mm or smaller shaft di- ameter. Mark the point 40 mm from the tip of the shaft. Insert the screwdriver into the plug hole until it lightly contacts the balancer shaft. CAUTION Do not apply heavy force on the screwdriver. Doing so may damage the No. 1 journal of the balancer shaft LH. ---===WSE_1505_00010_0116.djvu===--- 11-78 Turn the balancer shaft LH while applying light force on the screwdriver. The screwdriver will enter into the shaft locking hole and the balancer shaft will be locked. When the screwdriver enters into the locking hole, it will sink by5mm. Keep the balancer shaft LH locked until the vacuum pump is installed. Installation: Timing gears Install the oil pump gear by aligning mating mark "6" with that on the crankshaft gear, and mating mark "7" with that on the bal- ance shaft gear RH. Install the No. 1 idler gear by aligning mating mark "1" with that on the crankshaft gear. Install the fan shaft by aligning mating mark "2" with that on the No. 1 idler gear. Install the idler gear by aligning mating mark "4" with that on the fan shaft. TIMING GEARS AND BALANCE SHAFTS ---===WSE_1505_00010_0117.djvu===--- MEMO 11-79 11 ---===WSE_1505_00010_0118.djvu===--- 11-80 Disassembly sequence CAUTION The lower crankcase and the upper crankcase are machined as a matched set, and cannot be replaced in- dividually. Assembly sequence Follow the disassembly sequence in reverse. 1 Rear plate 2 Rear oil seal 3 Main bearing cap bolt 4 No. 1 Lower main bearing 5 Lower main bearing 6 Lower crankcase 7 Lower thrust plate 8 Upper thrust plate 9 Crankshaft gear 10 Rear oil seal slinger 11 Crankshaft 12 Upper main bearing 13 Check valve 14 Oil jet 15 Upper crankcase : Locating pin : Non-reusable parts CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0118.djvu===--- 11-80 Disassembly sequence CAUTION The lower crankcase and the upper crankcase are machined as a matched set, and cannot be replaced in- dividually. Assembly sequence Follow the disassembly sequence in reverse. 1 Rear plate 2 Rear oil seal 3 Main bearing cap bolt 4 No. 1 Lower main bearing 5 Lower main bearing 6 Lower crankcase 7 Lower thrust plate 8 Upper thrust plate 9 Crankshaft gear 10 Rear oil seal slinger 11 Crankshaft 12 Upper main bearing 13 Check valve 14 Oil jet 15 Upper crankcase : Locating pin : Non-reusable parts CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0118.djvu===--- 11-80 Disassembly sequence CAUTION The lower crankcase and the upper crankcase are machined as a matched set, and cannot be replaced in- dividually. Assembly sequence Follow the disassembly sequence in reverse. 1 Rear plate 2 Rear oil seal 3 Main bearing cap bolt 4 No. 1 Lower main bearing 5 Lower main bearing 6 Lower crankcase 7 Lower thrust plate 8 Upper thrust plate 9 Crankshaft gear 10 Rear oil seal slinger 11 Crankshaft 12 Upper main bearing 13 Check valve 14 Oil jet 15 Upper crankcase : Locating pin : Non-reusable parts CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0119.djvu===--- 11 11-81 CAUTION The main bearing cap bolts are tightened using the torque-turn tightening method. Any bolt that has three punch marks must be replaced. Do not overtighten the check valve. If it is tightened to a torque exceeding the specification, the check valve may malfunction, resulting in seizures in the engine. The No. 1 lower bearing has a oil groove. Be sure to install it in the correct position, otherwise a crank- shaft seizure may result. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy -- Crankshaft end play 0.10 to 0.28 0.4 Replace thrust plate 4, 5, 11, 12 Main bearing-to-crankshaft oil clear- ance All except No. 3 0.038 to 0.1 0.15 Replace No. 3 0.058 to 0.12 4, 5, 12 Main bearing span when free -- 91.5 11 Crankshaft Bend 0.02 or less 0.05 Replace Pins and journals Out-of-round- ness 0.01 or less 0.03 Rectify or replace Taper 0.006 or less -- Center-to-center distance between the journal and pin 60 ± 0.05 -- Replace Journal width No. 1 33.5 -- No.2to4 35 -- No. 5 35 -- Pin width 41 -- Fillet R4 -- 15 Upper crankcase Distortion of top surface 0.07 or less 0.2 Rectify or replace Cylinder block Roundness 0.005 or less -- Replace Cylindricity 0.015 or less -- Mark Parts to be tightened Tightening torque Remarks Bolt (rear plate installation) 64 {6.5} -- Bolt (lower crankcase installation) 23.5 {2.4} Wet Main cap bolt (lower crankcase installation) 50 {5.1} +90° Wet Reusable up to 3 times Check valve 29 {3.0} Wet Mark Points of application Specified lubricant and/or sealant Quantity Rear oil seal lip Engine oil As required Bolt and main bearing cap bolt threads and seating sur- face of head Main bearing inside surface Check valve threads Upper and lower crankcase mating surface of rear oil seal ThreeBond 1217H As required Lower crankcase mounting surface of upper crankcase +0.039 0 +0.12 0 ---===WSE_1505_00010_0120.djvu===--- 11-82 Special tools (Unit: mm) Work before removal Inspection: Crankshaft end play If the measurement exceeds the specified limit, replace the thrust plates with oversize ones. Available oversizes: +0.15 mm, +0.30 mm, +0.45 mm Replace the crankshaft if the end play is too large to adjust using oversize thrust plates. Removal procedure Removal: Lower crankcase Loosen the bolts in several passes in the order indicated in the illustration (1 to 16). After loosening the bolts, loosen the main cap bolts in several passes in the order indicated in the illustration (17 to 26), then remove the main cap bolts. Removal: Crankshaft gear CAUTION Do not tap off the crankshaft gear as this can damage it. Removal: Rear oil seal slinger Taking care not to damage the crankshaft, split the rear oil seal slinger using a chisel or a similar tool. Mark Tool name and shape Part No. Application Gear puller MH061326 Removal of crankshaft gear Rear oil seal slinger installer MH062677 Installation of rear oil seal slinger ABC φ103 φ100 φ15 CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0120.djvu===--- 11-82 Special tools (Unit: mm) Work before removal Inspection: Crankshaft end play If the measurement exceeds the specified limit, replace the thrust plates with oversize ones. Available oversizes: +0.15 mm, +0.30 mm, +0.45 mm Replace the crankshaft if the end play is too large to adjust using oversize thrust plates. Removal procedure Removal: Lower crankcase Loosen the bolts in several passes in the order indicated in the illustration (1 to 16). After loosening the bolts, loosen the main cap bolts in several passes in the order indicated in the illustration (17 to 26), then remove the main cap bolts. Removal: Crankshaft gear CAUTION Do not tap off the crankshaft gear as this can damage it. Removal: Rear oil seal slinger Taking care not to damage the crankshaft, split the rear oil seal slinger using a chisel or a similar tool. Mark Tool name and shape Part No. Application Gear puller MH061326 Removal of crankshaft gear Rear oil seal slinger installer MH062677 Installation of rear oil seal slinger ABC φ103 φ100 φ15 CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0121.djvu===--- 11 11-83 Inspection procedure Inspection: Main bearing span when free CAUTION Do not attempt to manually expand the bearings. If the measurement is less than the limit, replace upper and low- er bearings as a set. Inspection: Main bearing-to-crankshaft oil clearance Fit the upper bearing into the upper crankcase and the lower bearing into the lower crankcase. Tighten the main bearing cap bolts to a torque of 49 N·m {5.0 kgf·m}. Measure the inside diameter of the main bearing and the diame- ter of the corresponding crankshaft journal. If the difference between the measurements exceeds the speci- fied limit, machine the crankshaft journal to one of the specified undersize dimensions indicated on the next page. Inspection: Crankshaft (1) Bend Support the crankshaft at its No. 1 journal and No. 5 journal. Measure the extent of bending in the crankshaft at the center of the No. 3 journal. The amount of crankshaft bend is obtained by giving the crank- shaft one turn and dividing the dial gauge reading by two. If the measurement exceeds the specified limit, replace the crankshaft. (2) Out-of-roundness and taper of crankshaft journals and pins If any of the measurements exceeds the specified limits, grind the crankshaft journal(s) and/or pin(s) to undersize(s) or replace the crankshaft. ---===WSE_1505_00010_0122.djvu===--- 11-84 Grinding of crankshaft CAUTION If the crankshaft is ground to an undersize, the main bear- ings must be replaced with the undersize ones of the corre- sponding undersize. See the table of the service standards for the dimension of each part, and collect the parts as follows. Do not change the center-to-center distance A between the jour- nal and pin. A: 60±0.05mm Do not change the journal width B and the pin width C. B: 33.5 mm (No. 1 journal) 35 mm (No. 2 to No. 4 journals) 35 mm (No. 5 journal) C: 41 mm (No. 5 journal) Finish the fillets D smoothly. D: R4mm Carry out a magnetic inspection to check for cracks possibly caused by grinding. Also, check that the harness of the surface has not dropped below Shore hardness number (Hs) 75. Replace the crankshaft if defects are evident. Crankshaft undersize dimensions (Unit: mm) When grinding, turn both the crankshaft and the grinder counter- clockwise as viewed from the crankshaft front end. When finishing the crankshaft with whetstone or sandpaper, ro- tate the crankshaft clockwise. Inspection: Distortion of upper crankcase top surface If the measurement exceeds the specified limit, grind the crank- case top surface with a surface grinder. Limit the amount of removed metal to make sure that the amount of piston projection above the crankcase top surface stays within the standard value range. (See the PISTON AND CONNECT- ING ROD section.) Undersizes 0.25 0.50 0.75 1.00 Finished journal diameter No.1,2,4,5 85.68 to 85.70 85.43 to 85.45 85.18 to 85.20 84.93 to 84.95 No. 3 85.66 to 85.68 85.41 to 85.43 85.16 to 85.18 84.91 to 84.93 Finished pin diameter 64.69 to 64.71 64.44 to 64.46 64.19 to 64.21 63.94 to 63.96 Out-of-roundness 0.01 or less Taper 0.006 or less +0.039 0 +0.2 0 CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0123.djvu===--- 11 11-85 Installation procedure Installation: Rear oil seal slinger Press in the rear oil seal slinger until sits snugly on the crankshaft end surface. Installation: Crankshaft gear Heat the crankshaft gear to approximately 150°C with a gas burner or the like. CAUTION Be careful not to get burned. Align the locating pin in the crankshaft with the slot in the crank- shaft gear. Drive the gear into position by lightly striking its end face with a plastic hammer. Installation: Thrust plate Install the thrust plates on both sides of the rearmost main bear- ings with the oil grooves on the inner plates facing inward and those on the outer plates outward as shown in the illustration. CAUTION Be sure to orient the oil grooves as indicated above, other- wise seizures may occur in the engine. Use oversize thrust plates when adjusting the crankshaft end play. The upper and lower thrust plates on the same side must be of the same size. The thrust plates on one side may differ in size from those on the other side. Installation: Main bearings Install the main bearings with their lugs aligned as shown in the illustration. When the crankshaft journals have been ground to an undersize, use undersize main bearings. Available main bearing undersizes: 0.25 mm, 0.50 mm, 0.75 mm, 1.00 mm CAUTION The upper main bearing has an oil hole. The lower main bearing has no oil hole. Do not confuse the upper and lower bearings, as this can cause seizure in the engine. ---===WSE_1505_00010_0124.djvu===--- 11-86 Installation: Lower crankcase CAUTION Before installing the main bearing cap bolts, check the number of punch marks on the head of each bolt. (A bolt with two or less marks is reusable.) The number of punch marks corresponds with the number of times the main cap bolt has been tightened using the torque-turn tightening method. Any bolt that has three marks (i.e. that has been used three times) must be re- placed. Clean all sealant application surfaces. Apply evenly thick beads of sealant to the upper crankcase with- out any breaks as shown in the illustration. Install the lower crankcase within three minutes of applying the sealant, being careful not to dislodge the sealant. Apply engine oil to the main cap bolt threads and seating surfac- es of the bolt heads, then tighten them to a torque of 49 N·m {5.0 kgf·m} in the order indicated in the illustration (1 to 10). Tighten each main cap bolt further by 90° in the same order. Finally, tighten each bolt to the specified torque in the order indi- cated in the illustration (11 to 26). CAUTION After installing the bolts, wait at least an hour before start- ing the engine. Apply new beads of sealant whenever the main cap bolts have been loosened or removed. After tightening the bolts using the above torque-turn tightening method, make a punch mark on the head of each bolt to indicate the number of times that it has been used. CAUTION The bolts that have been tightened using the torque-turn method must never be additionally tightened after the final angular tightening. After installing the main bearing caps, rotate the crankshaft by hand. If it cannot be rotated smoothly, inspect the main bearing caps for correct installation. CRANKSHAFT AND CRANKCASE ---===WSE_1505_00010_0125.djvu===--- 11 11-87 Installation: Rear oil seal Apply engine oil to the lip of the rear oil seal. Clean the seal surface of the crankshaft. Apply a bead of sealant along the line on the rear oil seal evenly without any breaks. Install the rear oil seal within three minutes after applying the sealant. Be careful not to let the applied sealant slip out of place during installation. CAUTION After fitting the rear oil seal, wait at least an hour before starting the engine. Apply a new bead of sealant whenever the mounting bolts of the rear oil seal have been loosened. ---===WSE_1505_00010_0126.djvu===--- 11-88 Disassembly sequence 1 No. 1 balance shaft bushing 2 No. 2 balance shaft bushing 3 No. 3 balance shaft bushing * a: Balance shaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Special tools Inspection procedure Inspection: Balance shaft-to-balance shaft bushing clear- ance Replace the bushing if the measurement exceeds the specified limit. Location Maintenance item Standard value Limit Remedy 1to3, * a Balance shaft-to-balance shaft bushing clearance No. 1 0.055 to 0.099 0.15 Replace No. 2 0.075 to 0.119 No. 3 0.055 to 0.099 Mark Points of application Specified lubricant and/or sealant Quantity Balance shaft bushing inner surface Engine oil As required Mark Tool name and shape Part No. Application Balance shaft bushing in- staller and extractor MH062782 Removal and installation of balance shaft bushing BALANCE SHAFT BUSHINGS ---===WSE_1505_00010_0126.djvu===--- 11-88 Disassembly sequence 1 No. 1 balance shaft bushing 2 No. 2 balance shaft bushing 3 No. 3 balance shaft bushing * a: Balance shaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Special tools Inspection procedure Inspection: Balance shaft-to-balance shaft bushing clear- ance Replace the bushing if the measurement exceeds the specified limit. Location Maintenance item Standard value Limit Remedy 1to3, * a Balance shaft-to-balance shaft bushing clearance No. 1 0.055 to 0.099 0.15 Replace No. 2 0.075 to 0.119 No. 3 0.055 to 0.099 Mark Points of application Specified lubricant and/or sealant Quantity Balance shaft bushing inner surface Engine oil As required Mark Tool name and shape Part No. Application Balance shaft bushing in- staller and extractor MH062782 Removal and installation of balance shaft bushing BALANCE SHAFT BUSHINGS ---===WSE_1505_00010_0126.djvu===--- 11-88 Disassembly sequence 1 No. 1 balance shaft bushing 2 No. 2 balance shaft bushing 3 No. 3 balance shaft bushing * a: Balance shaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Special tools Inspection procedure Inspection: Balance shaft-to-balance shaft bushing clear- ance Replace the bushing if the measurement exceeds the specified limit. Location Maintenance item Standard value Limit Remedy 1to3, * a Balance shaft-to-balance shaft bushing clearance No. 1 0.055 to 0.099 0.15 Replace No. 2 0.075 to 0.119 No. 3 0.055 to 0.099 Mark Points of application Specified lubricant and/or sealant Quantity Balance shaft bushing inner surface Engine oil As required Mark Tool name and shape Part No. Application Balance shaft bushing in- staller and extractor MH062782 Removal and installation of balance shaft bushing BALANCE SHAFT BUSHINGS ---===WSE_1505_00010_0126.djvu===--- 11-88 Disassembly sequence 1 No. 1 balance shaft bushing 2 No. 2 balance shaft bushing 3 No. 3 balance shaft bushing * a: Balance shaft : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Lubricant and/or sealant Special tools Inspection procedure Inspection: Balance shaft-to-balance shaft bushing clear- ance Replace the bushing if the measurement exceeds the specified limit. Location Maintenance item Standard value Limit Remedy 1to3, * a Balance shaft-to-balance shaft bushing clearance No. 1 0.055 to 0.099 0.15 Replace No. 2 0.075 to 0.119 No. 3 0.055 to 0.099 Mark Points of application Specified lubricant and/or sealant Quantity Balance shaft bushing inner surface Engine oil As required Mark Tool name and shape Part No. Application Balance shaft bushing in- staller and extractor MH062782 Removal and installation of balance shaft bushing BALANCE SHAFT BUSHINGS ---===WSE_1505_00010_0127.djvu===--- 11 11-89 Replacement of balance shaft bushing Replace the bushing using . [Removal] To remove the bushings, use the rod fitted with an adapter corre- sponding to the size of each bushing. Unit: mm Remove the No. 1 bushing by tapping on the rod from the front of the engine. Remove the No. 2 bushing by tapping on the rod from the front of the engine. Remove the No. 3 bushing by tapping on the rod from the back of the engine. Bushing Adapter Identification mark ABC No. 1 Left "5" φ55.25 φ 51.5 26.5 Right "6" 21.5 No. 2 "7" φ55 φ51 No. 3 "8" φ 54.75 φ 50.5 ---===WSE_1505_00010_0128.djvu===--- 11-90 [Installation] To install the bushings, use the rod fitted with an adapter corre- sponding to the size of each bushing. Each bushing has an iden- tification mark. These identification marks are used to distinguish between the No. 1, No. 2 and No. 3 bushings. If the identification mark is not clear, measure the outside diameter of the bushing and use the measurement as a means of identifica- tion. Unit: mm Align the oil hole in the No. 3 bushing with the oil hole in the up- per crankcase. Force the No. 3 bushing into the upper crankcase as deep as the mark in the illustration by tapping on the rod from the rear of the engine. Bushing Adapter Guide piece Identi- fica- tion mark Out- side di- ameter Identi- fica- tion mark ABC Iden- tifica- tion mark D No. 1 Left "LH1" φ 55.25 "5" φ 55.25 φ 51.5 26.5 "5" φ 55.25 Right "1" φ 55.25 "6" 21.5 "6" No. 2 "2" φ55 "7" φ55 φ51 "7" φ55 No. 3 "3" φ 54.75 "8" φ 54.75 φ 50.5 "8" φ 54.75 BALANCE SHAFT BUSHINGS ---===WSE_1505_00010_0129.djvu===--- 11 11-91 Align the oil hole in the No. 2 bushing with the oil hole in the up- per crankcase. Force the No. 2 bushing into the upper crankcase to the illustrat- ed position by tapping on the rod from the front of the engine. Align the oil hole(s) in the No. 1 bushing with the oil hole(s) in the upper crankcase. Force the No. 1 bushing into the upper crankcase as deep as the mark in the illustration by tapping on the rod from the front of the engine. CAUTION The left and right No. 1 bushings are different from each other, and should not be installed in reverse positions. The left No. 1 bushing has two oil holes, whereas the right No. 1 bushing has only one oil hole. ---===WSE_1505_00010_0130.djvu===--- 12-1 GROUP 12 LUBRICATION SPECIFICATIONS............................................................................... 12-2 STRUCTURE AND OPERATION 1. Lubrication System....................................................................... 12-3 2. Oil Pump....................................................................................... 12-4 3. Oil Cooler ..................................................................................... 12-5 4. Oil Filter ........................................................................................ 12-6 5. Lubrication of Engine Components .............................................. 12-7 TROUBLESHOOTING . ..................................................................... 12-10 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Oil Filter Replacement ................................................................ 12-12 2. Engine Oil Replacement ............................................................. 12-14 3. Oil Pressure Measurement.......................................................... 12-15 OIL PAN, OIL STRAINER AND OIL JETS ....................................... 12-16 OIL PUMP ......................................................................................... 12-18 OIL FILTER ....................................................................................... 12-22 OIL COOLER .................................................................................... 12-24 ---===WSE_1505_00010_0131.djvu===--- 12-2 Item Specifications Method of lubrication Forced lubrication by oil pump Engine oil Grade API classification CD, CE, CF-4, CH-4 Quantity dm 3 {L} Oil pan Approx. 8 {8} Oil filter Approx. 1 {1} Oil cooler Model Shell and plate type (multiple-plate type) Bypass valve opening pressure kPa {kgf/cm 2 } 390±29{4.0±0.3} Oil filter Model Spin-on filter paper type Regulator valve opening pressure kPa {kgf/cm 2 } 600{6} +100 0 +1 0 SPECIFICATIONS ---===WSE_1505_00010_0132.djvu===--- 12 12-3 1. Lubrication System 1 Main oil gallery 2 Bypass valve 3 Bypass valve 4 Engine oil pressure switch 5 Oil cooler 6 Full-flow filter element 7 Regulator valve 8 Oil pump 9 Oil strainer 10 Turbo charger 11 Oil jet for gear 12 Vacuum pump 13 Idler bushing 14 Timing gear 15 Balance shaft bushing LH 16 Crankshaft main bearing 17 Connecting rod bearing 18 Connecting rod bushing 19 Piston 20 Balance shaft bushing RH 21 Supply pump gear bushing 22 Supply pump idler gear bushing 23 Supply pump idler gear shaft 24 Check valve for oil jet 25 Rocker bushing 26 Camshaft bushing 27 Rocker roller 28 Oil pan STRUCTURE AND OPERATION ---===WSE_1505_00010_0132.djvu===--- 12 12-3 1. Lubrication System 1 Main oil gallery 2 Bypass valve 3 Bypass valve 4 Engine oil pressure switch 5 Oil cooler 6 Full-flow filter element 7 Regulator valve 8 Oil pump 9 Oil strainer 10 Turbo charger 11 Oil jet for gear 12 Vacuum pump 13 Idler bushing 14 Timing gear 15 Balance shaft bushing LH 16 Crankshaft main bearing 17 Connecting rod bearing 18 Connecting rod bushing 19 Piston 20 Balance shaft bushing RH 21 Supply pump gear bushing 22 Supply pump idler gear bushing 23 Supply pump idler gear shaft 24 Check valve for oil jet 25 Rocker bushing 26 Camshaft bushing 27 Rocker roller 28 Oil pan STRUCTURE AND OPERATION ---===WSE_1505_00010_0133.djvu===--- 12-4 2. Oil Pump This engine uses a gear-type oil pump driven by the rotation of the crankshaft transmitted through the engage- ment of the crankshaft gear and the oil pump gear. STRUCTURE AND OPERATION ---===WSE_1505_00010_0134.djvu===--- 12 12-5 3. Oil Cooler 3.1 Bypass valve When the engine oil is cool and its vis- cosity is high, or when the oil cooler el- ement becomes clogged and restricts the flow of the engine oil, the bypass valve opens to let the engine oil by- pass the oil cooler and flow directly to the main oil gallery. 3.2 Engine oil pressure switch When the pressure of the engine oil to the main oil gallery drops below the specified level, an electrical contact in- side the engine oil pressure switch closes. This causes a warning lamp on the meter cluster to illuminate and notify the operator of the excessive pressure drop. ---===WSE_1505_00010_0135.djvu===--- 12-6 4. Oil Filter The oil filter used in this engine is a spin-on, paper-filter type. A bypass valve is installed in the lower part of the oil filter. When the filter elements are clogged, this valve opens to let the engine oil bypass the filter elements and flow directly to the oil cooler, thereby preventing seizures in the engine. A regulator valve is installed on the oil filter head. When the oil pressure in the main oil gallery exceeds the speci- fied level, the regulator valve opens to adjust the oil pressure by returning part of the engine oil to the oil pan. STRUCTURE AND OPERATION ---===WSE_1505_00010_0136.djvu===--- 12 12-7 5. Lubrication of Engine Components The engine oil in the main oil gallery lubricates the engine components in the following ways. 5.1 Main bearing and connecting rod bearing Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates the connecting rod's small end. 5.2 Timing gears ---===WSE_1505_00010_0137.djvu===--- 12-8 5.3 Valve mechanism The engine oil flows from the main oil gallery to the rocker shaft through the oil passages in the upper crankcase, cylinder head, and camshaft frame. The engine oil in the rocker shaft lubricates the rocker arms and camshaft, then returns to the oil pan. 5.4 Check valves and oil jets An oil jet is fitted in the lower part of the main oil gallery for each cylinder. Engine oil is sprayed out of the oil jet into the piston to cool the piston. Each oil jet is fitted with a check valve that opens and closes at predeter- mined oil pressure levels. At low en- gine speeds, the check valve closes to maintain the required volume of oil in the lubrication system and prevent re- ductions in oil pressure. STRUCTURE AND OPERATION ---===WSE_1505_00010_0138.djvu===--- 12 12-9 5.5 Vacuum pump Engine oil flows through the oil pas- sages in the front case to the vacuum pump. The oil in the pump lubricates the vanes, and then is discharged into the front case from the air discharge port of the vacuum pump along with air, and returns to the oil pan. 5.6 Turbocharger Engine oil is fed to the bearing hous- ing from the main oil gallery through the oil pipe to lubricate the inside of the turbocharger. The piston rings, which are installed on both sides of the turbine wheel shaft, serve as oil seals. ---===WSE_1505_00010_0139.djvu===--- 12-10 Symptoms Reference Gr Possible causes Oil cooler Incorrectly mounted element OOO Defective gasket OOO Defective O-ring OOO Clogged element OO Damaged element OOO Weakened bypass valve spring O Oil pump Malfunctioning oil pump OO Interference between oil pump gear and oil pump case and/or cover OO Oil filter Incorrect installation O Clogged element OO Defective gasket O Weakened regulator valve spring O Incorrectly mounted and/or clogged oil strainer OO Defective fan shaft front oil seal O Gr11 Defective crankshaft rear oil seal O Incorrectly mounted front case O Defective piston cooling oil jet(s) OO Incorrectly mounted gear lubrication oil jet O Oil working its way up into combustion chamber(s) through piston rings O Oil working its way down into combustion chamber(s) through valves O Too high oil viscosity O Poor oil quality O Deterioration of oil O Excess of oil O Fuel mixed with oil O TROUBLESHOOTING ---===WSE_1505_00010_0140.djvu===--- MEMO 12-11 12 ---===WSE_1505_00010_0141.djvu===--- 12-12 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt when working on the oil filter. Belts soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system. [Removal] Remove the drain plug and drain the oil out of the oil filter. Mark Parts to be tightened Tightening torque Remarks -- Drain plug 9.8 ± 1.96 {1.0 ± 0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity -- Oil filter Engine oil (API classification CD, CE, CF-4, CH-4) Approx. 1 dm 3 {1 L} -- Oil filter gasket Engine oil As required Mark Tool name and shape Part No. Application Oil filter element socket MH061566 Removal of oil filter ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0141.djvu===--- 12-12 1. Oil Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt when working on the oil filter. Belts soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system. [Removal] Remove the drain plug and drain the oil out of the oil filter. Mark Parts to be tightened Tightening torque Remarks -- Drain plug 9.8 ± 1.96 {1.0 ± 0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity -- Oil filter Engine oil (API classification CD, CE, CF-4, CH-4) Approx. 1 dm 3 {1 L} -- Oil filter gasket Engine oil As required Mark Tool name and shape Part No. Application Oil filter element socket MH061566 Removal of oil filter ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0142.djvu===--- 12 12-13 [Installation] Clean the oil filter mounting surfaces of the oil filter head. Apply a thin coat of engine oil on the oil filter gasket. Screw in the oil filter by hand until the gasket touches the oil filter head. Then, tighten the filter by turning it further by three quar- ters (3/4) of a turn. After installing the oil filter, start the engine and check that there are no oil leaks. Remove and reinstall the oil filter if it is leaky. Add a specified amount of engine oil. Run the engine for 1 minute or longer to fill the oil filter with the engine oil. Stop the engine and check the engine oil level. (See later sec- tion.) ---===WSE_1505_00010_0143.djvu===--- 12-14 2. Engine Oil Replacement Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt during engine oil replacement. Belts soiled with oil or grease may easily slip, resulting in deteriorated performance of the cooling system. [Draining] Before draining out the engine oil, warm up the engine until the water temperature gauge pointer begins to move. Remove the filler cap. Remove the drain plugs of the oil filter and oil pan to drain out the engine oil, for 5 minutes or longer. [Refilling] Tighten the drain plug to the specified torque, then pour a speci- fied amount of new engine oil into the engine. Run the engine for 1 minute or longer to fill the oil filter with the engine oil. Stop the engine and check the oil level. CAUTION If the specified quantity is exceeded as a result of addition of oil, increased oil consumption and/or deteriorated crank- case emission control system function may result. Mark Parts to be tightened Tightening torque Remarks -- Drain plug (oil filter) 9.8 ± 1.96 {1.0 ± 0.2} -- -- Drain plug (oil pan) 34.3 to 43.1 {3.5 to 4.4} -- Mark Points of application Specified lubricant and/or sealant Quantity -- Oil filter Engine oil (API classification CD, CE, CF-4, CH-4) Approx. 1 dm 3 {1 L} Oil pan Approx. 8 dm 3 {8 L} ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0144.djvu===--- 12 12-15 3. Oil Pressure Measurement Service standards Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Remove the engine oil pressure switch. Using an adapter, connect an oil pressure gauge to the engine oil pressure switch mounting hole. Warm up the engine until the oil temperature reaches 70 to 90°C. Measure the oil pressure while running the engine at a minimum speed and then at maximum speed, both under no load. If the measurements are below the specified limits, overhaul the lubrication system. After taking the measurements, install the engine oil pressure switch using the following procedure: Cool the engine adequately so that the engine oil pressure switch can be tightened with an accurate tightening torque. Apply sealant to the threaded portion of the engine oil pres- sure switch. Tighten the engine oil pressure switch to the specified torque. Location Maintenance item Standard value Limit Remedy -- Oil pressure (oil temperature at 70 to 90°C) No-load minimum speed 195 kPa {2.0 kgf/cm 2 } 98 kPa {1.0 kgf/ cm 2 } Inspect No-load maximum speed 295 to 490 kPa {3 to 5 kgf/cm 2 } 195 kPa {2.0 kgf/ cm 2 } Mark Parts to be tightened Tightening torque Remarks -- Engine oil pressure switch 12 {1.2} Sealant With cold en- gine Mark Points of application Specified lubricant and/or sealant Quantity -- Engine oil pressure switch threads ThreeBond 1215 As required ---===WSE_1505_00010_0145.djvu===--- 12-16 Disassembly sequence 1 Drain plug 2 Oil pan 3 Oil strainer 4 O-ring 5 Oil level sensor 6 O-ring 7 Check valve 8 Oil jet : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION Make sure to tighten the check valve only to the specified torque. Overtightening it can cause defec- tive operation, resulting in engine seizure. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 34.3 to 43.1 {3.5 to 4.4} -- Check valve 29.4 {3.0} Wet Bolt (oil pan mounting) 23.5 {2.4} -- Bolt (oil strainer mounting) 24 {2.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Crankcase mounting surface of oil pan ThreeBond 1217H As required O-ring Engine oil As required Check valve threads OIL PAN, OIL STRAINER AND OIL JETS ---===WSE_1505_00010_0145.djvu===--- 12-16 Disassembly sequence 1 Drain plug 2 Oil pan 3 Oil strainer 4 O-ring 5 Oil level sensor 6 O-ring 7 Check valve 8 Oil jet : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION Make sure to tighten the check valve only to the specified torque. Overtightening it can cause defec- tive operation, resulting in engine seizure. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 34.3 to 43.1 {3.5 to 4.4} -- Check valve 29.4 {3.0} Wet Bolt (oil pan mounting) 23.5 {2.4} -- Bolt (oil strainer mounting) 24 {2.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Crankcase mounting surface of oil pan ThreeBond 1217H As required O-ring Engine oil As required Check valve threads OIL PAN, OIL STRAINER AND OIL JETS ---===WSE_1505_00010_0145.djvu===--- 12-16 Disassembly sequence 1 Drain plug 2 Oil pan 3 Oil strainer 4 O-ring 5 Oil level sensor 6 O-ring 7 Check valve 8 Oil jet : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. CAUTION Make sure to tighten the check valve only to the specified torque. Overtightening it can cause defec- tive operation, resulting in engine seizure. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Mark Parts to be tightened Tightening torque Remarks Drain plug 34.3 to 43.1 {3.5 to 4.4} -- Check valve 29.4 {3.0} Wet Bolt (oil pan mounting) 23.5 {2.4} -- Bolt (oil strainer mounting) 24 {2.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Crankcase mounting surface of oil pan ThreeBond 1217H As required O-ring Engine oil As required Check valve threads OIL PAN, OIL STRAINER AND OIL JETS ---===WSE_1505_00010_0146.djvu===--- 12 12-17 Installation procedure Installation: Oil pan Clean the mating surfaces of each part. Apply a bead of sealant to the mating surface of the oil pan evenly and without any breaks as shown in the illustration. Mount the oil pan within three minutes of applying the sealant. Make sure that the sealant stays in place. CAUTION Do not start the engine less than an hour after installation. If the oil pan mounting bolts were loosened or removed, be sure to reapply sealant. ---===WSE_1505_00010_0147.djvu===--- 12-18 Disassembly sequence 1 Oil pump cover 2 Driven gear 3 Gear and case 4 O-ring * a: Drive gear : Locating pin : Non-reusable parts Assembly sequence Follow the disassembly procedure in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Location Maintenance item Standard value Limit Remedy 1, 2 Oil pump cover-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 1, * a Oil pump cover-to-drive gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3 Gear and case-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3, * a Sinkage of each gear from gear and case end surface 0.05 to 0.11 0.15 Replace Gear and case-to-tooth tip clearance for each gear 0.13 to 0.22 0.23 Replace Mark Parts to be tightened Tightening torque Remarks Bolt (oil pump cover mounting) 8.2 ± 2.46 {0.8 ± 0.25} -- Bolt (oil pump cover mounting) 9.8±2{1.0±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity Sliding parts of oil pump Engine oil As required O-ring Mark Tool name and shape Part No. Application Pump cover pin MH063431 Installation of oil pump cover AB φ72 0 0 --0.14 OIL PUMP ---===WSE_1505_00010_0147.djvu===--- 12-18 Disassembly sequence 1 Oil pump cover 2 Driven gear 3 Gear and case 4 O-ring * a: Drive gear : Locating pin : Non-reusable parts Assembly sequence Follow the disassembly procedure in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Location Maintenance item Standard value Limit Remedy 1, 2 Oil pump cover-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 1, * a Oil pump cover-to-drive gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3 Gear and case-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3, * a Sinkage of each gear from gear and case end surface 0.05 to 0.11 0.15 Replace Gear and case-to-tooth tip clearance for each gear 0.13 to 0.22 0.23 Replace Mark Parts to be tightened Tightening torque Remarks Bolt (oil pump cover mounting) 8.2 ± 2.46 {0.8 ± 0.25} -- Bolt (oil pump cover mounting) 9.8±2{1.0±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity Sliding parts of oil pump Engine oil As required O-ring Mark Tool name and shape Part No. Application Pump cover pin MH063431 Installation of oil pump cover AB φ72 0 0 --0.14 OIL PUMP ---===WSE_1505_00010_0147.djvu===--- 12-18 Disassembly sequence 1 Oil pump cover 2 Driven gear 3 Gear and case 4 O-ring * a: Drive gear : Locating pin : Non-reusable parts Assembly sequence Follow the disassembly procedure in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Location Maintenance item Standard value Limit Remedy 1, 2 Oil pump cover-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 1, * a Oil pump cover-to-drive gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3 Gear and case-to-driven gear shaft clearance 0.04 to 0.075 0.15 Replace 2, 3, * a Sinkage of each gear from gear and case end surface 0.05 to 0.11 0.15 Replace Gear and case-to-tooth tip clearance for each gear 0.13 to 0.22 0.23 Replace Mark Parts to be tightened Tightening torque Remarks Bolt (oil pump cover mounting) 8.2 ± 2.46 {0.8 ± 0.25} -- Bolt (oil pump cover mounting) 9.8±2{1.0±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity Sliding parts of oil pump Engine oil As required O-ring Mark Tool name and shape Part No. Application Pump cover pin MH063431 Installation of oil pump cover AB φ72 0 0 --0.14 OIL PUMP ---===WSE_1505_00010_0148.djvu===--- 12 12-19 Inspection procedure Inspection: Driven gear, drive gear and gear and case Carry out the following inspection. Replace the oil pump if any defects are found. (1) Sinkage of each gear from gear and case end surface (2) Gear and case-to-tooth tip clearance for each gear Inspection: Oil pump cover, driven gear, drive gear and gear and case Measure the clearance between each gear's shaft and the oil pump cover, as well as between each gear's shaft and the gear and case. If the measurements are not within the standard value range, re- place the oil pump. Installation procedure Installation: Oil pump cover and gear and case Apply engine oil to each component. Hold the oil pump cover in place on the gear and case by fitting two s in the illustrated locations. Install a bolt into an empty bolt hole and tighten it to the specified torque. Remove the two s. Install the rest of the bolts and tighten them to the specified torque. After installing all the bolts, turn the oil pump gear by hand and check that it rotates smoothly. Disassemble and reassemble the oil pump cover and gear and case if the oil pump gear does not rotate smoothly. ---===WSE_1505_00010_0148.djvu===--- 12 12-19 Inspection procedure Inspection: Driven gear, drive gear and gear and case Carry out the following inspection. Replace the oil pump if any defects are found. (1) Sinkage of each gear from gear and case end surface (2) Gear and case-to-tooth tip clearance for each gear Inspection: Oil pump cover, driven gear, drive gear and gear and case Measure the clearance between each gear's shaft and the oil pump cover, as well as between each gear's shaft and the gear and case. If the measurements are not within the standard value range, re- place the oil pump. Installation procedure Installation: Oil pump cover and gear and case Apply engine oil to each component. Hold the oil pump cover in place on the gear and case by fitting two s in the illustrated locations. Install a bolt into an empty bolt hole and tighten it to the specified torque. Remove the two s. Install the rest of the bolts and tighten them to the specified torque. After installing all the bolts, turn the oil pump gear by hand and check that it rotates smoothly. Disassemble and reassemble the oil pump cover and gear and case if the oil pump gear does not rotate smoothly. ---===WSE_1505_00010_0149.djvu===--- 12-20 Installation: Oil pump Place the No.1 cylinder piston at top dead center to bring the crankshaft gear to an appropriate position. Inject approximately 5 cm 3 {5 mL} of engine oil. Align the mating mark "6" on the crankshaft gear and the mating mark "7" on the balance shaft gear RH with the corresponding mating marks on the oil pump gear, and then install the oil pump gear. OIL PUMP ---===WSE_1505_00010_0150.djvu===--- MEMO 12-21 12 ---===WSE_1505_00010_0151.djvu===--- 12-22 Disassembly sequence 1 Drain plug 2 Oil filter 3 Oil pipe 4 O-ring 5 O-ring 6 Plug 7 Regulator valve spring 8 Regulator valve 9 Oil filter head 10 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt when working on the oil cooler and oil filter. Belts soiled with oil or grease may easily slip, resulting in deteriorated perfor- mance of the cooling system. Make sure to install the gasket in the correct position so that it does not cover up the oil hole. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 7 Load of installed regulator valve spring (installed length: 39 ) 93.5±0.5N {9.5 ± 0.05 kgf} --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Drain plug 9.8 ± 1.96 {1.0 ± 0.2} -- Plug (regulator valve mounting) 60 {6.0} -- Bolt (oil filter head mounting) 44.1 {4.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Oil filter gasket Engine oil As required O-ring +0.3 0 OIL FILTER ---===WSE_1505_00010_0151.djvu===--- 12-22 Disassembly sequence 1 Drain plug 2 Oil filter 3 Oil pipe 4 O-ring 5 O-ring 6 Plug 7 Regulator valve spring 8 Regulator valve 9 Oil filter head 10 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt when working on the oil cooler and oil filter. Belts soiled with oil or grease may easily slip, resulting in deteriorated perfor- mance of the cooling system. Make sure to install the gasket in the correct position so that it does not cover up the oil hole. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 7 Load of installed regulator valve spring (installed length: 39 ) 93.5±0.5N {9.5 ± 0.05 kgf} --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Drain plug 9.8 ± 1.96 {1.0 ± 0.2} -- Plug (regulator valve mounting) 60 {6.0} -- Bolt (oil filter head mounting) 44.1 {4.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Oil filter gasket Engine oil As required O-ring +0.3 0 OIL FILTER ---===WSE_1505_00010_0151.djvu===--- 12-22 Disassembly sequence 1 Drain plug 2 Oil filter 3 Oil pipe 4 O-ring 5 O-ring 6 Plug 7 Regulator valve spring 8 Regulator valve 9 Oil filter head 10 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Wipe up any spilled engine oil, as it can cause fires. To avoid any risk of burns, take care not to touch the engine oil when the engine is hot. CAUTION Make sure not to put any engine oil on the Belt when working on the oil cooler and oil filter. Belts soiled with oil or grease may easily slip, resulting in deteriorated perfor- mance of the cooling system. Make sure to install the gasket in the correct position so that it does not cover up the oil hole. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 7 Load of installed regulator valve spring (installed length: 39 ) 93.5±0.5N {9.5 ± 0.05 kgf} --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Drain plug 9.8 ± 1.96 {1.0 ± 0.2} -- Plug (regulator valve mounting) 60 {6.0} -- Bolt (oil filter head mounting) 44.1 {4.5} -- Mark Points of application Specified lubricant and/or sealant Quantity Oil filter gasket Engine oil As required O-ring +0.3 0 OIL FILTER ---===WSE_1505_00010_0152.djvu===--- 12 12-23 Special tools Removal procedure Removal: Oil filter Installation procedure Installation: Oil filter Clean the oil filter mounting surface of the oil filter head. Apply a thin coat of engine oil on the oil filter gasket. Screw in the oil filter by hand until the gasket touches the oil filter head. Then, tighten the filter by turning it further by three quar- ters (3/4) of a turn. After installing the oil filter, start the engine and check that there are no oil leaks from the gasket. Remove and reinstall the oil filter if it is leaky. Add a specified amount of engine oil. Run the engine for 1 minute or longer to fill the oil filter with the engine oil. Stop the engine and check the engine oil level. Add engine oil if necessary. Mark Tool name and shape Part No. Application Oil filter element socket MH061566 Removal of oil filter ---===WSE_1505_00010_0152.djvu===--- 12 12-23 Special tools Removal procedure Removal: Oil filter Installation procedure Installation: Oil filter Clean the oil filter mounting surface of the oil filter head. Apply a thin coat of engine oil on the oil filter gasket. Screw in the oil filter by hand until the gasket touches the oil filter head. Then, tighten the filter by turning it further by three quar- ters (3/4) of a turn. After installing the oil filter, start the engine and check that there are no oil leaks from the gasket. Remove and reinstall the oil filter if it is leaky. Add a specified amount of engine oil. Run the engine for 1 minute or longer to fill the oil filter with the engine oil. Stop the engine and check the engine oil level. Add engine oil if necessary. Mark Tool name and shape Part No. Application Oil filter element socket MH061566 Removal of oil filter ---===WSE_1505_00010_0153.djvu===--- 12-24 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. 1 Eyebolt 2 Oil pipe 3 Plug 4 O-ring 5 Bypass valve spring 6 Bypass valve 7 Oil cooler element 8 Gasket 9 Water drain plug 10 Engine oil pressure switch 11 Coolant temperature sensor (for water temperature gage) 12 Coolant temperature sensor (for engine control) 13 Oil cooler body 14 Gasket : Non-reusable parts OIL COOLER ---===WSE_1505_00010_0153.djvu===--- 12-24 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. 1 Eyebolt 2 Oil pipe 3 Plug 4 O-ring 5 Bypass valve spring 6 Bypass valve 7 Oil cooler element 8 Gasket 9 Water drain plug 10 Engine oil pressure switch 11 Coolant temperature sensor (for water temperature gage) 12 Coolant temperature sensor (for engine control) 13 Oil cooler body 14 Gasket : Non-reusable parts OIL COOLER ---===WSE_1505_00010_0153.djvu===--- 12-24 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. 1 Eyebolt 2 Oil pipe 3 Plug 4 O-ring 5 Bypass valve spring 6 Bypass valve 7 Oil cooler element 8 Gasket 9 Water drain plug 10 Engine oil pressure switch 11 Coolant temperature sensor (for water temperature gage) 12 Coolant temperature sensor (for engine control) 13 Oil cooler body 14 Gasket : Non-reusable parts OIL COOLER ---===WSE_1505_00010_0154.djvu===--- 12 12-25 Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Inspection procedure Inspection: Oil cooler element Plug the outlet of the oil cooler element and connect a hose to the engine oil inlet port. Then, immerse the oil cooler element in a tank of water. Apply an air pressure of 980 kPa {10 kgf/cm 2 } for 15 seconds through the hose, and check for any air leaks. Replace the element if it leaks air. Location Maintenance item Standard value Limit Remedy 6 Load of bypass valve spring (installed length: 48 ) 95.3±4.9N {9.7 ± 0.5 kgf} --R e p l a c e 8 Air leakage from oil cooler element (air pressure: 980 kPa {10 kgf/cm 2 } for 15 seconds) 0cm 3 {0 mL} -- Replace Mark Parts to be tightened Tightening torque Remarks Eyebolt (oil pipe mounting) 21.6 {2.2} -- Plug 34.3 ± 4.9 {3.5 ± 0.5} -- Nut (oil cooler element mounting) 25±5{2.5±0.5} -- Water drain plug Engine oil pressure switch 12 {1.2} Sealant With cold en- gine Coolant temperature sensor (for water temperature gage) 35 {3.6} -- Coolant temperature sensor (for engine control) 34 {3.5} Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Engine oil pressure switch threads ThreeBond 1215 As required 0 -0.5 ---===WSE_1505_00010_0155.djvu===--- 13-1 GROUP 13 FUEL AND ENGINE CONTROL SPECIFICATIONS............................................................................... 13-2 STRUCTURE AND OPERATION 1. Fuel System (Flow of Fuel) ........................................................... 13-3 2. Engine Control ............................................................................. 13-4 3. Fuel Filter ..................................................................................... 13-5 TROUBLESHOOTING ........................................................................ 13-6 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspecting and Adjusting No-load Minimum and Maximum Speeds ......................................................................................... 13-8 2. Air-bleeding of Fuel System.......................................................... 13-9 3. Fuel Filter Replacement .............................................................. 13-10 FUEL TANK....................................................................................... 13-12 SPARE FUEL TANK.......................................................................... 13-14 FUEL FILTER .................................................................................... 13-16 ENGINE CONTROL .......................................................................... 13-20 COMMON RAIL................................................................................. 13-24 SUPPLY PUMP ................................................................................. 13-28 INJECTOR......................................................................................... 13-32 ---===WSE_1505_00010_0156.djvu===--- 13-2 Item Specifications Supply pump Manufacturer Bosch Supply pump type CP3.3 NH Control system Electronically-controlled pump Model Radial, 3-cylinder Feed pump type External gear type MPROP (rail pres- sure control valve) Model MPROP Rated voltage V 24 Max. common rail pressure MPa {kgf/cm 2 } 180 {1840} Common rail Manufacturer Bosch Common rail capacity cm 3 {ml} 18.7 {18.7} Pressure limiting valve opening pressure MPa {kgf/cm 2 } 210 to 220 {2141 to 2243} Common rail pressure sensor supply voltage V 5 Injectors Manufacturer Bosch Control system Electrical Max. operating pressure MPa {kgf/cm 2 } 180 {1840} Min. operating pressure MPa {kgf/cm 2 } 25 {255} Engine electronic control unit Manufacturer Bosch Rated voltage V 24 SPECIFICATIONS ---===WSE_1505_00010_0157.djvu===--- 13 13-3 1. Fuel System (Flow of Fuel) The feed pump, which is driven by the camshaft inside the supply pump, draws up the fuel from inside the fuel tank and sends it through the fuel filter, where dust and other impurities in the fuel are filtered out. The filtered fuel is then sent to the supply pump, where it is compressed. The compressed fuel is accumulated in the common rail for a time, then sprayed out through the injection nozzles into the combustion chamber. The excess fuel from the injectors returns to the fuel tank through the fuel return hose. When the internal fuel pressure of the common rail exceeds the limit, the pressure limiting valve opens to allow part of the fuel to return to the fuel tank. When the internal fuel pressure of the supply pump exceeds the limit, the overflow valve opens to allow part of the fuel to return to the fuel tank. STRUCTURE AND OPERATION ---===WSE_1505_00010_0157.djvu===--- 13 13-3 1. Fuel System (Flow of Fuel) The feed pump, which is driven by the camshaft inside the supply pump, draws up the fuel from inside the fuel tank and sends it through the fuel filter, where dust and other impurities in the fuel are filtered out. The filtered fuel is then sent to the supply pump, where it is compressed. The compressed fuel is accumulated in the common rail for a time, then sprayed out through the injection nozzles into the combustion chamber. The excess fuel from the injectors returns to the fuel tank through the fuel return hose. When the internal fuel pressure of the common rail exceeds the limit, the pressure limiting valve opens to allow part of the fuel to return to the fuel tank. When the internal fuel pressure of the supply pump exceeds the limit, the overflow valve opens to allow part of the fuel to return to the fuel tank. STRUCTURE AND OPERATION ---===WSE_1505_00010_0158.djvu===--- 13-4 2. Engine Control The engine is electronically controlled by the engine electronic control unit. By processing accelerator pedal posi- tion data from the accelerator position sensor, the engine electronic control unit controls the injectors for optimum fuel injection. STRUCTURE AND OPERATION ---===WSE_1505_00010_0159.djvu===--- 13 13-5 3. Fuel Filter The fuel filter, which also serves as a water separator, removes impurities in the fuel through the filter element and also separates water from fuel. The water that has been separated from the fuel collects at the bottom of the fuel filter. A water separator sensor is installed in the fuel filter, which activates the warning lamp on the meter cluster when the water reaches a cer- tain level. The water can be drained through the drain hole by loosening the water separator sensor. A priming pump is provided at the fuel filter head. The priming pump is used for air-bleeding the fuel system. When the fuel temperature rises, the thermostat swells and the valve of the fuel filter head is closed. The high- temperature fuel entirely returns to the fuel tank through the fuel return pipe. When the fuel temperature lowers, the thermostat does not swell and the valve to the fuel filter remains open. The high-temperature fuel returning through the fuel return pipe is let through the valve to mix into the fuel around the element. The fuel around the element is warmed as a result and wax in it (precipitated when the fuel temperature is low) is dissolved to prevent clogging of the element. ---===WSE_1505_00010_0160.djvu===--- 13-6 *: Contact a Bosch service station for repair. Symptoms Reference Gr Possible causes Electronic control fuel system faulty O Gr13E Supply pump Feed pump check valve faulty O O OO * Defective feed pump O O OO * Defective sealing supply pump overflow valve O O OO * Open or short circuit failure, poor contact of supply pump magnetic valve OOOOO * Defective supply pump magnetic valve, defec- tive base supply pump OOO O * Incorrect injector fuel injection Open or short circuit failure, poor contact of injector magnetic valve OOO OO * Defective injector, defective injector magnetic valve, defective nozzle OOO O * Clogged fuel filter O O OO No fuel in fuel tank O Clogged fuel pipe and/or leaky pipe joints O Air or water in fuel system O O OO Use of low quality fuel OOOO Open or short circuit failure, poor contact of common rail pressure sensor, defective sensor OO OO O O * F u e ll e a k a g ef r o mh i g hp r e s s u r ej o i n t OOOO O * Engine control Poorly adjusted accelerator pedal stopper bolt O O Defective accelerator position sensor O Cracked fuel pipe and/or hose O TROUBLESHOOTING ---===WSE_1505_00010_0161.djvu===--- 13 13-7 Symptoms Reference Gr Possible causes Oil viscosity unsuitable O O Gr12 Valve clearance incorrect O O Gr11 Defective cylinder head gasket O O Wear of and/or carbon deposits on valve and valve seat O O Distorted valve springs O O Worn or damaged piston rings O O Worn or damaged piston ring groove O Worn piston and/or cylinder liner O O Poorly functioning cooling system O O Gr14 Defective starter switch OO Gr54 Defective glow plug O Open-circuited, short-circuited or poorly connected engine speed sensor and/or cylinder recognition sensor OO O Gr13E Open-circuited, short-circuited or poorly connected boost pressure sensor OOO O O Open-circuited, short-circuited or poorly connected coolant tempera- ture sensor OO O Poorly connected injection rate adjusting resistor OO O Open-circuited, short-circuited or poorly connected idling adjustment control OOO Blown fuse OO O O Gr54 ---===WSE_1505_00010_0162.djvu===--- 13-8 1. Inspecting and Adjusting No-load Minimum and Maximum Speeds Service standards [Work before inspection and adjustment] Before starting the inspection and adjustment, carry out the fol- lowing preparatory steps: Warm up the engine until the engine coolant temperature is ap- proximately 80 to 95°C; (Check by the service data "32: Water temperature" of the Multi-Use Tester.) Turn off all lamps and accessories; Put the transmission in neutral; Set the steering wheel at the straight-ahead position; and Attach a tachometer. [Inspection] (1) No-load minimum speed Without depressing the accelerator pedal, measure the engine speed. If the measurement is not within the standard value range, in- spect the accelerator position sensor and accelerator switch. (See Gr13E.) If no defects are evident during the above inspection, check the diagnosis code in the engine electronic control unit or the fuel system. (2) No-load maximum speed Depress the accelerator pedal as far as it will go. With the accelerator pedal touching the stopper bolt, measure the engine speed. If the measurement is not within the standard value range, in- spect the accelerator position sensor and accelerator switch. (See Gr13E.) If no defects are evident during the above inspection, check the diagnosis code in the engine electronic control unit or the fuel system. Location Maintenance item Standard value Limit Remedy -- Minimum no-load speed (idling speed) 650±25rpm -- Adjust -- Maximum no-load speed 3100 ± 50 rpm -- Adjust ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0162.djvu===--- 13-8 1. Inspecting and Adjusting No-load Minimum and Maximum Speeds Service standards [Work before inspection and adjustment] Before starting the inspection and adjustment, carry out the fol- lowing preparatory steps: Warm up the engine until the engine coolant temperature is ap- proximately 80 to 95°C; (Check by the service data "32: Water temperature" of the Multi-Use Tester.) Turn off all lamps and accessories; Put the transmission in neutral; Set the steering wheel at the straight-ahead position; and Attach a tachometer. [Inspection] (1) No-load minimum speed Without depressing the accelerator pedal, measure the engine speed. If the measurement is not within the standard value range, in- spect the accelerator position sensor and accelerator switch. (See Gr13E.) If no defects are evident during the above inspection, check the diagnosis code in the engine electronic control unit or the fuel system. (2) No-load maximum speed Depress the accelerator pedal as far as it will go. With the accelerator pedal touching the stopper bolt, measure the engine speed. If the measurement is not within the standard value range, in- spect the accelerator position sensor and accelerator switch. (See Gr13E.) If no defects are evident during the above inspection, check the diagnosis code in the engine electronic control unit or the fuel system. Location Maintenance item Standard value Limit Remedy -- Minimum no-load speed (idling speed) 650±25rpm -- Adjust -- Maximum no-load speed 3100 ± 50 rpm -- Adjust ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0163.djvu===--- 13 13-9 2. Air-bleeding of Fuel System Tightening torque (Unit: N·m {kgf·m}) Loosen one of the air vent plugs on the fuel filter. Move the priming pump up and down to pump out the fuel. Continue operating the priming pump until the fuel flowing out of the plug is free of air bubbles. When no more air bubbles are evident, tighten the air vent plug to the specified torque. Feed the fuel some more by operating the priming pump further until a strong resistance is felt. When the fuel temperature is low, you may not feel the resis- tance. Be sure to operate the priming pump several times even in such a case. Wipe up any spilled fuel and start the engine. Check that there is no fuel leakage. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Mark Parts to be tightened Tightening torque Remarks -- Plug 10±2{1±0.2} -- ---===WSE_1505_00010_0164.djvu===--- 13-10 3. Fuel Filter Replacement Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools [Removal] Loosen the water separator sensor and drain fuel from the case. Remove the case using . WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. CAUTION Be careful not to damage the case. [Installation] Clean the O-ring mounting surface of the fuel filter head and the O-ring groove of the case. Mark Parts to be tightened Tightening torque Remarks -- Water separator sensor 5±1{0.5±0.1} -- -- Case 30±2{3.1±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity -- O-ring Engine oil As required Mark Tool name and shape Part No. Application Filter wrench MH063203 Removal and installation of case ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0165.djvu===--- 13 13-11 Replace the filter element and O-ring with new one. Apply a thin coat of engine oil to the O-ring, and install it on the case and water separator sensor. CAUTION Be sure to use only genuine MITSUBISHI filter elements. The use of non-genuine fuel filters can cause engine failure. Prevent fine dust particles from entering the fuel filter and fuel hose, as they can cause problems such as faulty fuel injection. Use to tighten the case to the specified torque. Install the water separator sensor, and then air-bleed the fuel system. Start the engine, and check that there is no fuel leakage. Reinstall the fuel filter if there is any leakage. ---===WSE_1505_00010_0166.djvu===--- 13-12 <170L> Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Insert the air vent tube into fuel tank bracket, while taking care not to pinch or crush with the fuel tank band. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Drain plug 19.6 ± 4.9 {2.0 ± 0.5} -- Screw (fuel level sensor mounting) 0.96 to 1.47 {0.10 to 0.15} -- Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- 1 Drain plug 2 Suction hose 3 Return hose 4 Air vent tube 5 Air vent tube 6 Fuel level sensor 7 Fuel tank band 8 Fuel tank 9 Fuel tank bracket FUEL TANK ---===WSE_1505_00010_0166.djvu===--- 13-12 <170L> Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Insert the air vent tube into fuel tank bracket, while taking care not to pinch or crush with the fuel tank band. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Drain plug 19.6 ± 4.9 {2.0 ± 0.5} -- Screw (fuel level sensor mounting) 0.96 to 1.47 {0.10 to 0.15} -- Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- 1 Drain plug 2 Suction hose 3 Return hose 4 Air vent tube 5 Air vent tube 6 Fuel level sensor 7 Fuel tank band 8 Fuel tank 9 Fuel tank bracket FUEL TANK ---===WSE_1505_00010_0166.djvu===--- 13-12 <170L> Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Insert the air vent tube into fuel tank bracket, while taking care not to pinch or crush with the fuel tank band. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Drain plug 19.6 ± 4.9 {2.0 ± 0.5} -- Screw (fuel level sensor mounting) 0.96 to 1.47 {0.10 to 0.15} -- Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- 1 Drain plug 2 Suction hose 3 Return hose 4 Air vent tube 5 Air vent tube 6 Fuel level sensor 7 Fuel tank band 8 Fuel tank 9 Fuel tank bracket FUEL TANK ---===WSE_1505_00010_0167.djvu===--- 13 13-13 <100L> Removal sequence 1 Drain plug 2 Suction hose 3 Return hose 4 Air vent tube 5 Plug <Without spare fuel tank> 6 Fuel level sensor 7 Fuel tank band 8 Fuel tank 9 Fuel tank bracket : Non-reusable parts Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Insert the air vent tube into fuel tank bracket, while taking care not to pinch or crush with the fuel tank band. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Drain plug 19.6 ± 4.9 {2.0 ± 0.5} -- Screw (fuel level sensor mounting) 0.96 to 1.47 {0.10 to 0.15} -- Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- Lock nut (fuel tank band mounting) 9to14{0.9to1.4} -- Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- ---===WSE_1505_00010_0168.djvu===--- 13-14 Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- Fuel cock 15 to 25 {1.5 to 2.5} -- 1 Fuel hose 2 Fuel cock 3 Gasket 4 Connector 5 Fuel tank band 6 Fuel tank 7 Fuel tank bracket 8 Fuel hose bracket * a: Main fuel tank : Non-reusable parts SPARE FUEL TANK ---===WSE_1505_00010_0168.djvu===--- 13-14 Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- Fuel cock 15 to 25 {1.5 to 2.5} -- 1 Fuel hose 2 Fuel cock 3 Gasket 4 Connector 5 Fuel tank band 6 Fuel tank 7 Fuel tank bracket 8 Fuel hose bracket * a: Main fuel tank : Non-reusable parts SPARE FUEL TANK ---===WSE_1505_00010_0168.djvu===--- 13-14 Removal sequence Installation sequence Follow the removal sequence in reverse. DANGER Do not allow any flames or sources of heat near the fuel tank, as it may explode. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (fuel tank bracket mounting) 70 to 90 {7.1 to 9.1} -- Nut (fuel tank band mounting) 6.9 to 9.8 {0.7 to 1.0} -- Fuel cock 15 to 25 {1.5 to 2.5} -- 1 Fuel hose 2 Fuel cock 3 Gasket 4 Connector 5 Fuel tank band 6 Fuel tank 7 Fuel tank bracket 8 Fuel hose bracket * a: Main fuel tank : Non-reusable parts SPARE FUEL TANK ---===WSE_1505_00010_0169.djvu===--- MEMO 13-15 13 ---===WSE_1505_00010_0170.djvu===--- 13-16 Disassembly sequence 1 Fuel hose 2 Water separator sensor 3 O-ring 4 Case 5 O-ring 6 Filter element 7 Plug 8 Fuel filter head : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. CAUTION Be careful not to damage the case. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Water separator sensor 5±1{0.5±0.1} -- Case 30±2{3.1±0.2} -- Plug 10±2{1±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Filter wrench MH063203 Removal and installation of case FUEL FILTER ---===WSE_1505_00010_0170.djvu===--- 13-16 Disassembly sequence 1 Fuel hose 2 Water separator sensor 3 O-ring 4 Case 5 O-ring 6 Filter element 7 Plug 8 Fuel filter head : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. CAUTION Be careful not to damage the case. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Water separator sensor 5±1{0.5±0.1} -- Case 30±2{3.1±0.2} -- Plug 10±2{1±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Filter wrench MH063203 Removal and installation of case FUEL FILTER ---===WSE_1505_00010_0170.djvu===--- 13-16 Disassembly sequence 1 Fuel hose 2 Water separator sensor 3 O-ring 4 Case 5 O-ring 6 Filter element 7 Plug 8 Fuel filter head : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. WARNING Fuel is highly flammable. Keep it away from flames and sources of heat. To avoid risk of fire, wipe up any spilled fuel. CAUTION Be careful not to damage the case. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Water separator sensor 5±1{0.5±0.1} -- Case 30±2{3.1±0.2} -- Plug 10±2{1±0.2} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Filter wrench MH063203 Removal and installation of case FUEL FILTER ---===WSE_1505_00010_0171.djvu===--- 13 13-17 Removal procedure Removal: Case Loosen the water separator sensor and drain fuel from the case. Remove the case using . Installation procedure Installation: Case Clean the O-ring mounting surface of the fuel filter head and the O-ring groove of the case. Replace the filter element and O-ring with new one. Apply a thin coat of engine oil to the O-ring, and install it on the case and water separator sensor. CAUTION Be sure to use only genuine MITSUBISHI filter elements. The use of non-genuine fuel filters can cause engine failure. Prevent fine dust particles from entering the fuel filter and fuel pipe, as they can cause problems such as faulty fuel in- jection. ---===WSE_1505_00010_0171.djvu===--- 13 13-17 Removal procedure Removal: Case Loosen the water separator sensor and drain fuel from the case. Remove the case using . Installation procedure Installation: Case Clean the O-ring mounting surface of the fuel filter head and the O-ring groove of the case. Replace the filter element and O-ring with new one. Apply a thin coat of engine oil to the O-ring, and install it on the case and water separator sensor. CAUTION Be sure to use only genuine MITSUBISHI filter elements. The use of non-genuine fuel filters can cause engine failure. Prevent fine dust particles from entering the fuel filter and fuel pipe, as they can cause problems such as faulty fuel in- jection. ---===WSE_1505_00010_0172.djvu===--- 13-18 Use to tighten the case to the specified torque. Install the water separator sensor, and then air-bleed the fuel system. Start the engine, and check that there is no fuel leakage. Reinstall the fuel filter if there is any leakage. FUEL FILTER ---===WSE_1505_00010_0173.djvu===--- MEMO 13-19 13 ---===WSE_1505_00010_0174.djvu===--- 13-20 Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal Using pliers, pinch the hook of the stopper on the accelerator pedal. Separate the stopper from the pedal while turning the hook by about 15 degrees. CAUTION Do not yank on the stopper, as this may damage it. Installation procedure Installation: Accelerator pedal Depress the accelerator pedal until the accelerator lever touches the accelerator link stopper bolt. Check that the clearance between the stopper and the stopper bolt contact surface of the pedal is as indicated in the illustration. If the clearance is not within the indicated value range, adjust the stopper bolt and lock it with the nut. ENGINE CONTROL ---===WSE_1505_00010_0174.djvu===--- 13-20 Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal Using pliers, pinch the hook of the stopper on the accelerator pedal. Separate the stopper from the pedal while turning the hook by about 15 degrees. CAUTION Do not yank on the stopper, as this may damage it. Installation procedure Installation: Accelerator pedal Depress the accelerator pedal until the accelerator lever touches the accelerator link stopper bolt. Check that the clearance between the stopper and the stopper bolt contact surface of the pedal is as indicated in the illustration. If the clearance is not within the indicated value range, adjust the stopper bolt and lock it with the nut. ENGINE CONTROL ---===WSE_1505_00010_0174.djvu===--- 13-20 Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal Using pliers, pinch the hook of the stopper on the accelerator pedal. Separate the stopper from the pedal while turning the hook by about 15 degrees. CAUTION Do not yank on the stopper, as this may damage it. Installation procedure Installation: Accelerator pedal Depress the accelerator pedal until the accelerator lever touches the accelerator link stopper bolt. Check that the clearance between the stopper and the stopper bolt contact surface of the pedal is as indicated in the illustration. If the clearance is not within the indicated value range, adjust the stopper bolt and lock it with the nut. ENGINE CONTROL ---===WSE_1505_00010_0174.djvu===--- 13-20 Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal Using pliers, pinch the hook of the stopper on the accelerator pedal. Separate the stopper from the pedal while turning the hook by about 15 degrees. CAUTION Do not yank on the stopper, as this may damage it. Installation procedure Installation: Accelerator pedal Depress the accelerator pedal until the accelerator lever touches the accelerator link stopper bolt. Check that the clearance between the stopper and the stopper bolt contact surface of the pedal is as indicated in the illustration. If the clearance is not within the indicated value range, adjust the stopper bolt and lock it with the nut. ENGINE CONTROL ---===WSE_1505_00010_0174.djvu===--- 13-20 Removal sequence 1 Accelerator pedal (See later sec- tions.) 2 Accelerator link (See later sec- tions.) Installation sequence Follow the removal sequence in reverse. Removal procedure Removal: Accelerator pedal Using pliers, pinch the hook of the stopper on the accelerator pedal. Separate the stopper from the pedal while turning the hook by about 15 degrees. CAUTION Do not yank on the stopper, as this may damage it. Installation procedure Installation: Accelerator pedal Depress the accelerator pedal until the accelerator lever touches the accelerator link stopper bolt. Check that the clearance between the stopper and the stopper bolt contact surface of the pedal is as indicated in the illustration. If the clearance is not within the indicated value range, adjust the stopper bolt and lock it with the nut. ENGINE CONTROL ---===WSE_1505_00010_0175.djvu===--- 13 13-21 Accelerator Pedal Disassembly sequence 1 E-ring 2 Clevis pin 3 Accelerator pedal 4 Stopper bolt 5 Accelerator pedal bracket Assembly sequence Follow the disassembly sequence in re- verse. Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No. 1 (Li soap)] As required ---===WSE_1505_00010_0175.djvu===--- 13 13-21 Accelerator Pedal Disassembly sequence 1 E-ring 2 Clevis pin 3 Accelerator pedal 4 Stopper bolt 5 Accelerator pedal bracket Assembly sequence Follow the disassembly sequence in re- verse. Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No. 1 (Li soap)] As required ---===WSE_1505_00010_0175.djvu===--- 13 13-21 Accelerator Pedal Disassembly sequence 1 E-ring 2 Clevis pin 3 Accelerator pedal 4 Stopper bolt 5 Accelerator pedal bracket Assembly sequence Follow the disassembly sequence in re- verse. Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No. 1 (Li soap)] As required ---===WSE_1505_00010_0176.djvu===--- 13-22 Accelerator Linkage Disassembly sequence 1 Cover 2 Spring 3 Washer 4 Bushing 5 Return spring 6 Accelerator lever 7 Accelerator position sensor and accelerator switch assembly 8 Lever stopper 9 Rubber stopper 10 Accelerator link bracket Assembly sequence Follow the disassembly sequence in re- verse. NOTE Perform the inspection and adjust- ment of the accelerator position sensor. (See Gr13E.) Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator lever and return spring sliding surface Chassis grease [NLGI No. 1 (Li soap)] As required ENGINE CONTROL ---===WSE_1505_00010_0176.djvu===--- 13-22 Accelerator Linkage Disassembly sequence 1 Cover 2 Spring 3 Washer 4 Bushing 5 Return spring 6 Accelerator lever 7 Accelerator position sensor and accelerator switch assembly 8 Lever stopper 9 Rubber stopper 10 Accelerator link bracket Assembly sequence Follow the disassembly sequence in re- verse. NOTE Perform the inspection and adjust- ment of the accelerator position sensor. (See Gr13E.) Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator lever and return spring sliding surface Chassis grease [NLGI No. 1 (Li soap)] As required ENGINE CONTROL ---===WSE_1505_00010_0176.djvu===--- 13-22 Accelerator Linkage Disassembly sequence 1 Cover 2 Spring 3 Washer 4 Bushing 5 Return spring 6 Accelerator lever 7 Accelerator position sensor and accelerator switch assembly 8 Lever stopper 9 Rubber stopper 10 Accelerator link bracket Assembly sequence Follow the disassembly sequence in re- verse. NOTE Perform the inspection and adjust- ment of the accelerator position sensor. (See Gr13E.) Lubricant and/or sealant Mark Points of application Specified lubricant and/or sealant Quantity Accelerator lever and return spring sliding surface Chassis grease [NLGI No. 1 (Li soap)] As required ENGINE CONTROL ---===WSE_1505_00010_0177.djvu===--- MEMO 13-23 13 ---===WSE_1505_00010_0178.djvu===--- 13-24 Disassembly sequence WARNING Fuel is highly flammable. Do not handle it near flames or heat. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION If dust enters the common rail, the engine performance will be greatly affected. To prevent it, be sure to cover up openings left after pipes and other parts are removed. Also, wash eyebolts, gaskets, etc. in light oil to clear of dirt. Contact Bosch service station for any service needs of the common rail. Assembly sequence Follow the disassembly sequence in reverse. 1 Injection pipe 2 Fuel pipe 3 Eyebolt 4 Fuel return pipe B 5 Fuel pressure sensor (See Gr13E.) 6 Pressure limiting valve 7 O-ring 8 Common rail 9 Fuel temperature sensor 10 O-ring 11 Eyebolt 12 Fuel suction pipe B 13 Eyebolt 14 Fuel suction pipe A 15 Eyebolt 16 Fuel return pipe A 17 Eyebolt 18 Fuel return pipe C 19 Adaptor : Non-reusable parts COMMON RAIL ---===WSE_1505_00010_0178.djvu===--- 13-24 Disassembly sequence WARNING Fuel is highly flammable. Do not handle it near flames or heat. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION If dust enters the common rail, the engine performance will be greatly affected. To prevent it, be sure to cover up openings left after pipes and other parts are removed. Also, wash eyebolts, gaskets, etc. in light oil to clear of dirt. Contact Bosch service station for any service needs of the common rail. Assembly sequence Follow the disassembly sequence in reverse. 1 Injection pipe 2 Fuel pipe 3 Eyebolt 4 Fuel return pipe B 5 Fuel pressure sensor (See Gr13E.) 6 Pressure limiting valve 7 O-ring 8 Common rail 9 Fuel temperature sensor 10 O-ring 11 Eyebolt 12 Fuel suction pipe B 13 Eyebolt 14 Fuel suction pipe A 15 Eyebolt 16 Fuel return pipe A 17 Eyebolt 18 Fuel return pipe C 19 Adaptor : Non-reusable parts COMMON RAIL ---===WSE_1505_00010_0178.djvu===--- 13-24 Disassembly sequence WARNING Fuel is highly flammable. Do not handle it near flames or heat. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION If dust enters the common rail, the engine performance will be greatly affected. To prevent it, be sure to cover up openings left after pipes and other parts are removed. Also, wash eyebolts, gaskets, etc. in light oil to clear of dirt. Contact Bosch service station for any service needs of the common rail. Assembly sequence Follow the disassembly sequence in reverse. 1 Injection pipe 2 Fuel pipe 3 Eyebolt 4 Fuel return pipe B 5 Fuel pressure sensor (See Gr13E.) 6 Pressure limiting valve 7 O-ring 8 Common rail 9 Fuel temperature sensor 10 O-ring 11 Eyebolt 12 Fuel suction pipe B 13 Eyebolt 14 Fuel suction pipe A 15 Eyebolt 16 Fuel return pipe A 17 Eyebolt 18 Fuel return pipe C 19 Adaptor : Non-reusable parts COMMON RAIL ---===WSE_1505_00010_0179.djvu===--- 13 13-25 Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Removal procedure Removal: Injection pipe and fuel pipe Position on the pipe and then loosen the union nut. Location Parts to be tightened Tightening torque Remarks Injection pipe 40.5 ± 2.5 {4.1 ± 0.25} Use a wrench or other similar tools to tighten the inlet connector Fuel pipe Bolt (adaptor mounting) 44.5 {4.5} -- Bolt (common rail mounting) 23.2 {2.4} -- Fuel temperature sensor 17.6 to 21.5 {1.8 to 2.2} -- Eyebolt (fuel suction pipe mounting) 39.2 {4.0} -- Eyebolt (fuel return pipe mounting) Eyebolt (fuel return pipe mounting) 25 to 29 {2.6 to 3.0} -- Fuel pressure sensor 95±5{9.7±0.5} -- Pressure limiting valve 100±5{10.2±0.5} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Socket wrench MH063020 Removal and Installation of injection pipe and fuel pipe A 17 ---===WSE_1505_00010_0180.djvu===--- 13-26 Installation procedure Installation: Injection pipe and fuel pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. After temporary tightening, position the torque wrench on and then tighten them to the specified torque. Inspection after installation Fuel pressure sensor Start the engine and ensure that there is no fuel leakage from the fuel pressure sensor. Perform the actuator test (B2: Fuel Leak Check) with Multi-Use Tester and ensure that there is no fuel leakage from the fuel sys- tem (pipes or hoses). If there is fuel leakage, reinstall pipes or hoses correctly. COMMON RAIL ---===WSE_1505_00010_0180.djvu===--- 13-26 Installation procedure Installation: Injection pipe and fuel pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. After temporary tightening, position the torque wrench on and then tighten them to the specified torque. Inspection after installation Fuel pressure sensor Start the engine and ensure that there is no fuel leakage from the fuel pressure sensor. Perform the actuator test (B2: Fuel Leak Check) with Multi-Use Tester and ensure that there is no fuel leakage from the fuel sys- tem (pipes or hoses). If there is fuel leakage, reinstall pipes or hoses correctly. COMMON RAIL ---===WSE_1505_00010_0181.djvu===--- MEMO 13-27 13 ---===WSE_1505_00010_0182.djvu===--- 13-28 SUPPLY PUMP ---===WSE_1505_00010_0183.djvu===--- 13 13-29 Removal sequence WARNING Fuel is highly flammable. Do not handle it near flames or heat. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION Dirt and dust in the supply pump assembly can seriously detract from engine performance. To prevent this from happening, fully cover all open joints after removing any pipes or hoses. Contact Bosch service station for any service needs of the supply pump. Installation sequence Follow the removal sequence in reverse. CAUTION To start the engine, be sure to connect the connector of the MPROP (rail pressure control valve) to the en- gine harness. If the engine is started without connecting the MPROP connector, the engine electronic control unit cannot control the supply pump and the fault of the engine may result. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Eyebolt (fuel return pipe C mounting) 25 {2.6} -- Eyebolt (fuel section pipe A mounting) Fuel pipe 40.5 ± 2.5 {4.1 ± 0.25} -- Eyebolt (oil pipe mounting) 21 {2.14} -- Nut (supply pump gear mounting) 105 {11} -- Nut (supply pump mounting) 26.5 {2.7} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Cranking handle MH063704 Rotating the fan pulley 1 Eyebolt 2 Oil pipe 3 Eyebolt 4 Fuel return pipe C 5 Fuel pipe 6 Eyebolt (with gauze filter) 7 Fuel suction pipe A 8 Thrust plate 9 No. 2 idler gear 10 No. 2 idler shaft 11 Nut 12 Supply pump gear 13 Flange plate 14 O-ring 15 Key 16 Supply pump 17 O-ring * a: Front case : Non-reusable parts ---===WSE_1505_00010_0183.djvu===--- 13 13-29 Removal sequence WARNING Fuel is highly flammable. Do not handle it near flames or heat. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION Dirt and dust in the supply pump assembly can seriously detract from engine performance. To prevent this from happening, fully cover all open joints after removing any pipes or hoses. Contact Bosch service station for any service needs of the supply pump. Installation sequence Follow the removal sequence in reverse. CAUTION To start the engine, be sure to connect the connector of the MPROP (rail pressure control valve) to the en- gine harness. If the engine is started without connecting the MPROP connector, the engine electronic control unit cannot control the supply pump and the fault of the engine may result. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools Mark Parts to be tightened Tightening torque Remarks Eyebolt (fuel return pipe C mounting) 25 {2.6} -- Eyebolt (fuel section pipe A mounting) Fuel pipe 40.5 ± 2.5 {4.1 ± 0.25} -- Eyebolt (oil pipe mounting) 21 {2.14} -- Nut (supply pump gear mounting) 105 {11} -- Nut (supply pump mounting) 26.5 {2.7} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Cranking handle MH063704 Rotating the fan pulley 1 Eyebolt 2 Oil pipe 3 Eyebolt 4 Fuel return pipe C 5 Fuel pipe 6 Eyebolt (with gauze filter) 7 Fuel suction pipe A 8 Thrust plate 9 No. 2 idler gear 10 No. 2 idler shaft 11 Nut 12 Supply pump gear 13 Flange plate 14 O-ring 15 Key 16 Supply pump 17 O-ring * a: Front case : Non-reusable parts ---===WSE_1505_00010_0184.djvu===--- 13-30 Installation procedure Installation: Supply pump Remove the rocker cover. Bring the No. 1 cylinder piston to the top dead center (TDC) on the compression stroke by the following procedure: Hook on a groove in the fan pulley. Turn the fan pulley in the illustrated direction so that the pointer is aligned with the "I, IV" or "1" to "4" mark on the inscribed scale on the flywheel. This will place either the No. 1 or No. 4 cylinder piston at TDC on the compression stroke. The cylinder in which the rocker arms for both the intake and exhaust valves can be pushed down by hand by the valve clearance amounts has its piston at TDC. Ro- tate the engine by one full turn to switch the TDCs of the No. 1 and No. 4 cylinder pistons. Align the match mark "P" on the supply pump idler gear with that of the supply pump gear. Align the notch on the flange plate with the notch on the supply pump gear. Check that the notch on the flange plate and the notch on the supply pump gear are correctly aligned, and then push the sup- ply pump. Installation: Fuel pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. Tighten it to the specified torque after temporary tightening. SUPPLY PUMP ---===WSE_1505_00010_0185.djvu===--- MEMO 13-31 13 ---===WSE_1505_00010_0186.djvu===--- 13-32 Disassembly sequence WARNING Fuel is highly flammable. Wipe up spilled fuel to avoid the risk of fire. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION When removing the injectors, take care not to strike them with the too, etc. To prevent an injection failure or any other trouble, make sure that no dust enters the injectors and injec- tion pipes. Ensure that no water, oil, etc. is collected around the injection mounting position and then remove the injector. Contact Bosch service station for any service needs of the injector. Assembly sequence Follow the disassembly sequence in reverse. CAUTION When removing the injectors, take care not to strike them with the tool, etc. The injector mounting bolts must always be tightened to the specified torque. Overtightening them could result in a deformed injector and consequently defective fuel injection. 1 Snap ring 2 Fuel return hose 3 Injection pipe 4 Bolt (with hexagonal hole) 5 Injector 6 O-ring 7 Nozzle tip gasket : Non-reusable parts INJECTOR ---===WSE_1505_00010_0186.djvu===--- 13-32 Disassembly sequence WARNING Fuel is highly flammable. Wipe up spilled fuel to avoid the risk of fire. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION When removing the injectors, take care not to strike them with the too, etc. To prevent an injection failure or any other trouble, make sure that no dust enters the injectors and injec- tion pipes. Ensure that no water, oil, etc. is collected around the injection mounting position and then remove the injector. Contact Bosch service station for any service needs of the injector. Assembly sequence Follow the disassembly sequence in reverse. CAUTION When removing the injectors, take care not to strike them with the tool, etc. The injector mounting bolts must always be tightened to the specified torque. Overtightening them could result in a deformed injector and consequently defective fuel injection. 1 Snap ring 2 Fuel return hose 3 Injection pipe 4 Bolt (with hexagonal hole) 5 Injector 6 O-ring 7 Nozzle tip gasket : Non-reusable parts INJECTOR ---===WSE_1505_00010_0186.djvu===--- 13-32 Disassembly sequence WARNING Fuel is highly flammable. Wipe up spilled fuel to avoid the risk of fire. Spilled fuel may catch fire and therefore, must be wiped off completely. CAUTION When removing the injectors, take care not to strike them with the too, etc. To prevent an injection failure or any other trouble, make sure that no dust enters the injectors and injec- tion pipes. Ensure that no water, oil, etc. is collected around the injection mounting position and then remove the injector. Contact Bosch service station for any service needs of the injector. Assembly sequence Follow the disassembly sequence in reverse. CAUTION When removing the injectors, take care not to strike them with the tool, etc. The injector mounting bolts must always be tightened to the specified torque. Overtightening them could result in a deformed injector and consequently defective fuel injection. 1 Snap ring 2 Fuel return hose 3 Injection pipe 4 Bolt (with hexagonal hole) 5 Injector 6 O-ring 7 Nozzle tip gasket : Non-reusable parts INJECTOR ---===WSE_1505_00010_0187.djvu===--- 13 13-33 Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Removal procedure Removal: Injection pipe Position on the pipe and then loosen the union nut. Installation procedure Installation: Injection pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. After temporary tightening, position the torque wrench on and then tighten them to the specified torque. Mark Parts to be tightened Tightening torque Remarks Injection pipe 40.5 ± 2.5 {4.1 ± 0.25} -- Bolt (injector mounting) 5.2 to 7.2 {0.53 to 0.73} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Socket wrench MH063020 Removal and Installation of injection pipe A 17 ---===WSE_1505_00010_0187.djvu===--- 13 13-33 Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Special tools (Unit: mm) Removal procedure Removal: Injection pipe Position on the pipe and then loosen the union nut. Installation procedure Installation: Injection pipe Ensure that the pipe and mounting surfaces of the connector are flat and free from damage. Bring the pipe into intimate contact with mounting surfaces of the connector evenly, and temporarily tighten it without applying an excessive force. After temporary tightening, position the torque wrench on and then tighten them to the specified torque. Mark Parts to be tightened Tightening torque Remarks Injection pipe 40.5 ± 2.5 {4.1 ± 0.25} -- Bolt (injector mounting) 5.2 to 7.2 {0.53 to 0.73} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mark Tool name and shape Part No. Application Socket wrench MH063020 Removal and Installation of injection pipe A 17 ---===WSE_1505_00010_0188.djvu===--- 13E-1 GROUP 13E ENGINE CONTROL SYSTEM SPECIFICATIONS....................................................................(See Gr13.) STRUCTURE AND OPERATION 1. Overview .................................................................................... 13E-2 2. Electronic Control System ........................................................ 13E-11 3. Electronic Control Unit Connection Diagram ............................ 13E-16 TROUBLESHOOTING 1. Inspections Based on Diagnosis Codes ................................... 13E-18 2. Multi-Use Tester Service Data ................................................... 13E-52 3. Actuator Test Using Multi-Use Tester ........................................ 13E-55 4. Work When Replacing the Engine Electronic Control Unit ........ 13E-57 5. Electronic Control Unit Input/Output Table ............................... 13E-61 INSPECTION OF ELECTRICAL PARTS ............................... (See Gr54.) INSTALLED LOCATIONS OF PARTS ................................... (See Gr54.) ELECTRIC CIRCUIT DIAGRAM ............................................ (See Gr54.) ---===WSE_1505_00010_0189.djvu===--- 13E-2 1. Overview In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt- tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec- tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine's operation. The electronic control unit has a diagnosis function that enables it to recognize abnormalities in the common rail system's major components and alert the driver to them. The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail; and the electronic control unit and sensors that are used to control the other components. STRUCTURE AND OPERATION ---===WSE_1505_00010_0189.djvu===--- 13E-2 1. Overview In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt- tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec- tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in order to optimize the engine's operation. The electronic control unit has a diagnosis function that enables it to recognize abnormalities in the common rail system's major components and alert the driver to them. The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail; and the electronic control unit and sensors that are used to control the other components. STRUCTURE AND OPERATION ---===WSE_1505_00010_0190.djvu===--- 13E 13E-3 When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump) simultaneously draws fuel from the fuel tank and feeds it via the fuel filter to the MPROP (rail pressure control valve). A quantity of fuel metered by the MPROP is supplied via the inlet valves to the plunger chambers. The fuel in the plunger chambers is pressurized. The outlet valves are then opened, and the fuel is fed under pressure to the common rail. The pressurized fuel is held in the common rail and then uniformly fed to the injectors. In response to signals from the engine electronic control unit, a magnetic valve in each injector causes the injector to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity. ---===WSE_1505_00010_0191.djvu===--- 13E-4 1.1 Supply pump STRUCTURE AND OPERATION ---===WSE_1505_00010_0192.djvu===--- 13E 13E-5 CAUTION Be sure to connect the MPROP (rail pressure control valve) connector to the engine harness before start- ing the engine. If the engine were started with the MPROP connector not connected, control of the supply pump by the engine electronic control unit would not be possible and a fault would ensue. The supply pump pressurizes fuel and supplies it in a highly pressurized state. Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the MPROP (rail pressure control valve), which controls the amount of fuel reaching the plungers. If the fuel pressure exceeds a certain level, the overflow valve returns fuel to the inlet side of the feed pump. This operation keeps the pressure of the fuel fed to MPROP, constant. Rotation of the eccentric drive shaft causes (via the tappets) up-down movement of the plungers. Fuel in the plunger chambers is thus highly pressurized. ---===WSE_1505_00010_0193.djvu===--- 13E-6 (1) MPROP (rail pressure control valve) The MPROP receives fuel from the feed pump and feeds fuel to- ward the plungers of the supply pump in such a quantity that the fuel pressure corresponds to that required by the engine elec- tronic control unit. When the MPROP is not operating, i.e., when current is not flow- ing, fuel flows at its maximum rate. When current flows, the pis- ton in the MPROP is pressed down such that fuel is not fed toward the plungers. The engine electronic control unit controls the ratio of current-off time (duty ratio). (2) Zero delivery throttle A small amount of fuel can flow through the MPROP (rail pres- sure control valve) to the plunger even when the MPROP reduc- es fuel flow to the fullest extent. To stop the fuel feed to the plunger, the zero delivery throttle is opened to return fuel to the feed pump, causing the fuel flow for the plunger to reach zero. (3) Overflow valve The overflow valve opens when the pressure of the fuel sent from the feed pump exceeds the predetermined level to return the excess fuel to the inlet side of the feed pump. The fuel which has overflowed enters into the eccentric drive shaft chamber to lubricate the parts in the chamber. (4) Flow control valve The flow control valve diverts the excess of fuel sent from the feed pump into the eccentric drive shaft chamber for the part lu- brication. STRUCTURE AND OPERATION ---===WSE_1505_00010_0194.djvu===--- 13E 13E-7 1.2 Common rail The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump. Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel leakage from the injection pipe or excessive injection of fuel from the injector. The common rail pressure sensor is used in feedback control. It senses the fuel pressure inside the common rail and feeds a corresponding signal to the electronic control unit. If the fuel pressure in the common rail exceeds a certain, set level, the valve piston in the pressure limiting valve pushes and compresses the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel pressure from becoming higher than the set pressure. ---===WSE_1505_00010_0195.djvu===--- 13E-8 1.3 Injector In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti- mal quantity. The injector is divided into the control section and the injector section. The control section consists of the control chamber, magnet, valve spring, armature plate, valve ball, valve body, valve piston, orifice A, and orifice Z. The valve piston is located between the control section and the injec- tion section. The injection section consists of the nozzle body, nozzle needle, nozzle spring, and nozzle nut. STRUCTURE AND OPERATION ---===WSE_1505_00010_0196.djvu===--- 13E 13E-9 (5) Operation (5.1) Injection not taking place With the magnet not energized, the ar- mature plate is pushed up by the valve spring such that the ball seat is closed. The high-pressure fuel acts upon the control chamber via orifice Z. The same pressure acts upon the nozzle needle. The fuel pressure acting on the nozzle needle cannot overcome the valve pis- ton and nozzle spring, so the nozzle needle stays in its downward-pushed position and injection does not take place. (5.2) Start of injection When the magnet is energized, the re- sulting electromagnetic force draws the armature plate upward, causing the ball seat to open. Fuel in the control chamber passes through the ball seat and orifice A and flows to the fuel tank. With the pressure in the control cham- ber reduced, the fuel acting on the nozzle needle overcomes the valve piston and nozzle spring, pushing up the nozzle needle such that injection starts. If the magnet remains energized, the injection rate reaches its maximum level. ---===WSE_1505_00010_0197.djvu===--- 13E-10 (5.3) End of injection When energization of the magnet is stopped, the armature plate is pushed downward by the valve spring such that the ball seat closes. At this time, fuel flows into the control chamber via orifice Z, pushing down the valve pis- ton and nozzle needle such that injec- tion finishes. STRUCTURE AND OPERATION ---===WSE_1505_00010_0198.djvu===--- 13E 13E-11 2. Electronic Control System 2.1 System block diagram ---===WSE_1505_00010_0199.djvu===--- 13E-12 Part Main function/operation Engine speed sensor Sensing of engine speed Cylinder recognition sensor Cylinder recognition Water temperature sensor Sensing of coolant temperature Boost pressure sensor Sensing of boost pressure Common rail pressure sensor Sensing of common rail pressure Fuel temperature sensor Sensing of fuel temperature Intake air temperature sensor 1 Sensing of intake air temperature Intake air temperature sensor 2 Sensing of boost air temperature Starter switch Senses that the engine is in starting condition with the starter switch in START position. Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Accelerator pedal switch (incorporated into accelera- tor pedal position sensor) Sensing of released/depressed condition of accelerator pedal (ON with pedal released) Pulse divider (vehicle speed sensor) Sensing of vehicle speed Idling speed adjustment potentiometer Acceleration of warm-up Fuel injection rate adjustment resistor Correction of fuel injection rate DPF differential pressure sensor Detection of pressure differential between DPF inlet pressure and at- mospheric pressure Diagnosis switch Output of diagnosis codes Clutch switch Sensing of released/depressed condition of clutch pedal (OFF with pedal released) Transmission neutral switch Detection of transmission neutral condition (OFF with transmission in neutral) Exhaust brake switch Exhaust brake ON/OFF control Air flow sensor Sensing of intake air flow rate Torque limit switch Detection of 1st and reverse positions Injector magnetic valve Control of fuel injection rate, fuel injection quantity, and fuel injection timing MPROP (rail pressure control valve) Control of fuel injection pressure Engine warning lamp Indication of system abnormalities Tachometer Indication of engine speed (in meter cluster) Glow drive relay ON/OFF control of glow plugs Exhaust shutter 3-way magnetic valve ON/OFF control of exhaust shutter valve Safety relay Control of starter continuous energization prevention function EDU relay Switching ON/OFF supply of power to exhaust gas recirculation elec- tronic drive unit, throttle and turbocharger electronic drive unit CAN communication (EGR EDU, Throttle EDU, Turbo- charger EDU) Engine data recognized by the engine electronic control unit are output- ted to the CAN bus to enable systems to obtain data that they need for control. Each electronic drive unit issues signals to the engine electron- ic control unit via the CAN bus to enable it to effect engine control ap- propriate for each type of system control. CAN communication (Multi-Use Tester) Allowing the service personnel to read or erase diagnosis codes and obtain the electronic control unit and vehicle data using a scan tool. STRUCTURE AND OPERATION ---===WSE_1505_00010_0200.djvu===--- 13E 13E-13 2.2 Fuel injection control (1) Pilot injection Pilot injection entails the injection of an extremely small amount of fuel ahead of the main injection. Pilot injection suppresses heat generation early in the injection cycle and thus suppresses NOx generation and noise at the start of combustion. (2) Split injection control Split injection entails the injection of an extremely small amount of fuel two or more times ahead of the main injection. Split injection increases the fuel's combustibility and thus en- hances the engine's cold startability. 2.3 Fuel injection quantity control (1) Fuel injection quantity during engine startup During engine startup, the fuel injection quantity is determined in accordance with the engine speed and coolant temperature. (2) Basic fuel injection quantity The basic fuel injection quantity is determined in accordance with the engine speed and throttle opening. (3) Maximum injection quantity The maximum injection quantity is calculated from the engine speed and boost pressure. ---===WSE_1505_00010_0201.djvu===--- 13E-14 (4) Fuel injection rate adjustment resistor correction amount To limit inconsistency in the injection quantity, the injection quan- tity is corrected by the fuel injection rate adjustment resistor. 2.4 Fuel injection timing control (1) Main injection timing The main injection timing is calculated from the fuel injection quantity and engine speed. (2) Pilot injection timing (pilot interval) The pilot injection timing is calculated from the fuel injection quantity and engine speed. 2.5 Fuel injection pressure control The fuel injection pressure is calculated from the fuel injection quantity and engine speed. 2.6 Warm-up acceleration function The warm-up acceleration function accelerates engine warm-up by varying the engine's idling speed in accor- dance with the engine's coolant temperature. It can operate either automatically or manually. Selection is made using the idling speed adjustment potentiometer. Water temperature sensor Accelerator pedal position sensor Idling speed adjustment potentiometer Input signals Engine electronic control unit Output signals Comparison operations Target injection quantity Idling speed control STRUCTURE AND OPERATION ---===WSE_1505_00010_0202.djvu===--- 13E 13E-15 2.7 Auxiliary brake function The auxiliary brake function activates or deactivates the exhaust shutter 3-way magnetic valve according to the vehicle condition to control the exhaust brake. 2.8 Idle-up function The idle-up function increases the engine idling speed when a load is applied to the engine by other system (such as air conditioner) or when the warm-up acceleration function are activated. 2.9 Fault diagnosis function The sensors and other components are continuously monitored for faults. In the event that a component is found faulty, an indication is made in the meter cluster to alert the driver, the fault location is memorized in the form of a diagnosis code, and the control during fault is initiated. While the control during fault is taking place, the system's functionality is limited to ensure vehicle and driver safe- ty. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning lamp. The control during fault recovers by servicing the faults. However, for some diagnosis codes, the warning lamp stays illuminated until the normal signals are input for several times. Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. The Multi-Use Tester is capable of showing more detailed diagnosis codes. Accelerator pedal position sensor Clutch switch Transmission neutral switch Exhaust brake switch Input signals Engine electronic control unit Output signals Auxiliary brake function Exhaust shutter 3-way magnetic valve ---===WSE_1505_00010_0203.djvu===--- 13E-16 3. Electronic Control Unit Connection Diagram C10044-ECU-13E-1 Motor(U) Motor(V) Motor(W) Hall IC(U) Hall IC(power supply) Shield GND Hall IC(GND) POWER GND POWER THROTTLE ACT(M1) THROTTLE SENSOR(+5V) THROTTLE SENSOR(GND) THROTTLE SENSOR(SIG) THROTTLE ACT(M2) Hall IC(V) Shield GND Hall IC(W) Shield GND CAN(H) CAN(L) CAN(H) CAN(H) CAN(L) CAN(L) GND SIG CAN resistor Exhaust gas recirculation electronic drive unit Throttle electronic drive unit Motor Motor Exhaust gas recirculation valve Intake throttle (Diagnosis code display: TVA SNSR) GND Starter switch M9 B9 S1 M2 M8 M5 B LOCK ACC ON START MFS A B27 B5 B6 B44 B43 B40 B15 B58 B56 B54 B57 B55 B53 B35 B49 B34 B46 A20 A69 A3 A2 A21 A72 A23 A96 A24 A71 A46 A95 A48 A11 A38 A13 A37 A34 A14 A33 A12 A36 A35 A88 A40 A41 A89 A65 A63 A32 B1 B2 A86 B39 B14 SIG GND SIG GND SIG GND SIG GND SIG +5V GND SIG +5V GND SIG +5V GND Twist pair Twist pair Twist pair Twist pair Electronic drive unit relay Air flow sensor DC24V Battery STARTER SW(S) STARTER SW(M)-1 STARTER SW(M)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-1 ELECTRONIC CONTROL UNIT POWER(+VB)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-3 GND(POWER GND) GND(ANALOG GND) GND(POWER GND) (+) (+) (-) (-) (-) (+) (+) (+) (-) (+) (-) (-) Engine electronic control unit MPROP (rail pressure control valve) B33 B45 Common rail pressure sensor Boost pressure sensor Idling speed adjustment potentiometer Fuel injection rate adjustment resistor (Diagnosis code display: Q Adjustment Resistor Service data display: Q Adjustment Resistor No.) B30 13 5 2 3 4 1 6 7 8 14 16 15 4 7 3 6 2 5 1 8 12 11 10 13 5 5 2 3 4 2 3 4 1 6 6 7 8 14 13 14 16 15 16 15 4 7 3 6 2 4 3 2 5 1 8 12 11 11 10 10 B29 SIG GND Intake air temperature sensor 2 (Diagnosis code display: EGR Gas Temp Sensor) Water temperature sensor Fuel temperature sensor Intake air temperature sensor 1 (Red) (Amber) Diagnosis switch No. 1 cylinder (No. 1 injection) No. 3 cylinder (No. 2 injection) No. 4 cylinder (No. 3 injection) No. 2 cylinder (No. 4 injection) Injector magnetic valve Engine warning lamp (+) (-) Motor(U) Motor(V) Motor(W) Hall IC(U) Hall IC(power supply) Shield GND Hall IC(GND) POWER GND Hall IC(V) Shield GND Hall IC(W) Shield GND CAN(H) CAN(L) Turbocharger electronic drive unit Motor Position sensor Position sensor Position sensor Turbocharger actuator Accelerator pedal position sensor Accelerator pedal switch (Opened when pressed : closed when released) Sensor 1 Sensor 2 +5V SIG GND +5V SIG GND Fuse box High-current fuse box 9 POWER OUT STRUCTURE AND OPERATION ---===WSE_1505_00010_0204.djvu===--- 13E 13E-17 C10044-ECU-13E-2 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 13 53 55 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 39 57 54 56 58 52 1 2 3 4 5 6 7 8 9 10 11 12 25 26 27 28 29 30 31 32 33 34 35 36 20 44 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 13 37 61 85 14 38 62 86 15 39 63 87 16 40 64 88 17 41 65 89 18 42 66 90 19 43 67 91 68 92 21 45 69 93 22 46 70 94 23 47 71 95 24 48 72 96 B:GE58A B A:GE96A A A81 A49 A17 A76 A73 A7 A51 A67 A25 B11 B12 A6 B4 B51 B37 Twist pair Twist pair (+) (-) SIG CAN(H) CAN(L) Clutch switch To Starter relay Engine electronic control unit Safety relay Transmission neutral switch Exhaust brake switch (Diagnosis code display: Auxiliary Brake SW 1) Exhaust shutter 3-way magnetic valve (Diagnosis code display: Auxiliary Brake PWR Service data and actuator test display: Auxiliary Brake M/V 1) To Glow plug Glow drive relay Glow relay (+) (-) CAN(H) CAN(L) Multi-Use Tester connector Meter cluster Pulse divider Tachometer IN OUT CAN resistor Vehicle speed sensor A10 A9 A78 A59 A83 SIG SIG GND GND +5V Engine speed sensor Cylinder recognition sensor (Diagnosis code display: Camshaft Position SNSR) A61 A84 A85 SIG +5V GND Diesel particulate filter differential pressure sensor (Diagnosis code display: DPF Diff SNSR) A92 Torque limit switch ---===WSE_1505_00010_0205.djvu===--- 13E-18 1. Inspections Based on Diagnosis Codes 1.1 Diagnosis code list Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. The Multi-Use Tester is capable of showing more detailed diagnosis codes. The control during fault recovers by servicing the faults. However, for some diagnosis codes, the warning lamp stays illuminated until the normal signals are input for several times. Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange Red P0016 Ne SNSR Offset/Backup Mode 14 O O P0045 VGT Actuator (Open) 51 O -- P0046 VGT Actuator (Performance) 51 O -- P0047 VGT Actuator (Low) 51 O -- P0069 Boost Press SNSR (Correlation) 32 O -- P0087 CRS (Too Low) 22 O O 36 O -- P0088 CRS (Too High) 23 O O P0089 MPROP (Over Load) 63 O -- P0090 MPROP (Open Circuit) 63 O -- P0091 MPROP (Low) 63 O -- P0092 MPROP (High) 63 O -- P0093 CRS (Fuel Leak) 22 O O P0101 Airflow Sensor (Plausibility) 17 O -- P0102 Airflow Sensor (Low) 17 O -- P0103 Airflow Sensor (High) 17 O -- P0112 INT Air Temp. SNSR (Low) 44 O -- P0113 INT Air Temp. SNSR (High) 44 O -- P0116 Water Temp SNSR (Plausibility) 21 O -- P0117 Water Temp SNSR (Low) 21 O -- P0118 Water Temp SNSR (High) 21 O -- P0120 TVA SNSR 28 O -- P0148 CRS (Fuel Delivery) 22,23 O O 36 O -- P0182 Fuel Temp. Sensor (inlet) Low 41 -- -- P0183 Fuel Temp. Sensor (inlet) High 41 -- -- P0191 CRS Pressure SNSR (Plausibility) 11 O -- P0192 CRS Pressure SNSR (Low) 11 O -- P0193 CRS Pressure SNSR (High) 11 O -- P0201 Injector M/V-Cylinder 1 (Load) 37 O -- P0202 Injector M/V-Cylinder 2 (Load) 38 O -- P0203 Injector M/V-Cylinder 3 (Load) 39 O -- P0204 Injector M/V-Cylinder 4 (Load) 8 O -- P0219 Engine Overrunning 7 -- O P0234 Over Boost 54 O -- P0236 Boost Press SNSR (Plausi) 54 O -- P0237 Boost Press SNSR (Low) 32 O -- P0238 Boost Press SNSR (High) 32 O -- P0261 Injector #1-A (Low) 37 O -- P0262 Injector #1-A (High) 37 O -- P0264 Injector #2-A (Low) 38 O -- P0265 Injector #2-A (High) 38 O -- TROUBLESHOOTING ---===WSE_1505_00010_0205.djvu===--- 13E-18 1. Inspections Based on Diagnosis Codes 1.1 Diagnosis code list Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. The Multi-Use Tester is capable of showing more detailed diagnosis codes. The control during fault recovers by servicing the faults. However, for some diagnosis codes, the warning lamp stays illuminated until the normal signals are input for several times. Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange Red P0016 Ne SNSR Offset/Backup Mode 14 O O P0045 VGT Actuator (Open) 51 O -- P0046 VGT Actuator (Performance) 51 O -- P0047 VGT Actuator (Low) 51 O -- P0069 Boost Press SNSR (Correlation) 32 O -- P0087 CRS (Too Low) 22 O O 36 O -- P0088 CRS (Too High) 23 O O P0089 MPROP (Over Load) 63 O -- P0090 MPROP (Open Circuit) 63 O -- P0091 MPROP (Low) 63 O -- P0092 MPROP (High) 63 O -- P0093 CRS (Fuel Leak) 22 O O P0101 Airflow Sensor (Plausibility) 17 O -- P0102 Airflow Sensor (Low) 17 O -- P0103 Airflow Sensor (High) 17 O -- P0112 INT Air Temp. SNSR (Low) 44 O -- P0113 INT Air Temp. SNSR (High) 44 O -- P0116 Water Temp SNSR (Plausibility) 21 O -- P0117 Water Temp SNSR (Low) 21 O -- P0118 Water Temp SNSR (High) 21 O -- P0120 TVA SNSR 28 O -- P0148 CRS (Fuel Delivery) 22,23 O O 36 O -- P0182 Fuel Temp. Sensor (inlet) Low 41 -- -- P0183 Fuel Temp. Sensor (inlet) High 41 -- -- P0191 CRS Pressure SNSR (Plausibility) 11 O -- P0192 CRS Pressure SNSR (Low) 11 O -- P0193 CRS Pressure SNSR (High) 11 O -- P0201 Injector M/V-Cylinder 1 (Load) 37 O -- P0202 Injector M/V-Cylinder 2 (Load) 38 O -- P0203 Injector M/V-Cylinder 3 (Load) 39 O -- P0204 Injector M/V-Cylinder 4 (Load) 8 O -- P0219 Engine Overrunning 7 -- O P0234 Over Boost 54 O -- P0236 Boost Press SNSR (Plausi) 54 O -- P0237 Boost Press SNSR (Low) 32 O -- P0238 Boost Press SNSR (High) 32 O -- P0261 Injector #1-A (Low) 37 O -- P0262 Injector #1-A (High) 37 O -- P0264 Injector #2-A (Low) 38 O -- P0265 Injector #2-A (High) 38 O -- TROUBLESHOOTING ---===WSE_1505_00010_0206.djvu===--- 13E 13E-19 P0267 Injector #3-A (Low) 39 O -- P0268 Injector #3-A (High) 39 O -- P0270 Injector #4-A (Low) 8 O -- P0271 Injector #4-A (High) 8 O -- P0335 Engine Revolution SNSR 15 O -- P0339 Engine Revolution SNSR (Plausi) 15 O O P0340 Camshaft Position SNSR 12 O -- P0344 Camshaft Position SNSR (Plausi) 12 O -- P0380 Relay for Glow Relay 26 -- -- P0381 Glow Lamp 89 -- -- P0401 EGR Flow (Insufficient) 2 O -- P0402 EGR Flow (Excessive) 2 O -- P0403 EGR1 (Actuator Circuit) 67 O -- P0404 EGR System 2 O -- P0409 EGR1 (Position Sensor) 67 O -- P040C EGR Gas Temp Sensor (Low) 9 O -- P040D EGR Gas Temp Sensor (High) 9 O -- P0475 Exhaust Brake PWR (Open) 93 O -- P0476 Exhaust Brake PWR (Performance) 93 O -- P0477 Exhaust Brake PWR (Low) 93 O -- P0478 Exhaust Brake PWR (High) 93 O -- P0500 Vehicle Speed Sensor 25 O -- P0508 Idle Volume & Idle Acc (Low) 31 -- -- P0509 Idle Volume & Idle Acc (High) 31 -- -- P0562 Power Supply Voltage (Low) 33 O -- P0563 Power Supply Voltage (High) 33 O -- P0600 CAN Communication 64 -- O 73 O -- P0607 ECU System 33 O O P060B A/D Converter 33 O O 63 O -- P0615 Starter Safety Relay (Over Load) 48 -- O P0616 Starter Safety Relay (Low) 48 -- O P0617 Starter Safety Relay (High) 48 -- O P061B ECU Performance (Calc) 33 O -- P061C ECU Performance (Ne) 33 O -- P062D Injector Bank 1 82 O -- P062E Injector Bank 2 82 O -- P062F ECU System (EEPROM) 33 O -- P0642 Sensor Supply Voltage 1 (Low) 81 O -- P0643 Sensor Supply Voltage 1 (High) 81 O -- P0650 MIL 3 -- -- P0652 Sensor Supply Voltage 2 (Low) 81 O -- P0653 Sensor Supply Voltage 2 (High) 81 O -- P0657 M/V Voltage (Low) 79 O -- P0685 EDU Relay (Open) 84 O -- P0686 EDU Relay (Low) 84 O -- P0687 EDU Relay (High) 84 O -- Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange Red ---===WSE_1505_00010_0207.djvu===--- 13E-20 P0698 Sensor Supply Voltage 3 (Low) 81 O -- P0699 Sensor Supply Voltage 3 (High) 81 O -- P1171 Q Adjustment Resistor (Low) 34 O -- P1172 Q Adjustment Resistor (High) 34 O -- P1C01 Inter Cooler Performance 27 O -- P1C11 Injector #1-A (Plausibility) 37 O -- P1C12 Injector #2-A (Plausibility) 38 O -- P1C13 Injector #3-A (Plausibility) 39 O -- P1C14 Injector #4-A (Plausibility) 8 O -- P2002 DPF MFF 55 O -- P2100 TVA (Open) 28 O -- P2101 TVA (System) 28 O -- P2102 TVA (Short) 28 O -- P2120 Acc Switch 65 -- -- P2122 Acc Sensor 1 (Low) 24 O -- P2123 Acc Sensor 1 (High) 24 O -- P2127 Acc Sensor 2 (Low) 16 O -- P2128 Acc Sensor 2 (High) 16 O -- P2135 TVA SNSR (Voltage) 28 O -- P2138 Acc Sensor Correlation 24,58 O -- P2147 Injector Bank 1 (Low) 82 O -- P2148 Injector Bank 1 (High) 82 O -- P2150 Injector Bank 2 (Low) 82 O -- P2151 Injector Bank 2 (High) 82 O -- P2199 EGR Temp Sensor (Correlation) 9 O -- P2227 Atm Press SNSR (Plausibility) 19 O -- P2228 Atm Press SNSR (Low) 19 O -- P2229 Atm Press SNSR (High) 19 O -- P2263 VGT System 51,54 O -- P2279 Intake Pipe Leak 27 O -- P2413 EGR System 67 O -- P242F DPF MFF (Accumulation) 55 O -- P2453 DPF Diff SNSR (Plausi) & MFF 97 O -- P2454 DPF Diff SNSR (Low) & MFF 97 O -- P2455 DPF Diff SNSR (High) & MFF 97 O -- P2457 EGR Cooler Performance 2 O -- P2562 VGT Position Sensor 51 O -- P2670 MPROP Voltage (Low) 36 O -- Multi-Use Tester indication Warning lamp indication Remarks Code Message Flashes Orange Red TROUBLESHOOTING ---===WSE_1505_00010_0208.djvu===--- 13E 13E-21 1.2 Diagnosis code generation conditions and inspection items P0016: Ne SNSR Offset/Backup Mode (warning lamp flashes: 14) P0045: VGT Actuator (Open) (warning lamp flashes: 51) P0046: VGT Actuator (Performance) (warning lamp flashes: 51) Generation condition There is too large difference between engine speed sensor signal and cylinder recognition sensor signal. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and engine speed sensor Open-circuit or short-circuit of harness between engine electronic control unit and cylinder recognition sensor Malfunction of each connector Malfunction of engine speed sensor Malfunction of cylinder recognition sensor Malfunction of engine electronic control unit Generation condition Open turbocharger actuator circuit Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and tur- bocharger actuator Malfunction of each connector Malfunction of motor (built in turbocharger actuator) Malfunction of position sensor (built in turbocharger actuator) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Turbocharger actuator circuit is locked. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and tur- bocharger actuator Malfunction of each connector Malfunction of motor (built in turbocharger actuator) Malfunction of position sensor (built in turbocharger actuator) Malfunction of electronic drive unit Malfunction of electronic drive unit relay ---===WSE_1505_00010_0209.djvu===--- 13E-22 P0047: VGT Actuator (Low) (warning lamp flashes: 51) P0069: Boost Press SNSR (Correlation) (warning lamp flashes: 32) P0087: CRS (Too Low) (warning lamp flashes: 22, 36) P0088: CRS (Too High) (warning lamp flashes: 23) Generation condition Turbocharger actuator circuit is shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and tur- bocharger actuator Malfunction of each connector Malfunction of motor (built in turbocharger actuator) Malfunction of position sensor (built in turbocharger actuator) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Engine electronic control unit has judged boost pressure sensor abnormal as a result of comparison with conditions of other sensors. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Boost pressure sensor Malfunction of each connector Malfunction of Boost pressure sensor Malfunction of engine electronic control unit Generation condition Common rail pressure too low Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of supply pump Malfunction of pressure limiter Injector not airtight Clogged fuel system Generation condition Common rail pressure too high Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of supply pump TROUBLESHOOTING ---===WSE_1505_00010_0210.djvu===--- 13E 13E-23 P0089: MPROP (Over Load) (warning lamp flashes: 63) P0090: MPROP (Open Circuit) (warning lamp flashes: 63) P0091: MPROP (Low) (warning lamp flashes: 63) P0092: MPROP (High) (warning lamp flashes: 63) Generation condition MPROP (rail pressure control valve) circuit is overloaded. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and MPROP (rail pressure control valve) Malfunction of each connector Malfunction of MPROP (rail pressure control valve) Malfunction of engine electronic control unit Generation condition MPROP (rail pressure control valve) circuit open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and MPROP (rail pressure control valve) Malfunction of each connector Malfunction of MPROP (rail pressure control valve) Malfunction of engine electronic control unit Generation condition MPROP (rail pressure control valve) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and MPROP (rail pressure control valve) Malfunction of each connector Malfunction of MPROP (rail pressure control valve) Malfunction of engine electronic control unit Generation condition MPROP (rail pressure control valve) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and MPROP (rail pressure control valve) Malfunction of each connector Malfunction of MPROP (rail pressure control valve) Malfunction of engine electronic control unit ---===WSE_1505_00010_0211.djvu===--- 13E-24 P0093: CRS (Fuel Leak) (warning lamp flashes: 22) P0101: Airflow Sensor (Plausibility) (warning lamp flashes: 17) P0102: Airflow Sensor (Low) (warning lamp flashes: 17) P0103: Airflow Sensor (High) (warning lamp flashes: 17) Generation condition Fuel system is leaking (significant leakage). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine stops. Possible causes Malfunction of supply pump Malfunction of pressure limiter Airtight malfunction of injector Clogging of fuel system Generation condition Engine electronic control unit has judged air flow sensor abnormal as a result of comparison with conditions of other sensors. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Carries out control using a backup value (airflow rate equivalent to rate for low idle speed operation). Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Air flow sensor Malfunction of each connector Malfunction of air flow sensor Malfunction of engine electronic control unit Generation condition Airflow sensor voltage is lower than specified value. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Carries out control using a backup value (airflow rate equivalent to rate for low idle speed operation). Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and air flow sensor Malfunction of each connector Malfunction of air flow sensor Malfunction of engine electronic control unit Generation condition Airflow sensor voltage is higher than specified value. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Carries out control using a backup value (airflow rate equivalent to rate for low idle speed operation). Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and air flow sensor Malfunction of each connector Malfunction of air flow sensor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0212.djvu===--- 13E 13E-25 P0112: INT Air Temp. SNSR (Low) (warning lamp flashes: 44) P0113: INT Air Temp. SNSR (High) (warning lamp flashes: 44) P0116: Water Temp SNSR (Plausibility) (warning lamp flashes: 21) P0117: Water Temp SNSR (Low) (warning lamp flashes: 21) Generation condition Intake air temperature sensor 1 voltage is at or below the specified value (0.15 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Backup value (25°C) is used. Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and intake air temperature sensor 1 Malfunction of each connector Malfunction of intake air temperature sensor 1 Malfunction of engine electronic control unit Generation condition Intake air temperature sensor 1 voltage is at or above the specified value (4.87 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Backup value (25°C) is used. Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and intake air temperature sensor 1 Malfunction of each connector Malfunction of intake air temperature sensor 1 Malfunction of engine electronic control unit Generation condition Engine electronic control unit has judged water temperature sensor abnormal as a result of comparison with conditions of other sensors. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Backup value (80°C) is used. Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and water temperature sensor Malfunction of each connector Malfunction of water temperature sensor Malfunction of engine electronic control unit Generation condition Water temperature sensor voltage is at or below the specified value (0.2 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Backup value (80°C) is used. Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Op en-circuit or short-circuit of harness between engine electronic control unit and water temperature sensor Malfunction of each connector Malfunction of water temperature sensor Malfunction of engine electronic control unit ---===WSE_1505_00010_0213.djvu===--- 13E-26 P0118: Water Temp SNSR (High) (warning lamp flashes: 21) P0120: TVA SNSR (warning lamp flashes: 28) P0148: CRS (Fuel Delivery) (warning lamp flashes: 22, 23, 36) P0182: Fuel Temp. Sensor (inlet) (Low) (warning lamp flashes: 41) P0183: Fuel Temp. Sensor (inlet) (High) (warning lamp flashes: 41) Generation condition Water temperature sensor voltage is at or above the specified value (4.8 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Backup value (80°C) is used. Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and water temperature sensor Malfunction of each connector Malfunction of water temperature sensor Malfunction of engine electronic control unit Generation condition Throttle electronic drive unit judges throttle position sensor faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and in- take throttle Malfunction of each connector Malfunction of motor (built in intake throttle) Malfunction of throttle position sensor (built in intake throttle) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Leakage (large amount of leakage) was found in the fuel system. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine stops. Possible causes Malfunction of supply pump Malfunction of pressure limiter Airtight malfunction of injector Clogging of fuel system Generation condition Fuel temperature sensor voltage is at or below the specified value (0.15 V). Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Engine is controlled using backup value (40°C). Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and fuel temperature sensor Malfunction of each connector Malfunction of fuel temperature sensor Malfunction of engine electronic control unit Generation condition Fuel temperature sensor voltage is at or above the specified value (4.8 V). Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Engine is controlled using backup value (40°C). Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and fuel temperature sensor Malfunction of each connector Malfunction of fuel temperature sensor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0214.djvu===--- 13E 13E-27 P0191: CRS Pressure SNSR (Plausibility) (warning lamp flashes: 11) P0192: CRS Pressure SNSR (Low) (warning lamp flashes: 11) P0193: CRS Pressure SNSR (High) (warning lamp flashes: 11) P0201: Injector M/V-Cylinder 1 (Load) (warning lamp flashes: 37) Generation condition Engine electronic control unit has judged that common rail pressure sensor was faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and common rail pressure sensor Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of engine electronic control unit Generation condition Common rail pressure sensor voltage is at or below the specified value (0.2 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and common rail pressure sensor Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of engine electronic control unit Generation condition Common rail pressure sensor voltage is at or above the specified value (4.8 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and common rail pressure sensor Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 1 cylinder) circuit shorted or open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 1 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 1 cylinder) Malfunction of engine electronic control unit ---===WSE_1505_00010_0215.djvu===--- 13E-28 P0202: Injector M/V-Cylinder 2 (Load) (warning lamp flashes: 38) P0203: Injector M/V-Cylinder 3 (Load) (warning lamp flashes: 39) P0204: Injector M/V-Cylinder 4 (Load) (warning lamp flashes: 8) P0219: Engine Overrunning (warning lamp flashes: 7) Generation condition Injector magnetic valve (No. 2 cylinder) circuit shorted or open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 2 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 2 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 3 cylinder) circuit shorted or open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 3 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 3 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 4 cylinder) circuit shorted or open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 4 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 4 cylinder) Malfunction of engine electronic control unit Generation condition Engine speed is higher than specification (3,700 rpm). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Fuel injection is stopped. Possible causes Mistake of shifting TROUBLESHOOTING ---===WSE_1505_00010_0216.djvu===--- 13E 13E-29 P0234: Over Boost (warning lamp flashes: 54) P0236: Boost Press SNSR (Plausi) (warning lamp flashes: 54) P0237: Boost Press SNSR (Low) (warning lamp flashes: 32) P0238: Boost Press SNSR (High) (warning lamp flashes: 32) Generation condition Boost pressure is more than a regulated value the engine running. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Mechanical failure of turbocharger Generation condition Engine electronic control unit has judged that boost pressure sensor was faulty Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Boost pressure sensor Malfunction of each connector Malfunction of Boost pressure sensor Malfunction of engine electronic control unit Generation condition Boost pressure sensor voltage is at or below the specified value (0.3 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and boost pressure sensor Malfunction of each connector Malfunction of boost pressure sensor Malfunction of engine electronic control unit Generation condition Boost pressure sensor voltage is at or above the specified value (4.8 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and boost pressure sensor Malfunction of each connector Malfunction of boost pressure sensor Malfunction of engine electronic control unit ---===WSE_1505_00010_0217.djvu===--- 13E-30 P0261: Injector #1-A (Low) (warning lamp flashes: 37) P0262: Injector #1-A (High) (warning lamp flashes: 37) P0264: Injector #2-A (Low) (warning lamp flashes: 38) P0265: Injector #2-A (High) (warning lamp flashes: 38) Generation condition Injector magnetic valve (No. 1 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 1 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 1 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 1 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 1 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 1 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 2 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 2 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 2 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 2 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 2 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 2 cylinder) Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0218.djvu===--- 13E 13E-31 P0267: Injector #3-A (Low) (warning lamp flashes: 39) P0268: Injector #3-A (High) (warning lamp flashes: 39) P0270: Injector #4-A (Low) (warning lamp flashes: 8) P0271: Injector #4-A (High) (warning lamp flashes: 8) Generation condition Injector magnetic valve (No. 3 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 3 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 3 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 3 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 3 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 3 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 4 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 4 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 4 cylinder) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 4 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 4 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 4 cylinder) Malfunction of engine electronic control unit ---===WSE_1505_00010_0219.djvu===--- 13E-32 P0335: Engine Revolution SNSR (warning lamp flashes: 15) P0339: Engine Revolution SNSR (Plausi) (warning lamp flashes: 15) P0340: Camshaft Position SNSR (warning lamp flashes: 12) P0344: Camshaft Position SNSR (Plausi) (warning lamp flashes: 12) Generation condition No engine speed sensor signals are received. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using cylinder recognition sensors. Injection quantity is limited. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and engine speed sensor Malfunction of each connector Malfunction of engine speed sensor Malfunction of engine electronic control unit Generation condition Engine speed sensor signal indicates too high speeds (6,000 rpm or higher). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using cylinder recognition sensors. Injection quantity is limited. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and engine speed sensor Malfunction of each connector Malfunction of engine speed sensor Malfunction of engine electronic control unit Generation condition No cylinder recognition sensor signals are received. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using engine speed sensors. Injection quantity is limited. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and cylinder recognition sensor Malfunction of each connector Malfunction of cylinder recognition sensor Malfunction of engine electronic control unit Generation condition Cylinder recognition sensor signals are irregular (due to too large inconsistency in angular recognition between camshaft and crankshaft). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using engine speed sensors. Injection quantity is limited. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and cylinder recognition sensor Malfunction of each connector Malfunction of cylinder recognition sensor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0220.djvu===--- 13E 13E-33 P0380: Relay for Glow Relay (warning lamp flashes: 26) P0381: Glow Lamp (warning lamp flashes: 89) P0401: EGR Flow (Insufficient) (warning lamp flashes: 2) P0402: EGR Flow (Excessive) (warning lamp flashes: 2) Generation conditions Glow drive relay short or open circuit, or overload Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit Suspend glow control Possible causes Open-circuited or short-circuited harness between engine electronic control unit and glow drive relay Malfunction of each connector Malfunction of glow drive relay Malfunction of engine electronic control unit Generation conditions Glow indicator lamp short or open circuit, or overload Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit Normal control Possible causes Open-circuited or short-circuited harness between engine electronic control unit and meter cluster (glow indicator lamp) Malfunction of each connector Malfunction of meter cluster (glow indicator lamp) Malfunction of engine electronic control unit Generation conditions Exhaust gas recirculation flow rate is excessively low. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Exhaust gas recirculation valve Malfunction of each connector Malfunction of Exhaust gas recirculation valve Malfunction of engine electronic control unit Generation conditions Exhaust gas recirculation flow rate is excessively high. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Exhaust gas recirculation valve Malfunction of each connector Malfunction of Exhaust gas recirculation valve Malfunction of engine electronic control unit ---===WSE_1505_00010_0221.djvu===--- 13E-34 P0403: EGR 1 (Actuator Circuit) (warning lamp flashes: 67) P0404: EGR System (warning lamp flashes: 2) P0409: EGR 1 (Position Sensor) (warning lamp flashes: 67) P040C: EGR Gas Temp Sensor (Low) (warning lamp flashes: 9) Generation condition Exhaust gas recirculation electronic drive unit has judged that exhaust gas recir- culation valve motor was faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and exhaust gas recirculation valve Malfunction of each connector Malfunction of motor (built in exhaust gas recirculation valve) Malfunction of position sensor (built in exhaust gas recirculation valve) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Motor abnormality (permanent) Recoverability System recovers (power is re-supplied to electronic control unit) if signal be- comes normal when starter switch is turned OFF → ON. Control effected by electronic control unit Engine output lowered. Possible causes Failure of exhaust gas recirculation system Generation condition Exhaust gas recirculation electronic drive unit judges exhaust gas recirculation position sensor faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and exhaust gas recirculation valve Malfunction of each connector Malfunction of motor (built in exhaust gas recirculation valve) Malfunction of position sensor (built in exhaust gas recirculation valve) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Intake air temperature sensor 2 voltage is at or below the specified value (0.15 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and intake air temperature sensor 2 Malfunction of each connector Malfunction of intake air temperature sensor 2 Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0222.djvu===--- 13E 13E-35 P040D: EGR Gas Temp Sensor (High) (warning lamp flashes: 9) P0475: Exhaust Brake PWR (Open) (warning lamp flashes: 93) P0476: Exhaust Brake PWR (Performance) (warning lamp flashes: 93) P0477: Exhaust Brake PWR (Low) (warning lamp flashes: 93) Generation condition Intake air temperature sensor 2 voltage is at or above the specified value (4.8 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and intake air temperature sensor 2 Malfunction of each connector Malfunction of intake air temperature sensor 2 Malfunction of engine electronic control unit Generation condition Exhaust shutter 3-way magnetic valve circuit is open. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control of auxiliary brake function is deactivated. White smoke reduction control is deactivated if idling condition is held for an extended period of time. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and exhaust shutter 3-way magnetic valve Malfunction of each connector Malfunction of exhaust shutter 3-way magnetic valve Malfunction of engine electronic control unit Generation condition Exhaust shutter 3-way magnetic valve circuit is overloaded. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control of auxiliary brake function is deactivated. White smoke reduction control is deactivated if idling condition is held for an extended period of time. Possible causes Short-circuited harness between engine electronic control unit and exhaust shutter 3-way magnetic valve Malfunction of each connector Malfunction of exhaust shuttter 3-way magnetic valve Malfunction of engine electronic control unit Generation condition Exhaust shutter 3-way magnetic valve circuit is shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control of auxiliary brake function is deactivated. White smoke reduction control is deactivated if idling condition is held for an extended period of time. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and exhaust shutter 3-way magnetic valve Malfunction of each connector Malfunction of exhaust shutter 3-way magnetic valve Malfunction of engine electronic control unit ---===WSE_1505_00010_0223.djvu===--- 13E-36 P0478: Exhaust Brake PWR (High) (warning lamp flashes: 93) P0500: Vehicle Speed Sensor (warning lamp flashes: 25) P0508: Idle Volume & Idle Acc (Low) (warning lamp flashes: 31) P0509: Idle Volume & Idle Acc (High) (warning lamp flashes: 31) P0562: Power Supply Voltage (Low) (warning lamp flashes: 33) Generation condition Exhaust shutter 3-way magnetic valve circuit is shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control of auxiliary brake function is deactivated. White smoke reduction control is deactivated if idling condition is held for an extended period of time. Possible causes Short-circuited harness between engine electronic control unit and exhaust shutter 3-way magnetic valve Malfunction of each connector Malfunction of exhaust shutter 3-way magnetic valve Malfunction of engine electronic control unit Generation condition No vehicle speed sensor signals are received. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine speed is limited. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and pulse divider (built in meter cluster) Malfunction of each connector Malfunction of pulse divider (built in meter cluster) Malfunction of engine electronic control unit Generation condition Idling speed adjustment potentiometer voltage is at or below the specified value (0.7 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine idling speed control is fixed to automatic control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and idling speed adjustment potentiometer Malfunction of each connector Malfunction of idling speed adjustment potentiometer Malfunction of engine electronic control unit Generation condition Idling speed adjustment potentiometer voltage is at or above the specified value (4.6 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine idling speed control is fixed to automatic control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and idling speed adjustment potentiometer Malfunction of each connector Malfunction of idling speed adjustment potentiometer Malfunction of engine electronic control unit Generation condition Battery voltage is too low. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control of engine is stopped. Possible causes Malfunction of electronic control unit (Replacement of electronic control unit) TROUBLESHOOTING ---===WSE_1505_00010_0224.djvu===--- 13E 13E-37 P0563: Power Supply Voltage (High) (warning lamp flashes: 33) P0600: CAN Communication (warning lamp flashes: 64, 73) P0607: ECU System (warning lamp flashes: 33) P060B: A/D Converter (warning lamp flashes: 33, 63) Generation condition Battery voltage is too high. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control of engine is stopped. Possible causes Malfunction of electronic control unit (Replacement of electronic control unit) Generation condition Abnormal CAN bus communications between engine electronic control unit and malfunction vehicle control unit or between engine electronic control unit and any of electronic drive units (exhaust gas recirculation, intake throttle and turbocharg- er units). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Turbocharger control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and each of electronic drive units (exhaust gas recirculation, throttle and tur- bocharger) Malfunction of each connector Malfunction of engine electronic control unit Malfunction of each of electronic drive units (exhaust gas recirculation, throttle and turbocharger) Generation condition System is overloaded. Data processing time of engine electronic control unit has exceeded time-out period. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine is stopped. Possible causes Malfunction of engine electronic control unit (Replacement of engine electron- ic control unit) Generation condition Voltage after conversion inside engine electronic control unit is higher than spec- ification (5 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Engine is stopped. Engine speed is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of engine electronic control unit (Replacement of engine electron- ic control unit) ---===WSE_1505_00010_0225.djvu===--- 13E-38 P0615: Starter Safety Relay (Over Load) (warning lamp flashes: 48) P0616: Starter Safety Relay (Low) (warning lamp flashes: 48) P0617: Starter Safety Relay (High) (warning lamp flashes: 48) P061B: ECU Performance (Calc) (warning lamp flashes: 33) P061C: ECU Performance (Ne) (warning lamp flashes: 33) Generation conditions Safety relay overload Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit Normal control Possible causes Short-circuited harness between engine electronic control unit and safety re- lay Malfunction of each connector Malfunction of safety relay Malfunction of engine electronic control unit Generation conditions Safety relay ground short or open circuit Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit Normal control Possible causes Open-circuited or short-circuited harness between engine electronic control unit and safety relay Malfunction of each connector Malfunction of safety relay Malfunction of engine electronic control unit Generation conditions Safety relay Battery short or open circuit Recoverability System recovers if signal becomes with starter switch ON position. Control effected by electronic control unit Normal control Possible causes Open-circuited or short-circuited harness between engine electronic control unit and safety relay Malfunction of each connector Malfunction of safety relay Malfunction of engine electronic control unit Generation condition Abnormal condition has occurred in arithmetic processing inside engine electron- ic control unit. Recoverability System recovers if any valid signal is input with starter switch in ON position. Control effected by electronic control unit No particular control takes place. Possible causes Malfunction of engine electronic control unit (Replacement of engine electron- ic control unit) Generation condition Abnormal condition has occurred in engine speed processing inside engine elec- tronic control unit. Recoverability System recovers if any valid signal is input with starter switch in ON position. Control effected by electronic control unit No particular control takes place. Possible causes Malfunction of engine electronic control unit (Replacement of engine electron- ic control unit) TROUBLESHOOTING ---===WSE_1505_00010_0226.djvu===--- 13E 13E-39 P062D: Injector Bank 1 (warning lamp flashes: 82) P062E: Injector Bank 2 (warning lamp flashes: 82) P062F: ECU System (EEPROM) (warning lamp flashes: 33) P0642: Sensor Supply Voltage 1 (Low) (warning lamp flashes: 81) Generation condition Injector magnetic valve (for No. 1 and No. 4 cylinders) has stopped functioning temporarily. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 1 and No. 4 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 1, 4) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 1, 4) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (for No. 2 and No. 3 cylinders) has stopped functioning temporarily. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 2 and No. 3 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 2, 3) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 2, 3) Malfunction of engine electronic control unit Generation condition Some error has occurred in reading or writing process. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit No particular control takes place. Possible causes Malfunction of engine electronic control unit (Replacement of engine electron- ic control unit) Generation condition Engine electronic control unit internal voltage (sensor supply voltage 1) is lower than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and idling speed adjustment potentiometer Open-circuited or short-circuited harness between engine electronic control unit and accelerator pedal position sensor 1 Open-circuited or short-circuited harness between engine electronic control unit and intake air temperature sensor 1 Malfunction of each connector Malfunction of idling speed adjustment potentiometer Malfunction of accelerator pedal position sensor 1 Malfunction of intake air temperature sensor 1 Malfunction of engine electronic control unit ---===WSE_1505_00010_0227.djvu===--- 13E-40 P0643: Sensor Supply Voltage 1 (High) (warning lamp flashes: 81) P0650: MIL (warning lamp flashes: 3) P0652: Sensor Supply Voltage 2 (Low) (warning lamp flashes: 81) Generation condition Engine electronic control unit internal voltage (sensor supply voltage 1) is higher than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and idling speed adjustment potentiometer Open-circuited or short-circuited harness between engine electronic control unit and accelerator pedal position sensor 1 Open-circuited or short-circuited harness between engine electronic control unit and intake air temperature sensor 1 Malfunction of each connector Malfunction of idling speed adjustment potentiometer Malfunction of accelerator pedal position sensor 1 Malfunction of intake air temperature sensor 1 Malfunction of engine electronic control unit Generation condition Engine warning lamp (orange) circuit shorted, open-circuited, or overloaded Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and meter cluster Malfunction of each connector Malfunction of meter cluster Malfunction of engine electronic control unit Generation condition Engine electronic control unit internal voltage (sensor supply voltage 2) is lower than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Output to sensor is stopped if voltage is lower than 3.5 V. Output level is lowered if voltage is higher than 3.5 V. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and boost pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and accelerator pedal position sensor 2 Open-circuited or short-circuited harness between engine electronic control unit and fuel temperature sensor Malfunction of each connector Malfunction of boost pressure sensor Malfunction of accelerator pedal position sensor 2 Malfunction of fuel temperature sensor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0228.djvu===--- 13E 13E-41 P0653: Sensor Supply Voltage 2 (High) (warning lamp flashes: 81) P0657: M/V Voltage (Low) (warning lamp flashes: 79) P0685: EDU Relay (Open) (warning lamp flashes: 84) P0686: EDU Relay (Low) (warning lamp flashes: 84) Generation condition Engine electronic control unit internal voltage (sensor supply voltage 2) is higher than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Output to sensor is stopped if voltage is lower than 3.5 V. Output level is lowered if voltage is higher than 3.5 V. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and boost pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and accelerator pedal position sensor 2 Open-circuited or short-circuited harness between engine electronic control unit and fuel temperature sensor Malfunction of each connector Malfunction of boost pressure sensor Malfunction of accelerator pedal position sensor 2 Malfunction of fuel temperature sensor Malfunction of engine electronic control unit Generation condition Exhaust shutter 3-way magnetic valve circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control of auxiliary braking function is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and exhaust shutter 3-way magnetic valve Malfunction of each connector Malfunction of exhaust shutter 3-way magnetic valve Malfunction of engine electronic control unit Generation condition Electronic drive unit relay open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and electronic drive unit relay Malfunction of each connector Malfunction of electronic drive unit relay Malfunction of engine electronic control unit Generation condition Electronic drive unit relay circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and electronic drive unit relay Malfunction of each connector Malfunction of electronic drive unit relay Malfunction of engine electronic control unit ---===WSE_1505_00010_0229.djvu===--- 13E-42 P0687: EDU Relay (High) (warning lamp flashes: 84) P0698: Sensor Supply Voltage 3 (Low) (warning lamp flashes: 81) P0699: Sensor Supply Voltage 3 (High) (warning lamp flashes: 81) P1171: Q Adjustment Resistor (Low) (warning lamp flashes: 34) Generation condition Electronic drive unit relay circuit shorted to power source. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and electronic drive unit relay Malfunction of each connector Malfunction of electronic drive unit relay Malfunction of engine electronic control unit Generation condition Engine electronic control unit internal voltage (sensor supply voltage 3) is lower than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and common rail pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and diesel particulate filter pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and intake air temperature sensor 2 Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of diesel particulate filter differential pressure sensor Malfunction of intake air temperature sensor 2 Malfunction of engine electronic control unit Generation condition Engine electronic control unit internal voltage (sensor supply voltage 3) is higher than specification. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and common rail pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and diesel particulate filter pressure sensor Open-circuited or short-circuited harness between engine electronic control unit and intake air temperature sensor 2 Malfunction of each connector Malfunction of common rail pressure sensor Malfunction of diesel particulate filter differential pressure sensor Malfunction of intake air temperature sensor 2 Malfunction of engine electronic control unit Generation condition Voltage of fuel injection rate adjustment resistor is too low (below 0.2 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control is made using a backup value (No. 1). Possible causes Open-circuited or short-circuited harness between engine electronic control unit and fuel injection rate adjustment resistor Malfunction of each connector Malfunction of fuel injection rate adjustment resistor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0230.djvu===--- 13E 13E-43 P1172: Q Adjustment Resistor (High) (warning lamp flashes: 34) P1C01: Inter Cooler Performance (warning lamp flashes: 27) P1C11: Injector #1-A (Plausibility) (warning lamp flashes: 37) P1C12: Injector #2-A (Plausibility) (warning lamp flashes: 38) Generation condition Voltage of fuel injection rate adjustment resistor is too high (above 4.8 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Control is made using a backup value (No. 1). Possible causes Open-circuited or short-circuited harness between engine electronic control unit and fuel injection rate adjustment resistor Malfunction of each connector Malfunction of fuel injection rate adjustment resistor Malfunction of engine electronic control unit Generation condition The electronic control unit has judged that the intercooler was not operating properly, based on the diagnostic results of the intake system. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Foreign substances deposited on intercooler front core Intercooler air leakage Air inlet hose/air inlet pipe fitted poorly Generation condition The engine electronic control unit has judged that injector magnetic valve (for No. 1 cylinder) was faulty in comparison with the condition of other injector magnetic valves. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 1 and No. 4 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 1 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 1 cylinder) Malfunction of engine electronic control unit Generation condition The engine electronic control unit has judged that injector magnetic valve (for No. 2 cylinder) was faulty in comparison with the condition of other injector magnetic valves. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 2 and No. 3 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 2 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 2 cylinder) Malfunction of engine electronic control unit ---===WSE_1505_00010_0231.djvu===--- 13E-44 P1C13: Injector #3-A (Plausibility) (warning lamp flashes: 39) P1C14: Injector #4-A (Plausibility) (warning lamp flashes: 8) P2002: DPF MFF (warning lamp flashes: 55) P2100: TVA (Open) (warning lamp flashes: 28) Generation condition The engine electronic control unit has judged that injector magnetic valve (for No. 3 cylinder) was faulty in comparison with the condition of other injector magnetic valves. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 2 and No. 3 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 3 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 3 cylinder) Malfunction of engine electronic control unit Generation condition The engine electronic control unit has judged that injector magnetic valve (for No. 4 cylinder) was faulty in comparison with the condition of other injector magnetic valves. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not extinguish unless 3 consecutive valid sig- nals are input). Control effected by electronic control unit Fuel injection amount is limited to a default value. Occurrence of abnormal injection control is communicated through CAN. Injector magnetic valve (for No. 1 and No. 4 cylinders) is deactivated. Exhaust gas recirculation control is deactivated. Throttle control is deactivated. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (No. 4 cylinder) Malfunction of each connector Malfunction of injector magnetic valve (No. 4 cylinder) Malfunction of engine electronic control unit Generation condition Diesel particulate filter differential pressure is determined to exceed the pro- grammed value. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Possible causes Clogged diesel particulate filter Generation condition Throttle electronic drive unit judges intake throttle open-circuited. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and in- take throttle Malfunction of each connector Malfunction of motor (built in intake throttle) Malfunction of throttle position sensor (built in intake throttle) Malfunction of electronic drive unit Malfunction of electronic drive unit relay TROUBLESHOOTING ---===WSE_1505_00010_0232.djvu===--- 13E 13E-45 P2101: TVA (System) (warning lamp flashes: 28) P2102: TVA (Short) (warning lamp flashes: 28) P2120: Acc Switch (warning lamp flashes: 65) P2122: Acc Sensor 1 (Low) (warning lamp flashes: 24) Generation condition The throttle electronic drive unit has judged that the power supply to intake throt- tle was faulty or the throttle position sensor was faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and in- take throttle Malfunction of each connector Malfunction of motor (built in intake throttle) Malfunction of throttle position sensor (built in intake throttle) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Throttle electronic drive unit judges intake throttle shorted. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and in- take throttle Malfunction of motor (built in intake throttle) Malfunction of throttle position sensor (built in intake throttle) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Accelerator pedal switch signal is abnormal when compared with outputs of ac- celerator pedal position sensors 1 and 2. Recoverability System recovers if signal becomes normal with starter switch in ON position. Control effected by electronic control unit Effects no special control. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and accelerator pedal switch Malfunction of each connector Malfunction of accelerator pedal switch Malfunction of engine electronic control unit Generation condition Accelerator pedal position sensor 1 voltage is at or below the specified value (0.49 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using output from accelerator pedal position sensor 2. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and accelerator pedal position sensor 1 Malfunction of each connector Malfunction of accelerator pedal position sensor 1 Malfunction of engine electronic control unit ---===WSE_1505_00010_0233.djvu===--- 13E-46 P2123: Acc Sensor 1 (High) (warning lamp flashes: 24) P2127: Acc Sensor 2 (Low) (warning lamp flashes: 16) P2128: Acc Sensor 2 (High) (warning lamp flashes: 16) P2135: TVA SNSR (Voltage) (warning lamp flashes: 28) Generation condition Accelerator pedal position sensor 1 voltage is at or above the specified value (4.7 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using output from accelerator pedal position sensor 2. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and accelerator pedal position sensor 1 Malfunction of each connector Malfunction of accelerator pedal position sensor 1 Malfunction of engine electronic control unit Generation condition Accelerator pedal position sensor 2 voltage is at or below the specified value (0.49 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using output from accelerator pedal position sensor 1. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and accelerator pedal position sensor 2 Malfunction of each connector Malfunction of accelerator pedal position sensor 2 Malfunction of engine electronic control unit Generation condition Accelerator pedal position sensor 2 voltage is at or above the specified value (4.7 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Control is carried out using output from accelerator pedal position sensor 1. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and accelerator pedal position sensor 2 Malfunction of each connector Malfunction of accelerator pedal position sensor 2 Malfunction of engine electronic control unit Generation condition Throttle electronic drive unit judges throttle position sensor power abnormal. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between electronic drive unit and in- take throttle Malfunction of each connector Malfunction of motor (built in intake throttle) Malfunction of throttle position sensor (built in intake throttle) Malfunction of electronic drive unit Malfunction of electronic drive unit relay TROUBLESHOOTING ---===WSE_1505_00010_0234.djvu===--- 13E 13E-47 P2138: Acc Sensor Correlation (warning lamp flashes: 24, 58) P2147: Injector Bank 1 (Low) (warning lamp flashes: 82) P2148: Injector Bank 1 (High) (warning lamp flashes: 82) P2150: Injector Bank 2 (Low) (warning lamp flashes: 82) Generation condition Output voltages from accelerator pedal position sensors 1 and 2 are out of spec- ified range or result of comparison between two voltages deviates from specifica- tion. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Effects no special control. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and accelerator pedal position sensor Malfunction of each connector Malfunction of accelerator pedal position sensor Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 1 and No. 4 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 1, 4) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 1, 4) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 1 and No. 4 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 1 and No. 4 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 1, 4) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 1, 4) Malfunction of engine electronic control unit Generation condition Injector magnetic valve (No. 2 and No. 3 cylinder) circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 2, 3) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 2, 3) Malfunction of engine electronic control unit ---===WSE_1505_00010_0235.djvu===--- 13E-48 P2151: Injector Bank 2 (High) (warning lamp flashes: 82) P2199: EGR Temp Sensor (Correlation) (warning lamp flashes: 9) P2227: Atm Press SNSR (Plausibility) (warning lamp flashes: 19) P2228: Atm Press SNSR (Low) (warning lamp flashes: 19) Generation condition Injector magnetic valve (No. 2 and No. 3 cylinder) circuit shorted to power supply. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Outputs injection control fault signal through CAN bus. Injector magnetic valves (No. 2 and No. 3 cylinders) are stopped. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuited or short-circuited harness between engine electronic control unit and injector magnetic valve (cylinder 2, 3) Malfunction of each connector Malfunction of injector magnetic valve (cylinder 2, 3) Malfunction of engine electronic control unit Generation condition The exhaust gas recirculation temperature sensor was judged faulty based on the diagnostic results obtained by comparing boost temperature sensor and in- take air temperature sensor outputs. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and Intake air temperature sensor Open-circuit or short-circuit of harness between engine electronic control unit and Boost air temperature sensor Malfunction of each connector Malfunction of Intake air temperature sensor Malfunction of Boost air temperature sensor Malfunction of engine electronic control unit Generation condition The engine electronic control unit has judged that the atmospheric pressure sen- sor Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of atmospheric pressure sensor (inside engine electronic control unit) Malfunction of Boost pressure sensor Malfunction of engine electronic control unit Generation condition Voltage of atmospheric pressure sensor (inside engine electronic control unit) is lower than specification (0.19 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of atmospheric pressure sensor Malfunction of engine electronic control unit TROUBLESHOOTING ---===WSE_1505_00010_0236.djvu===--- 13E 13E-49 P2229: Atm Press SNSR (High) (warning lamp flashes: 19) P2263: VGT System (warning lamp flashes: 51, 54) P2279: Intake Pipe Leak (warning lamp flashes: 27) P2413: EGR System (warning lamp flashes: 67) Generation condition Voltage of atmospheric pressure sensor (inside engine electronic control unit) is higher than specification (4.7 V). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of atmospheric pressure sensor Malfunction of engine electronic control unit Generation condition Turbocharger system is abnormal. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Fuel injection rate is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Intake throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and tur- bocharger actuator Malfunction of each connector Malfunction of motor (built in turbocharger actuator) Malfunction of position sensor (built in turbocharger actuator) Malfunction of electronic drive unit Malfunction of electronic drive unit relay Generation condition Air leakage occurs in intake air system. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Foreign substances deposited on intercooler front core Intercooler air leakage Air inlet hose/air inlet pipe fitted poorly Generation condition Exhaust gas recirculation system abnormal Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between electronic drive unit and ex- haust gas recirculation valve Malfunction of each connector Malfunction of motor (built in exhaust gas recirculation valve) Malfunction of position sensor (built in exhaust gas recirculation valve) Malfunction of electronic drive unit Malfunction of electronic drive unit relay ---===WSE_1505_00010_0237.djvu===--- 13E-50 P242F: DPF MFF (Accumulation) (warning lamp flashes: 55) P2453: DPF Diff SNSR (Plausi) & MFF (warning lamp flashes: 97) P2454: DPF Diff SNSR (Low) & MFF (warning lamp flashes: 97) P2455: DPF Diff SNSR (High) & MFF (warning lamp flashes: 97) P2457: EGR Cooler Performance (warning lamp flashes: 2) Generation condition The voltage of diesel particulate filter pressure sensor is excessively high. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Possible causes Clogged diesel particulate filter Generation condition Output of diesel particulate filter pressure after start of engine is too low (vacu- um). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and diesel particulate filter pressure sensor Malfunction of each connector Malfunction of diesel particulate filter differential pressure sensor Malfunction of engine electronic control unit Dissolution, blockage, and damage of diesel particulate filter Generation condition Diesel particulate filter pressure sensor circuit shorted to ground. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and diesel particulate filter pressure sensor Malfunction of each connector Malfunction of diesel particulate filter differential pressure sensor Malfunction of engine electronic control unit Generation condition Diesel particulate filter differential pressure sensor circuit shorted to power source. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Possible causes Open-circuit or short-circuit of harness between engine electronic control unit and diesel particulate filter pressure sensor Malfunction of each connector Malfunction of diesel particulate filter differential pressure sensor Malfunction of engine electronic control unit Generation condition Engine electronic control unit has judged operation of exhaust gas recirculation cooler abnormal as a result of diagnosis of exhaust gas recirculation system. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. Possible causes Malfunction of Exhaust gas recirculation system. TROUBLESHOOTING ---===WSE_1505_00010_0238.djvu===--- 13E 13E-51 P2562: VGT Position Sensor (warning lamp flashes: 51) P2670: MPROP Voltage (Low) (warning lamp flashes: 36) Generation condition Turbocharger electronic drive unit determines the turbocharger position sensor to be faulty. Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit Fuel injection rate is limited. Turbocharger target opening value is replaced by a backup value. Exhaust gas recirculation control is stopped. Intake throttle control is stopped. Possible causes Open-circuit or short-circuit of harness between engine electronic drive unit and turbocharger actuator Malfunction of each connector Malfunction of motor (built in turbocharger actuator) Malfunction of position sensor (built in turbocharger actuator) Malfunction of electronic drive unit Malfunction of engine electronic drive unit relay Generation condition Diagnosis code is generated under either of the following conditions. (1) MPROP (rail pressure control valve) circuit shorted to ground. (2) Engine electronic control unit has received too low (0 V) return voltage from MPROP (rail pressure control valve). Recoverability System recovers if any valid signal is input when starter switch is turned from OFF to ON (the warning lamp does not go out unless 3 consecutive valid signals are input). Control effected by electronic control unit In the case of above problem (1) Injection quantity is limited. Exhaust gas recirculation control is stopped. Throttle control is stopped. In the case of above problem (2) Injection quantity is fixed to current quantity. Possible causes Malfunction of supply pump Malfunction of pressure limiter Injector not airtight Plugged fuel system ---===WSE_1505_00010_0239.djvu===--- 13E-52 2. Multi-Use Tester Service Data It is possible to see service data and actuator tests simultaneously. No. Item Data Inspection condition Requirement 01 Engine Revolution Racing (engine running) Value corresponds to ta- chometer indication. 02 LOAD Value Starter switch in ON position 0% 0A Reference Injection Quantity Starter switch in ON position 0% 20 Atmospheric Pressure Altitude: 0 m 101 kPa Altitude: 600 m 95 kPa 21 Boost Pressure Starter switch ON (engine stopped) Agrees with atmospheric pressure. Accelerator pedal pressed after start of engine Gradually increases. 22 Difference pressure across DPF Idling 0 kPa 30 Intake Air Temp. (upper stream) On a cold engine Equal to ambient tempera- ture 31 Intake Air Temp. (downstream) On a cold engine Equal to ambient tempera- ture 32 Water Temperature Engine cold Value corresponds to ambient temperature. Engine in process of warming up Value gradually increases. Engine stopped after warming up Value gradually decreases. 33 Fuel Temperature (inlet) Engine cold Value corresponds to ambient temperature. Engine in process of warming up Value gradually increases. Engine stopped after warming up Value gradually decreases. 40 Accel Pedal Sensor Voltage 1 Accelerator pedal gradually pressed from released position 0.85 to 4.15 V 41 Accel Pedal Sensor Voltage 2 Accelerator pedal gradually pressed from released position 0.85 to 4.15 V 42 Accel Pedal Position (unfiltered) Accelerator pedal not pressed 0% Accelerator pedal gradually pressed Value gradually increases. Accelerator pedal fully pressed 100 % 43 Accel Pedal Position (filtered) Accelerator pedal not pressed 0% Accelerator pedal gradually pressed Value gradually increases. Accelerator pedal fully pressed 100 % 50 Target EGR Valve Position Idling 0% 51 Actual EGR Valve Position Idling 0% [Actuator test] A0: EGR 1 52 Target Intake Throttle Position Idling 90% 53 Actual Intake Throttle Position Idling 90% [Actuator test] A3: Intake Throttle 1 54 Target VGT Position Starter switch ON 10% 55 Actual VGT Position Starter switch ON 10% [Actuator test] A4: VGT 1, A5: EGR, ETV, VGT 60 Air mass flow Accelerator pedal is pressed gradually. Flow rate to be increased accordingly 80 Power Supply Voltage Starter switch ON Value matches battery voltage. 81 Idle Volume Voltage SLOW to FAST 1to3V 82 Q Adjustment Resistor No. (Part name: Fuel injection rate adjustment resistor) 1/2/3/4/5/6/7/8/9/10/ 11/NON -- Number matches number marked on fuel injection rate adjustment resistor. 90 Vehicle Speed Vehicle in motion Value corresponds to speedometer indication. .rpm .% .% . kPa . kPa . kPa . °C . °C . °C . °C . V . V .% .% .% .% .% .% .% .% . g/s .V . V .km/h TROUBLESHOOTING ---===WSE_1505_00010_0240.djvu===--- 13E 13E-53 No. Item Data Inspection condition Requirement A0 Starter SW (S) ON/OFF Engine cranked by means of starter switch. ON Starter switch in position except START OFF A1 Starter SW (M) ON/OFF Starter switch in ON position ON Starter switch in position except ON OFF A2 Accel SW ON/OFF Accelerator pedal not pressed ON Accelerator pedal pressed OFF A4 Auxiliary Brake SW 1 (Part name: Exhaust brake switch) ON/OFF Combination switch ON ON Combination switch OFF OFF A5 Clutch SW ON/OFF Clutch pedal pressed ON Clutch pedal not pressed OFF B0 Neutral SW ON/OFF Transmission in neutral ON Transmission not in neutral OFF B1 Idle Up Cancel SW ON/OFF --O N Continuously OFF C1 Diagnosis SW ON/OFF Diagnosis switch OFF (fuse fitted) ON Diagnosis switch ON (fuse removed) OFF C2 Auxiliary Brake M/V 1 (Part name: Exhaust shutter 3- way magnetic valve) ON/OFF Exhaust brake operating ON Exhaust brake not operating OFF [Actuator test] AA: Auxiliary Brake M/V 1 D0 Auxiliary Brake Indicator Lamp ON/OFF Exhaust brake operating ON Exhaust brake not operating OFF [Actuator test] AB: Auxiliary Brake Indicator Lamp D1 Glow Relay ON/OFF With engine coolant temperature at 60°C or less, turn starter switch OFF and ON. Inspect immediately after turning start- er switch ON. ON With engine coolant temperature at 60°C or more. OFF With engine coolant temperature at 60°C or less, turn starter switch OFF and ON. Inspect about 192 seconds after turn- ing starter switch ON. [Actuator test] AC: Relay for Glow Relay D2 Glow Relay Indicator Lamp ON/OFF With engine coolant temperature at 0°C or less, turn starter switch OFF and ON. Inspect immediately after turning start- er switch ON. ON With engine coolant temperature at 0°C or more. OFF With engine coolant temperature at 0°C or less, turn starter switch OFF and ON. Inspect about 8 seconds after turning starter switch ON. [Actuator test] AD: Glow Indicator Lamp D3 Starter Safety Relay ON/OFF Carry out the actuator test "AE - Starter Safety Relay" using Multi-Use Tester. The relay should be ON. ON When not testing OFF [Actuator test] AE: Starter Safety Relay D4 EDU Power Relay ON/OFF Starter switch ON ON Starter switch OFF OFF [Actuator test] AF: EDU Relay ---===WSE_1505_00010_0241.djvu===--- 13E-54 E0 MIL ON/OFF Starter switch ON (engine not started) ON No error after engine startup OFF [Actuator test] B0: MIL E1 Diagnosis Lamp ON/OFF Starter switch ON (engine not started) ON No error after engine startup OFF [Actuator test] B1: Diagnosis Lamp No. Item Data Inspection condition Requirement TROUBLESHOOTING ---===WSE_1505_00010_0242.djvu===--- 13E 13E-55 3. Actuator Test Using Multi-Use Tester It is possible to see service data and actuator tests simultaneously. No. Item Explanation Confirmation method A0 EGR1 Maintain exhaust gas recirculation valve opening indicated by Multi-Use Tester during engine operation. [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON (engine started) Transmission: neutral Diagnosis switch: OFF (with fuse removed) Check that the exhaust gas recirculation valve opening is changed. [Service data] 51: Actual EGR Valve Po- sition A3 Intake Throttle 1 Maintain intake throttle opening indicated by Multi-Use Tester during engine operation. [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON (engine started) Transmission: neutral Diagnosis switch: OFF (with fuse removed) Check that the throttle opening is changed. [Service data] 53: Actual Intake Throttle Position A4 VGT1 Maintain turbocharger throttle opening indicated by Multi-Use Tester during engine operation. [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON (engine started) Transmission: neutral Diagnosis switch: OFF (with fuse removed) NOTE Adjust turbocharger throttle opening within the range from 15% to 80%. See "Measurement and Adjustment of Turbocharg- er Boost Pressure". [Service data] 54: Target VGT Position 55: Actual VGT Position A5 EGR, ETV, VGT Maintain exhaust gas recirculation, intake throttle and turbo- charger throttle opening indicated by Multi-Use Tester during engine operation or stop. [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON (engine started) Transmission: neutral Diagnosis switch: OFF (with fuse removed) NOTE If the actuator test is to be continued with the engine stationary, turn the starter switch OFF after starting the engine, and then turn the starter switch ON again within 15 seconds. Check that the valve open- ing of each device is changed. [Service data] 51: Actual EGR Valve Po- sition 53: Actual Intake Throttle Position 54: Target VGT Position 55: Actual VGT Position AA Auxiliary Brake M/V 1 (Part name: Exhaust shutter 3- way magnetic valve) Exhaust shutter 3-way magnetic valve drive signal [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON Engine: stopped Operating sound of mag- netic valve [Service data] C2: Auxiliary Brake Indica- tor Lamp AB Auxiliary Brake Indicator Lamp Exhaust brake indicator lamp drive signal [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Starter switch: ON Engine: stopped ON/OFF condition of indi- cator lamp [Service data] D0: Auxiliary Brake Indica- tor Lamp AC Relay for Glow Relay Glow drive relay drive signal Actuation noise should be heard. [Service data] D1: Glow Relay AD Glow Indicator Lamp Glow indicator lamp illumination signal Actuation noise should be heard. [Service data] D2: Glow Relay Indicator Lamp ---===WSE_1505_00010_0243.djvu===--- 13E-56 AE Starter Safety Relay Starter safety relay drive signal Actuation noise should be heard. [Service data] D3: Starter Safety Relay AF EDU Relay Electronic drive unit relay drive signal (Errors related to exhaust gas recirculation and to the intake throttle can be detected when this actuator test is executed.) Operating sound of relay [Service data] D4: EDU Power Relay B0 MIL Engine warning lamp (orange) drive signal [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Transmission: Neutral Engine: stopped ON/OFF condition of warn- ing lamp (orange) [Service data] E0: MIL B1 Diagnosis Lamp Engine warning lamp (red) drive signal [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Transmission: Neutral Engine: stopped ON/OFF condition of warn- ing lamp (red) [Service data] E1: Diagnosis Lamp B2 Fuel Leak Check Rail pressure increased on a constant slope (for 6 seconds) [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Transmission: Neutral Diagnosis switch: OFF (with fuse removed) Check that no fuel leaks from fuel system. BB Injector Test 1 Selected injector magnetic valve forcibly deactivated [Can be executed when the following conditions are satisfied] Vehicle: stationary (vehicle speed 0 km/h) Engine speed: Below 1500 rpm Transmission: Neutral No active diagnosis code generated Check that injector mag- net valve for No. 1 cylinder stops operating. BC Injector Test 2 Check that injector mag- net valve for No. 4 cylinder stops operating. BD Injector Test 3 Check that injector mag- net valve for No. 2 cylinder stops operating. BE Injector Test 4 Check that injector mag- net valve for No. 3 cylinder stops operating. No. Item Explanation Confirmation method TROUBLESHOOTING ---===WSE_1505_00010_0244.djvu===--- 13E 13E-57 4. Work When Replacing the Engine Electronic Control Unit A vehicle identification number (VIN) must be written (registered) to the engine electronic control unit after: The current engine electronic control unit is replaced with a new one. The current engine electronic control unit is replaced with one that has been used on another vehicle. Writing a VIN (entire flow) 4.1 Procedure for writing a VIN (1) System check Select "POWERTRAIN" from the system check menu. After a while, a menu related to POWERTRAIN/ENGINE appears. Select "ENGINE." OBD requirements are automatically detected. Confirm that "TYPE: EOBD" is detected. Click the OK button. Connect the Multi-Use Tester (See Gr00). Confirm the VIN on the vehicle nameplate (See Gr00). Enter the VIN in the "VIN Writing" window of the Multi-Use Tester to write it to the engine electronic control unit. Turn the starter switch ON (the engine remains stopped). Check the diagnosis code that is currently recorded, and delete it. Disconnect the Multi-Use Tester. View the "VIN Information" window of the Multi-Use Tester to confirm the VIN written to the engine electronic control unit. ---===WSE_1505_00010_0245.djvu===--- 13E-58 A system test automatically starts and "INCOMPLETE" is indi- cated. This raises no problem because VIN writing is incomplete at this stage. Click the OK button. (2) Writing a VIN [ENGINE menu] window Select "Coding". [Coding] window Select "VIN Writing". [VIN Writing] window Enter the VIN (17 digits), which has been confirmed from the ve- hicle nameplate. (If a VIN was entered previously, the VIN entered currently is dis- played in the "Current VIN".) Click the OK button. [Confirmation of VIN writing] window Click the OK button to start writing the VIN to the engine elec- tronic control unit. TROUBLESHOOTING ---===WSE_1505_00010_0246.djvu===--- 13E 13E-59 [Write error] window An error is displayed if a VIN is entered while the engine is on or the transmission is set at a position except Neutral. If so, stop the engine or set the transmission to the Neutral position, and restart from the beginning. [Completion of VIN writing] window Click the OK button. [Result of VIN writing] window The VIN that was written to the engine electronic control unit is displayed. Confirm that the VIN is the right one. If the right VIN is displayed, click the Back button and confirm VIN information in step (3). If a wrong VIN is displayed, click the Back button and perform VIN writing in step (2) again. (3) VIN confirmation [Coding] window Select "VIN Information." [VIN Information] window Confirm that the displayed VIN is the right one, and click the Back button. ---===WSE_1505_00010_0247.djvu===--- 13E-60 (4) Confirming and deleting the diagnosis code (memory clear) [ENGINE menu] window Select "Self-diagnosis." [Self-diagnostic] window Check the "Pending DTC" field for generation of a diagnosis code. Click the "Confirmed/Stored DTCs" button. Check the "Confirmed/Stored DTCs" field for generation of a di- agnosis code. If a diagnosis code is generated in either "Pending DTC" or "Confirmed/Stored DTCs," click the Delete button to erase the diagnosis code. [Erase diagnosis code] window Click the OK button to start deleting the diagnosis code. [Diagnosis code erasing complete] window Click the OK button. TROUBLESHOOTING ---===WSE_1505_00010_0248.djvu===--- 13E 13E-61 5. Electronic Control Unit Input/Output Table For terminal locations of each signal and ground. See the Electronic control unit connection diagram. Hardware to be connected Terminal Input/Output Voltage or waveform Water temperature sensor A40-A41 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 20°C: 2.45 ± 0.14 kΩ 80°C: 0.32 kΩ (reference value) 110°C: 147.1 ± 2 kΩ Accelerator pedal position sensor 1 B34-B33 B34-B45 Input [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] With accelerator pedal not pressed: 0.85 ± 0.1 V With accelerator pedal pressed: 4.15 ± 0.1 V Accelerator pedal position sensor 2 B46-B33 B46-B45 Input Fuel temperature sensor A89-A65 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 20°C: 2.45 kΩ 80°C: 0.318 ± 0.008 kΩ 11 0 °C: 0.1417 ± 0.0018 kΩ Injector magnetic valve (No. 1 cylinder) A72-A23 Output [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 0.255±0.04Ω Injector magnetic valve (No. 2 cylinder) A95-A48 Output Injector magnetic valve (No. 3 cylinder) A96-A24 Output Injector magnetic valve (No. 4 cylinder) A71-A46 Output Engine speed sensor A10-A9 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 860±86Ω(20°C) Cylinder recognition sensor A78-A83 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 200to1800Ω Vehicle speed sensor A67-chassis ground Input [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) Turn wheels slowly using chassis dynamometer. [Requirements] High pulse voltage:Approx. 8 ± 1 V Low pulse voltage: 0.5 V or lower Idling speed adjustment potentiometer A12-A36 Input [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] AUTO position: 4.0 ± 0.1 V SLOW position: 3.0 ± 0.1 V FAST position: 1.0 ± 0.1 V +0.14 --0.13 ---===WSE_1505_00010_0249.djvu===--- 13E-62 Accelerator pedal switch A20-B33 A20-B45 Output [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] With accelerator pedal pressed: 0 V With accelerator pedal not pressed: 5 V Fuel injection rate adjustment resistor A35-A88 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] No. 1 resistor: 270 ± 13.5 Ω No. 2 resistor: 510 ± 25.5 Ω No.3resistor:820±41Ω No. 4 resistor: 1300 ± 65 Ω No. 5 resistor: 2000 ± 100 Ω No. 6 resistor: 3300 ± 165 Ω No. 7 resistor: 5600 ± 280 Ω No. 8 resistor: 15000 ± 750 Ω No. 9 resistor: 390 ± 19.5 Ω No. 10 resistor: 4300 ± 215 Ω No. 11 resistor: 9100 ± 455 Ω MPROP (rail pressure control valve) A69-A21 A69-A2 A3-A21 A3-A2 Output [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 2.6to3.15Ω Exhaust shutter 3-way magnetic valve A76-A6 Output [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] With exhaust brake operating: Corresponding to battery volt- age With exhaust brake not operating: 0 V Intake air temperature sensor 1 A63-A32 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 50°C: 2.20 kΩ 100°C: 0.51 kΩ 150°C: 0.16 kΩ Intake air temperature sensor 2 A29-B30 Input [Conditions] Starter switch OFF Disconnect connector. Perform inspection on vehicle-side con- nector. [Requirements] 0°C: 162.3 kΩ 20°C: 61.47 kΩ 80°C: 6.120 kΩ Diesel particulate filter differential pressure sensor A61-A85 A84-A85 Input [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] <Power supply voltage> 5V <Output voltage> 1to4.5V Hardware to be connected Terminal Input/Output Voltage or waveform +0.405 --0.334 +0.071 --0.061 +0.018 --0.016 +48.8 --36.5 +15.99 --12.35 +1.095 --0.907 TROUBLESHOOTING ---===WSE_1505_00010_0250.djvu===--- 13E 13E-63 Electronic drive unit relay B39-B14 Output [Conditions] Starter switch ON Vehicle-side harness connected (Perform inspection on back of connector.) [Requirements] With relay operating: Corresponding to battery voltage With relay not operating: 0 V Safety relay voltage A81-A49 Output [Conditions] Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) [Normal status] RelayON:12V RelayOFF:0V Glow drive relay A73-A7 Output [Conditions] Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) Carry out the actuator test "AC - Relay for Glow Relay" using Multi-Use Tester. [Normal status] Battery voltage Glow indicator lamp A51-ground Input [Conditions] Keep the vehicle harnesses connected to the electronic control unit connector halves. (Inspection is made at the back of the vehicle connectors.) Carry out the actuator test "AD - Glow Indicator Lamp" using Multi-Use Tester. [Normal status] The glow indicator lamp should illuminate. Hardware to be connected Terminal Input/Output Voltage or waveform ---===WSE_1505_00010_0251.djvu===--- 14-1 GROUP 14 COOLING SPECIFICATIONS............................................................................... 14-2 STRUCTURE AND OPERATION 1. Cooling System (Flow of Coolant) ................................................ 14-4 2. Thermostat ................................................................................... 14-5 3. Water Pump .................................................................................. 14-5 TROUBLESHOOTING . ....................................................................... 14-6 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Inspection and Adjustment of Belt Tension .................................. 14-8 2. Inspection of Cracks or Damage of the Belt................................ 14-12 3. Coolant Replacement and Cleaning of Cooling System .............. 14-13 4. Air Bleeding of Cooling System .................................................. 14-15 5. Air/Gas Leakage Test .................................................................. 14-15 DISCONNECTION AND CONNECTION OF HOSES AND PIPES... 14-16 RADIATOR ........................................................................................ 14-20 COOLING FAN, BELT AND WATER PUMP..................................... 14-22 TENSION PULLEY............................................................................ 14-25 THERMOSTAT .................................................................................. 14-26 PRESSURE CAP AND WATER OUTLET CASE ............................. 14-28 ---===WSE_1505_00010_0252.djvu===--- 14-2 Item Specifications Cooling system Forced water circulation system Water pump Belt-driven involute type Thermostat Wax pellet, bottom bypass type (with jiggle valve) Automatic cooling fan coupling Continuous control type Radiator Tube and corrugated fin type Coolant capacity dm 3 {L} 16 {16} SPECIFICATIONS ---===WSE_1505_00010_0253.djvu===--- MEMO 14-3 14 ---===WSE_1505_00010_0254.djvu===--- 14-4 1. Cooling System (Flow of Coolant) STRUCTURE AND OPERATION ---===WSE_1505_00010_0254.djvu===--- 14-4 1. Cooling System (Flow of Coolant) STRUCTURE AND OPERATION ---===WSE_1505_00010_0255.djvu===--- 14 14-5 2. Thermostat It is a bottom bypass type that uses a wax-filled pellet as its flow-regulating element. When the wax is heated, it melts from solid to liquid, changing its total volume. This allows the valve to open or close in accordance with the coolant temperature, regulating and adjusting the flow of coolant to the ra- diator and to the cylinder head (by- passing the radiator). 3. Water Pump The water pump has a drain hole to prevent coolant from entering the unit bearing in the case of defect of the unit seal. ---===WSE_1505_00010_0255.djvu===--- 14 14-5 2. Thermostat It is a bottom bypass type that uses a wax-filled pellet as its flow-regulating element. When the wax is heated, it melts from solid to liquid, changing its total volume. This allows the valve to open or close in accordance with the coolant temperature, regulating and adjusting the flow of coolant to the ra- diator and to the cylinder head (by- passing the radiator). 3. Water Pump The water pump has a drain hole to prevent coolant from entering the unit bearing in the case of defect of the unit seal. ---===WSE_1505_00010_0256.djvu===--- 14-6 Symptoms Reference Gr Possible causes Belt Loose or damaged O O Excessive tension O Oil on belt O Water pump Incorrectly mounted water pump O O Defective gasket O O Defective unit bearing O O Defective impeller O Defective unit seal O O Too loose fit of unit bearing on flange and impeller O O Thermostat Incorrectly mounted case O O Valve opening temperature too high (valve remains closed) O Valve opening temperature too low (valve remains open) O Radiator Clogged core O Cracked core and/or separation in welds O O Cracks in upper tank and/or lower tank O O Poor clinching of upper tank and/or lower tank O O Defective packing of upper tank and/or lower tank O O Automatic cooling fan coupling Defective bearing O O Damaged bimetal O Contaminated bimetal OO Silicone oil leakage O O Cylinder head Incorrectly mounted cylinder head O O Gr11 Defective gasket O O Oil cooler Incorrectly mounted oil cooler O O Gr12 Defective gasket O O Leakage from coolant temperature sensor O O Exhaust gas recircula- tion system Poor installation of exhaust gas recirculation cooler bracket OO Gr17 Poor installation of exhaust gas recirculation cooler O O Poor installation of connectors O O Poor installation of adapter O O Damaged O-rings O O TROUBLESHOOTING ---===WSE_1505_00010_0257.djvu===--- 14 14-7 Symptoms Reference Gr Possible causes Breather cover Poor installation of breather cover O O Gr17 Poor installation of gaskets O O Damaged O-rings O O Tension pulley Poor installation of bearing O O Poorly airtight pressure cap O Insufficient coolant amount O Clogged or scaled coolant passage O Incorrectly connected hoses O O Poor installation of pipes O O Excessively low exterior temperature O ---===WSE_1505_00010_0258.djvu===--- 14-8 1. Inspection and Adjustment of Belt Tension CAUTION Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. Service standards (Unit: mm) Special tools [Inspection] 1.1 Measurement by belt tension gauge Press each belt at a central portion between pulleys with a force of approximately 98 N {10 kgf} as shown in the illustration and measure the amount of deflection of the belt. A: Alternator pulley B: Tension pulley C: Fan pulley D: Water pump pulley Place the small O-ring on at the scale mark corresponding to 98 N {10 kgf} (press force). Place the large O-ring on at the scale mark corresponding to the maximum permissible deflection value specified for the belt. Location Maintenance item Standard value Limit Remedy -- Belt tension When new When belt tension gauge is used Deflection 8to10 --A d j u s t When sonic belt tension gauge is used Tension 598 to 872 N When reused When belt tension gauge is used Deflection 10 to 12 When sonic belt tension gauge is used Tension 412 to 578 N Mark Tool name and shape Part No. Application Belt tension gauge MH062345 Measurement of tension of belt Sonic belt tension gauge ME357715 ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0258.djvu===--- 14-8 1. Inspection and Adjustment of Belt Tension CAUTION Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. Service standards (Unit: mm) Special tools [Inspection] 1.1 Measurement by belt tension gauge Press each belt at a central portion between pulleys with a force of approximately 98 N {10 kgf} as shown in the illustration and measure the amount of deflection of the belt. A: Alternator pulley B: Tension pulley C: Fan pulley D: Water pump pulley Place the small O-ring on at the scale mark corresponding to 98 N {10 kgf} (press force). Place the large O-ring on at the scale mark corresponding to the maximum permissible deflection value specified for the belt. Location Maintenance item Standard value Limit Remedy -- Belt tension When new When belt tension gauge is used Deflection 8to10 --A d j u s t When sonic belt tension gauge is used Tension 598 to 872 N When reused When belt tension gauge is used Deflection 10 to 12 When sonic belt tension gauge is used Tension 412 to 578 N Mark Tool name and shape Part No. Application Belt tension gauge MH062345 Measurement of tension of belt Sonic belt tension gauge ME357715 ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0259.djvu===--- 14 14-9 Place at a central portion between pulleys of the belt and push the handle (indicated by the arrow in the illustration) until the O-ring touches the flange. Measure the amount of deflection of the belt. If the measured value deviates from the standard value range, adjust the tension of the belt as follows. 1.2 Measurement using sonic belt tension gauge Direct the sensor microphone of to the position shown in the drawing and measure the belt tension. For the operation of the sonic belt tension gauge, refer to the in- struction manual of the sonic belt tension gauge. A: Alternator pulley B: Tension pulley (without air conditioner) C: Fan pulley D: Water pump pulley P1: Measuring point on the belt CAUTION If the surface temperature of the belt is high, the tension be- comes higher. For the correct measurement, measure the tension with the belt surface temperature being similar to the room temperature. Turn on and set the sensitivity of its sensor microphone. ON ( : means "low"): Measuring in noisy environment, or out- doors in heavy wind ON ( : means "high"): Measuring in silent environment, or mea- suring a hard-to-vibrate belt Press " (means "execute")" key with no belt type number entered. ---===WSE_1505_00010_0260.djvu===--- 14-10 Enter the unit mass of the belt and push " (means "exe- cute")". Select the type of the belt. (Select "3" for ribbed belt.) Enter the number of ribs and push " (means "execute")". Enter the length of span and push " (means "execute")". Measuring point on the belt Unit mass of the belt P1 0.016 kg/m Measuring point on the belt Number of ribs P1 6 Measuring point on the belt Length of span P1 317 mm ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0261.djvu===--- 14 14-11 Set the sensor microphone of approx. 10 mm above the belt, at the middle position between pulleys. Tap the belt lightly with a grip of a screwdriver to vibrate the belt. Measure the tension a few times and calculate the average val- ue. If the average value is out of the standard value, adjust the belt tension. [Adjustment] Loosen the tension pulley mounting sleeve and turn in or out the adjustment bolt to adjust the tension of the belt. After the adjustment is completed, retighten the mounting sleeve firmly. CAUTION Excessive tension in the belt may damage not only the belt itself but also the bearings of the related components. ---===WSE_1505_00010_0262.djvu===--- 14-12 2. Inspection of Cracks or Damage of the Belt Visually check the belts for possible cracks and damage. If any faults are found, replace the belts. Belt condition Remaining service life (reference) The driving distance over the which the belt can still be used is at least as long as that over which the belt has been used since the vehicle was new or since the belt was replaced (whichever is more recent). The driving distance over the which the belt can still be used is about half of that over which the belt has been used since the vehi- cle was new or since the belt was replaced (whichever is more re- cent). The driving distance over the which the belt can still be used is about a quarter of that over which the belt has been used since the vehicle was new or since the belt was replaced (whichever is more recent). The belt has reached the end of its service life and must be re- placed. ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0263.djvu===--- 14 14-13 3. Coolant Replacement and Cleaning of Cooling System Tightening torque (Unit: N·m {kgf·m}) Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation, which may cause engine overheating. The cooling system must be cleaned periodically. 3.1 Draining of coolant Drain the coolant when it is sufficiently cold. Before draining the coolant, wrap the pressure cap with shop towel and slowly loos- en the cap to reduce the pressure in the cooling system. Re- member to drain the coolant in the reservoir tank as well. WARNING If the pressure cap is opened when the coolant is hot, the hot coolant will gush out and you may get seriously scald- ed. 3.2 Cleaning procedure Keep the coolant temperature at approximately 90°C so that the thermostat valve remains open and the coolant continues to circulate in the radiator. For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator with corrugated cardboard or something similar. Set the temperature adjusting lever of the heater controller at maximum so that the coolant can circulate freely in the heater piping area. In cases where a great amount of rust has accumulated it often happens that as a result of cleaning the radiator starts leaking. Conduct a thorough check for leakage after cleaning. Soft water to be used should have the following properties. CAUTION Do not use hard water as it causes scale and rust. Required properties of soft water Mark Parts to be tightened Tightening torque Remarks -- Radiator drain cock 2.0 {0.2} -- -- Water drain plug 25±5{2.5±0.5} -- Total hardness 300 ppm or less Sulfate SO 100 ppm or less Chloride Cl -- 100 ppm or less Total dissolved solids 500 ppm or less pH 6to8 -- 4 ---===WSE_1505_00010_0264.djvu===--- 14-14 Select an appropriate cleaning method according to the condition of the cooling system as shown below. WARNING If you accidentally splash coolant in your eyes, wash it out immediately with water and seek medical at- tention. CAUTION Coolant is flammable. Keep them away from heat and flames. Ordinary condition Coolant extremely dirty Radiator clogged Flushing with water. Cleaning using radiator cleaner. Drain out coolant. Make water solution of radiator cleaner at 5 to 10% concentration in volume. Pour solution into reservoir tank. Let the engine idle for 30 minutes with the solution at approximately 90°C. CAUTION Limit the engine idling period to one hour. Operating an engine containing the cleaning solution for long- er time may lead to damage of the cooling system. Drain out coolant/cleaning solution. Pour tap water (preferably hot) into the reservoir tank. Let the engine idle for 10 minutes with water at approximately 90°C. Cleaning is complete if drained water is clear. Repeat procedure if drained water is not clear. CAUTION After cleaning the cooling system using cleaning so- lution, fill it with coolant containing the specified ad- ditive as soon as possible. To prevent freezing of the coolant and corrosion of the cooling system, use the coolant with the speci- fied ratio of coolant. Drain out water. ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0265.djvu===--- 14 14-15 4. Air Bleeding of Cooling System With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com- pletely out of the cooling system. After air bleeding is completed, refill the reservoir tank with coolant as needed. 5. Air/Gas Leakage Test Presence of air or exhaust gas in coolant accelerates corrosion of the cooling system components. To prevent this, carry out air/ gas leakage tests in accordance with the following procedure. Remove the pressure cap. WARNING If the engine is hot, boiling coolant may spurt out from the filler port when the pressure cap is loosened. To avoid a scold, make sure to remove the pressure cap only when the coolant is cold. Run the engine until the coolant temperature rises to approxi- mately 90°C. If air bubbles appear continuously through the filler port, there is air or exhaust gas penetrating into the cooling system. Presence of air in coolant can be an indication of loose cylinder head bolts, loose water pump mounting bolts, loose hose con- nections, and/or a damaged hose. Presence of exhaust gas in coolant can be an indication of a damaged cylinder head gasket and/or cracks in the cylinder head. ---===WSE_1505_00010_0265.djvu===--- 14 14-15 4. Air Bleeding of Cooling System With the pressure cap removed and the coolant temperature at 90°C, let the engine idle in order to bleed air com- pletely out of the cooling system. After air bleeding is completed, refill the reservoir tank with coolant as needed. 5. Air/Gas Leakage Test Presence of air or exhaust gas in coolant accelerates corrosion of the cooling system components. To prevent this, carry out air/ gas leakage tests in accordance with the following procedure. Remove the pressure cap. WARNING If the engine is hot, boiling coolant may spurt out from the filler port when the pressure cap is loosened. To avoid a scold, make sure to remove the pressure cap only when the coolant is cold. Run the engine until the coolant temperature rises to approxi- mately 90°C. If air bubbles appear continuously through the filler port, there is air or exhaust gas penetrating into the cooling system. Presence of air in coolant can be an indication of loose cylinder head bolts, loose water pump mounting bolts, loose hose con- nections, and/or a damaged hose. Presence of exhaust gas in coolant can be an indication of a damaged cylinder head gasket and/or cracks in the cylinder head. ---===WSE_1505_00010_0266.djvu===--- 14-16 DISCONNECTION AND CONNECTION OF HOSES AND PIPES ---===WSE_1505_00010_0267.djvu===--- 14 14-17 ---===WSE_1505_00010_0268.djvu===--- 14-18 Removal sequence Installation sequence Follow the removal sequence in reverse. CAUTION Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured be- tween the hose clamp and its surrounding parts. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Installation procedure Installation: Water hose Install the water hose with the white mark on its end aligned with the padding on the water pipe. Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 4.5 {0.3 to 0.5} -- Clamp 1.5 to 2.0 {0.15 to 0.2} Wet Clamp 4 {0.4} -- Eyebolt (water pipe mounting) 26 {2.7} -- Bolt (adapter mounting) 23.2 {2.4} -- Eyebolt (water pipe mounting) 25.5 {2.6} -- Mark Points of application Specified lubricant and/or sealant Quantity Clamp screw threads Engine oil As required O-ring Soapy water As required 1 Upper radiator hose 2 Lower radiator hose 3 Heater hose 4 Heater pipe 5 Heater hose 6 Heater hose 7 Heater pipe 8 Heater hose 9 Water hose 10 Water hose 11 Water hose 12 Water hose 13 Adapter 14 O-ring 15 Water hose 16 Water hose 17 Water pipe 18 Eyebolt 19 Eyebolt 20 Water pipe 21 Eyebolt 22 Eyebolt 23 Water pipe 24 Eyebolt 25 Eyebolt 26 Water pipe 27 Radiator pipe 28 Radiator hose * a: Radiator * b: Thermostat cover * c: Breather cover * d: Exhaust gas recirculation valve * e: Exhaust gas recirculation cooler : Non-reusable parts DISCONNECTION AND CONNECTION OF HOSES AND PIPES ---===WSE_1505_00010_0268.djvu===--- 14-18 Removal sequence Installation sequence Follow the removal sequence in reverse. CAUTION Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured be- tween the hose clamp and its surrounding parts. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Installation procedure Installation: Water hose Install the water hose with the white mark on its end aligned with the padding on the water pipe. Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 4.5 {0.3 to 0.5} -- Clamp 1.5 to 2.0 {0.15 to 0.2} Wet Clamp 4 {0.4} -- Eyebolt (water pipe mounting) 26 {2.7} -- Bolt (adapter mounting) 23.2 {2.4} -- Eyebolt (water pipe mounting) 25.5 {2.6} -- Mark Points of application Specified lubricant and/or sealant Quantity Clamp screw threads Engine oil As required O-ring Soapy water As required 1 Upper radiator hose 2 Lower radiator hose 3 Heater hose 4 Heater pipe 5 Heater hose 6 Heater hose 7 Heater pipe 8 Heater hose 9 Water hose 10 Water hose 11 Water hose 12 Water hose 13 Adapter 14 O-ring 15 Water hose 16 Water hose 17 Water pipe 18 Eyebolt 19 Eyebolt 20 Water pipe 21 Eyebolt 22 Eyebolt 23 Water pipe 24 Eyebolt 25 Eyebolt 26 Water pipe 27 Radiator pipe 28 Radiator hose * a: Radiator * b: Thermostat cover * c: Breather cover * d: Exhaust gas recirculation valve * e: Exhaust gas recirculation cooler : Non-reusable parts DISCONNECTION AND CONNECTION OF HOSES AND PIPES ---===WSE_1505_00010_0268.djvu===--- 14-18 Removal sequence Installation sequence Follow the removal sequence in reverse. CAUTION Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured be- tween the hose clamp and its surrounding parts. Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Installation procedure Installation: Water hose Install the water hose with the white mark on its end aligned with the padding on the water pipe. Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 4.5 {0.3 to 0.5} -- Clamp 1.5 to 2.0 {0.15 to 0.2} Wet Clamp 4 {0.4} -- Eyebolt (water pipe mounting) 26 {2.7} -- Bolt (adapter mounting) 23.2 {2.4} -- Eyebolt (water pipe mounting) 25.5 {2.6} -- Mark Points of application Specified lubricant and/or sealant Quantity Clamp screw threads Engine oil As required O-ring Soapy water As required 1 Upper radiator hose 2 Lower radiator hose 3 Heater hose 4 Heater pipe 5 Heater hose 6 Heater hose 7 Heater pipe 8 Heater hose 9 Water hose 10 Water hose 11 Water hose 12 Water hose 13 Adapter 14 O-ring 15 Water hose 16 Water hose 17 Water pipe 18 Eyebolt 19 Eyebolt 20 Water pipe 21 Eyebolt 22 Eyebolt 23 Water pipe 24 Eyebolt 25 Eyebolt 26 Water pipe 27 Radiator pipe 28 Radiator hose * a: Radiator * b: Thermostat cover * c: Breather cover * d: Exhaust gas recirculation valve * e: Exhaust gas recirculation cooler : Non-reusable parts DISCONNECTION AND CONNECTION OF HOSES AND PIPES ---===WSE_1505_00010_0269.djvu===--- MEMO 14-19 14 ---===WSE_1505_00010_0270.djvu===--- 14-20 Removal sequence Installation sequence Follow the removal sequence in reverse. See the previous section ''DISCONNECTION AND CONNECTION OF HOSES AND PIPES'' for the correct inser- tion depth of radiator hoses into the radiator as well as the correct tightening torque of clamps. 1 Upper shroud 2 Lower shroud 3 Baffle plate RH 4 Baffle plate RH 5 Baffle plate LH 6 Baffle plate LH 7 Baffle plate upper 8 Baffle plate RH 9 Baffle plate LH 10 Support rod 11 Support cushion 12 Upper support 13 Radiator drain cock 14 O-ring 15 Radiator support cushion 16 Radiator : Non-reusable parts RADIATOR ---===WSE_1505_00010_0270.djvu===--- 14-20 Removal sequence Installation sequence Follow the removal sequence in reverse. See the previous section ''DISCONNECTION AND CONNECTION OF HOSES AND PIPES'' for the correct inser- tion depth of radiator hoses into the radiator as well as the correct tightening torque of clamps. 1 Upper shroud 2 Lower shroud 3 Baffle plate RH 4 Baffle plate RH 5 Baffle plate LH 6 Baffle plate LH 7 Baffle plate upper 8 Baffle plate RH 9 Baffle plate LH 10 Support rod 11 Support cushion 12 Upper support 13 Radiator drain cock 14 O-ring 15 Radiator support cushion 16 Radiator : Non-reusable parts RADIATOR ---===WSE_1505_00010_0270.djvu===--- 14-20 Removal sequence Installation sequence Follow the removal sequence in reverse. See the previous section ''DISCONNECTION AND CONNECTION OF HOSES AND PIPES'' for the correct inser- tion depth of radiator hoses into the radiator as well as the correct tightening torque of clamps. 1 Upper shroud 2 Lower shroud 3 Baffle plate RH 4 Baffle plate RH 5 Baffle plate LH 6 Baffle plate LH 7 Baffle plate upper 8 Baffle plate RH 9 Baffle plate LH 10 Support rod 11 Support cushion 12 Upper support 13 Radiator drain cock 14 O-ring 15 Radiator support cushion 16 Radiator : Non-reusable parts RADIATOR ---===WSE_1505_00010_0271.djvu===--- 14 14-21 Service standards Tightening torque (Unit: N·m {kgf·m}) Inspection before removal Inspection: Radiator air leakage Connect a hose and radiator cap tester to the upper tank. Plug the lower tank and put the entire radiator into a tank filled with water. Use the radiator cap tester to apply an air pressure of 177 kPa {1.77 kgf/cm 2 } and check for air leakage. If air leakage is found, repair or replace the radiator. Location Maintenance item Standard value Limit Remedy -- Air leakage from radiator (air pressure 177 kPa {1.77 kgf/cm 2 }) 0cm 3 {0 mL} -- Repair or replace Mark Parts to be tightened Tightening torque Remarks Bolt (upper shroud mounting) 5to7{0.5to0.7} -- Bolt (lower shroud mounting) Bolt (support rod mounting) 12 to 15 {1.18 to 1.47} -- Nut (radiator support cushion mounting) Bolt (upper support mounting) Nut (support cushion mounting) Radiator drain cock 2.0 {0.2} -- ---===WSE_1505_00010_0272.djvu===--- 14-22 Removal sequence The automatic cooling fan coupling and the water pump cannot be disassembled. It must be replaced if defective. Installation sequence Follow the removal sequence in reverse. CAUTION Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. After installation, check and adjust the belt tension. (See "ON-VEHICLE INSPECTION AND ADJUSTMENT".) Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (fan pulley mounting) 373 {38} -- 1 Cooling fan 2 Automatic cooling fan coupling 3 Belt 4 Water pump 5 Gasket 6 Fan pulley * a: Alternator * b: Tension pulley : Non-reusable parts COOLING FAN, BELT AND WATER PUMP ---===WSE_1505_00010_0272.djvu===--- 14-22 Removal sequence The automatic cooling fan coupling and the water pump cannot be disassembled. It must be replaced if defective. Installation sequence Follow the removal sequence in reverse. CAUTION Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. After installation, check and adjust the belt tension. (See "ON-VEHICLE INSPECTION AND ADJUSTMENT".) Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (fan pulley mounting) 373 {38} -- 1 Cooling fan 2 Automatic cooling fan coupling 3 Belt 4 Water pump 5 Gasket 6 Fan pulley * a: Alternator * b: Tension pulley : Non-reusable parts COOLING FAN, BELT AND WATER PUMP ---===WSE_1505_00010_0272.djvu===--- 14-22 Removal sequence The automatic cooling fan coupling and the water pump cannot be disassembled. It must be replaced if defective. Installation sequence Follow the removal sequence in reverse. CAUTION Make sure that there is no oil or grease on the belts. Belts soiled with oil or grease may easily slip, result- ing in deteriorated performance of the cooling system. After installation, check and adjust the belt tension. (See "ON-VEHICLE INSPECTION AND ADJUSTMENT".) Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Nut (fan pulley mounting) 373 {38} -- 1 Cooling fan 2 Automatic cooling fan coupling 3 Belt 4 Water pump 5 Gasket 6 Fan pulley * a: Alternator * b: Tension pulley : Non-reusable parts COOLING FAN, BELT AND WATER PUMP ---===WSE_1505_00010_0273.djvu===--- 14 14-23 Special tools (Unit: mm) Inspection and cleaning procedure Inspection: Automatic cooling fan coupling Make an inspection of the following points. Replace the automat- ic cooling fan coupling if defective. Check that: the hydraulic oil sealed inside the coupling is not leaking; the coupling does not make any abnormal noise or rotate un- evenly due to defects in the inside bearing when rotated man- ually; and the automatic cooling fan coupling does not move too much when pushed and pulled in the axial directions when the en- gine is cold. Cleaning: Automatic cooling fan coupling When removing foreign matter from the bimetal, be careful not to press too hard against the bimetal. CAUTION Be careful not to deform the bimetal. Removal procedure Removal: Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts. While holding , loosen the fan pulley mounting nut. Mark Tool name and shape Part No. Application Holding bar MH062970 Holding of fan pulley AB 114 φ9 ---===WSE_1505_00010_0273.djvu===--- 14 14-23 Special tools (Unit: mm) Inspection and cleaning procedure Inspection: Automatic cooling fan coupling Make an inspection of the following points. Replace the automat- ic cooling fan coupling if defective. Check that: the hydraulic oil sealed inside the coupling is not leaking; the coupling does not make any abnormal noise or rotate un- evenly due to defects in the inside bearing when rotated man- ually; and the automatic cooling fan coupling does not move too much when pushed and pulled in the axial directions when the en- gine is cold. Cleaning: Automatic cooling fan coupling When removing foreign matter from the bimetal, be careful not to press too hard against the bimetal. CAUTION Be careful not to deform the bimetal. Removal procedure Removal: Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts. While holding , loosen the fan pulley mounting nut. Mark Tool name and shape Part No. Application Holding bar MH062970 Holding of fan pulley AB 114 φ9 ---===WSE_1505_00010_0274.djvu===--- 14-24 Installation procedure Installation: Fan pulley Put in position on the studs of the fan pulley and fix the tool by using nuts. Tighten the fan pulley mounting nut to the specified torque while holding . COOLING FAN, BELT AND WATER PUMP ---===WSE_1505_00010_0275.djvu===--- 14 14-25 Disassembly sequence 1 Sleeve 2 Snap ring 3 Bearing 4 Tension pulley 5 Spacer 6 Shaft 7 Tension pulley bracket Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Sleeve 15 {1.5} -- Bolt (fixing of shaft) TENSION PULLEY ---===WSE_1505_00010_0275.djvu===--- 14 14-25 Disassembly sequence 1 Sleeve 2 Snap ring 3 Bearing 4 Tension pulley 5 Spacer 6 Shaft 7 Tension pulley bracket Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Sleeve 15 {1.5} -- Bolt (fixing of shaft) TENSION PULLEY ---===WSE_1505_00010_0275.djvu===--- 14 14-25 Disassembly sequence 1 Sleeve 2 Snap ring 3 Bearing 4 Tension pulley 5 Spacer 6 Shaft 7 Tension pulley bracket Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Sleeve 15 {1.5} -- Bolt (fixing of shaft) TENSION PULLEY ---===WSE_1505_00010_0276.djvu===--- 14-26 Disassembly sequence 1 Thermostat cover 2 Thermostat * a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Inspection procedure Inspection: Thermostat Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature Hold the thermostat with wire to keep it away from the heat source. Heat the water gradually to the valve opening temperature. Maintain this temperature for five minutes and make sure that the valve is completely open. Make sure that the valve closes completely when the water tem- perature drops below 65°C. (2) Valve lift Raise the water temperature to 95°C to fully open the valve. Keep this condition for 5 minutes and then measure the valve lift. Installation procedure Installation: Thermostat Mount the thermostat on the thermostat cover in the illustrated direction. Location Maintenance item Standard value Limit Remedy 2 Thermostat Valve opening temperature 82±2°C --R e p l a c e Valve lift at 95°C 10 or more THERMOSTAT ---===WSE_1505_00010_0276.djvu===--- 14-26 Disassembly sequence 1 Thermostat cover 2 Thermostat * a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Inspection procedure Inspection: Thermostat Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature Hold the thermostat with wire to keep it away from the heat source. Heat the water gradually to the valve opening temperature. Maintain this temperature for five minutes and make sure that the valve is completely open. Make sure that the valve closes completely when the water tem- perature drops below 65°C. (2) Valve lift Raise the water temperature to 95°C to fully open the valve. Keep this condition for 5 minutes and then measure the valve lift. Installation procedure Installation: Thermostat Mount the thermostat on the thermostat cover in the illustrated direction. Location Maintenance item Standard value Limit Remedy 2 Thermostat Valve opening temperature 82±2°C --R e p l a c e Valve lift at 95°C 10 or more THERMOSTAT ---===WSE_1505_00010_0276.djvu===--- 14-26 Disassembly sequence 1 Thermostat cover 2 Thermostat * a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Inspection procedure Inspection: Thermostat Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature Hold the thermostat with wire to keep it away from the heat source. Heat the water gradually to the valve opening temperature. Maintain this temperature for five minutes and make sure that the valve is completely open. Make sure that the valve closes completely when the water tem- perature drops below 65°C. (2) Valve lift Raise the water temperature to 95°C to fully open the valve. Keep this condition for 5 minutes and then measure the valve lift. Installation procedure Installation: Thermostat Mount the thermostat on the thermostat cover in the illustrated direction. Location Maintenance item Standard value Limit Remedy 2 Thermostat Valve opening temperature 82±2°C --R e p l a c e Valve lift at 95°C 10 or more THERMOSTAT ---===WSE_1505_00010_0276.djvu===--- 14-26 Disassembly sequence 1 Thermostat cover 2 Thermostat * a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Inspection procedure Inspection: Thermostat Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature Hold the thermostat with wire to keep it away from the heat source. Heat the water gradually to the valve opening temperature. Maintain this temperature for five minutes and make sure that the valve is completely open. Make sure that the valve closes completely when the water tem- perature drops below 65°C. (2) Valve lift Raise the water temperature to 95°C to fully open the valve. Keep this condition for 5 minutes and then measure the valve lift. Installation procedure Installation: Thermostat Mount the thermostat on the thermostat cover in the illustrated direction. Location Maintenance item Standard value Limit Remedy 2 Thermostat Valve opening temperature 82±2°C --R e p l a c e Valve lift at 95°C 10 or more THERMOSTAT ---===WSE_1505_00010_0276.djvu===--- 14-26 Disassembly sequence 1 Thermostat cover 2 Thermostat * a: Oil cooler Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Inspection procedure Inspection: Thermostat Stir the water using a stirring rod to maintain an even water tem- perature in the container, then conduct the tests indicated below. If the measured values deviate from the standard value ranges, replace the thermostat. (1) Valve opening temperature Hold the thermostat with wire to keep it away from the heat source. Heat the water gradually to the valve opening temperature. Maintain this temperature for five minutes and make sure that the valve is completely open. Make sure that the valve closes completely when the water tem- perature drops below 65°C. (2) Valve lift Raise the water temperature to 95°C to fully open the valve. Keep this condition for 5 minutes and then measure the valve lift. Installation procedure Installation: Thermostat Mount the thermostat on the thermostat cover in the illustrated direction. Location Maintenance item Standard value Limit Remedy 2 Thermostat Valve opening temperature 82±2°C --R e p l a c e Valve lift at 95°C 10 or more THERMOSTAT ---===WSE_1505_00010_0277.djvu===--- MEMO 14-27 14 ---===WSE_1505_00010_0278.djvu===--- 14-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 1 Pressure cap valve opening pressure 110±15kPa {1.1 ± 0.15 kgf/cm 3 } --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (water pipe mounting) 23.2 {2.4} -- Bolt (water outlet pipe mounting) Eyebolt (water pipe mounting) 25.5 {2.6} -- 1 Pressure cap 2 Clip 3 Eyebolt 4 Water pipe 5 Water pipe 6 Clip 7 Water hose 8 Water outlet case 9 Gasket * a: Vacuum hose * b: Breather cover : Non-reusable parts PRESSURE CAP AND WATER OUTLET CASE ---===WSE_1505_00010_0278.djvu===--- 14-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 1 Pressure cap valve opening pressure 110±15kPa {1.1 ± 0.15 kgf/cm 3 } --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (water pipe mounting) 23.2 {2.4} -- Bolt (water outlet pipe mounting) Eyebolt (water pipe mounting) 25.5 {2.6} -- 1 Pressure cap 2 Clip 3 Eyebolt 4 Water pipe 5 Water pipe 6 Clip 7 Water hose 8 Water outlet case 9 Gasket * a: Vacuum hose * b: Breather cover : Non-reusable parts PRESSURE CAP AND WATER OUTLET CASE ---===WSE_1505_00010_0278.djvu===--- 14-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 1 Pressure cap valve opening pressure 110±15kPa {1.1 ± 0.15 kgf/cm 3 } --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (water pipe mounting) 23.2 {2.4} -- Bolt (water outlet pipe mounting) Eyebolt (water pipe mounting) 25.5 {2.6} -- 1 Pressure cap 2 Clip 3 Eyebolt 4 Water pipe 5 Water pipe 6 Clip 7 Water hose 8 Water outlet case 9 Gasket * a: Vacuum hose * b: Breather cover : Non-reusable parts PRESSURE CAP AND WATER OUTLET CASE ---===WSE_1505_00010_0279.djvu===--- 14 14-29 Inspection procedure Inspection: Pressure cap (1) Pressure valve opening pressure Replace the pressure cap if the measured value deviates from the standard value range. (2) Inspection of vent valve Before starting the inspection, check the level of coolant in the reservoir tank. Run the engine at full speed. Stop the engine when the level of coolant in the reservoir tank noticeably rises. Wait until the coolant temperature drops to the ambient tempera- ture. Then, check if the coolant in the reservoir tank has returned to the same level as that confirmed before the engine was start- ed. If the coolant has failed to return to its original level, the vent valve is defective. In this case, replace the pressure cap. CAUTION Be aware that removing the pressure cap before the coolant cools down to the ambient temperature will result in loss of vacuum in the radiator, which disables the coolant from be- ing returned to the reservoir tank. ---===WSE_1505_00010_0280.djvu===--- 15-1 GROUP 15 INTAKE AND EXHAUST SPECIFICATIONS............................................................................... 15-2 STRUCTURE AND OPERATION 1. Air Cleaner.................................................................................... 15-2 2. Turbocharger ................................................................................ 15-3 3. Exhaust Shutter Valve .................................................................. 15-4 4. Diesel Particulate Filter................................................................. 15-4 TROUBLESHOOTING ........................................................................ 15-5 ON-VEHICLE INSPECTION AND ADJUSTMENT 1. Measurement and Adjustment of Turbocharger Boost Pressure ....................................................................................... 15-6 2. Cleaning and Inspection of Air Cleaner Element ......................... 15-12 3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts ..................................................................................... 15-12 4. Check for Cracks and Gas Leakage in Exhaust Manifold ............ 15-12 5. Check for Cracks and Gas Leakage in Turbocharger .................. 15-12 6. Loose Turbocharger ................................................................... 15-13 AIR DUCT AND AIR CLEANER ....................................................... 15-14 TURBOCHARGER............................................................................ 15-18 INTERCOOLER................................................................................. 15-24 INTAKE MANIFOLD.......................................................................... 15-28 EXHAUST MANIFOLD...................................................................... 15-30 EXHAUST PIPE ................................................................................ 15-31 DIESEL PARTICULATE FILTER....................................................... 15-34 ---===WSE_1505_00010_0281.djvu===--- 15-2 SPECIFICATIONS STRUCTURE AND OPERATION 1. Air Cleaner The air cleaner is a single element type. When the engine slows down below the predetermined speed, the level of vacuum changes and causes the un- loader valve to vibrate. Vibration of the unloader valve allows the air cleaner to automatically discharge any water and dust that has accumulated in its inside. Item Specifications Air cleaner element type Filter paper type Turbocharger Model TD04 Manufacturer Mitsubishi Heavy Industries, Ltd. Cooling system Water-cooled Intercooler type Tube and corrugated fin air cooled type Diesel particulate filter type Continuous regeneration type (PM-CAT) SPECIFICATIONS / STRUCTURE AND OPERATION ---===WSE_1505_00010_0281.djvu===--- 15-2 SPECIFICATIONS STRUCTURE AND OPERATION 1. Air Cleaner The air cleaner is a single element type. When the engine slows down below the predetermined speed, the level of vacuum changes and causes the un- loader valve to vibrate. Vibration of the unloader valve allows the air cleaner to automatically discharge any water and dust that has accumulated in its inside. Item Specifications Air cleaner element type Filter paper type Turbocharger Model TD04 Manufacturer Mitsubishi Heavy Industries, Ltd. Cooling system Water-cooled Intercooler type Tube and corrugated fin air cooled type Diesel particulate filter type Continuous regeneration type (PM-CAT) SPECIFICATIONS / STRUCTURE AND OPERATION ---===WSE_1505_00010_0281.djvu===--- 15-2 SPECIFICATIONS STRUCTURE AND OPERATION 1. Air Cleaner The air cleaner is a single element type. When the engine slows down below the predetermined speed, the level of vacuum changes and causes the un- loader valve to vibrate. Vibration of the unloader valve allows the air cleaner to automatically discharge any water and dust that has accumulated in its inside. Item Specifications Air cleaner element type Filter paper type Turbocharger Model TD04 Manufacturer Mitsubishi Heavy Industries, Ltd. Cooling system Water-cooled Intercooler type Tube and corrugated fin air cooled type Diesel particulate filter type Continuous regeneration type (PM-CAT) SPECIFICATIONS / STRUCTURE AND OPERATION ---===WSE_1505_00010_0282.djvu===--- 15 15-3 2. Turbocharger TD04 model is equipped with turbocharger, which is a variable nozzle vane type turbocharger with adjustable, heat-resistive alloy turbine vanes provided at the turbine exhaust gas inlet port. ---===WSE_1505_00010_0283.djvu===--- 15-4 3. Exhaust Shutter Valve When a driver turns on the exhaust brake switch, the engine electronic control unit sends a signal to the ex- haust shutter 3-way magnetic valve. This turns on the exhaust shutter 3- way magnetic valve, and the valve ap- plies the vacuum pressure from the vacuum tank to the exhaust shutter valve to activate the exhaust shutter valve. 4. Diesel Particulate Filter The diesel particulate filter consists of the following 2 sections: an oxidation catalyst and a metal filter. The oxidation catalyst oxidizes PM (particulate matter) contained in the exhaust gas and the metal filter captures the residual PM and makes it burn for removal from ex- haust gas. The size of the filtration openings has been optimized to eliminate the de- posit of ash (product of combustion) generated in the engine. The filter re- quires no maintenance, including peri- odical cleaning. STRUCTURE AND OPERATION ---===WSE_1505_00010_0283.djvu===--- 15-4 3. Exhaust Shutter Valve When a driver turns on the exhaust brake switch, the engine electronic control unit sends a signal to the ex- haust shutter 3-way magnetic valve. This turns on the exhaust shutter 3- way magnetic valve, and the valve ap- plies the vacuum pressure from the vacuum tank to the exhaust shutter valve to activate the exhaust shutter valve. 4. Diesel Particulate Filter The diesel particulate filter consists of the following 2 sections: an oxidation catalyst and a metal filter. The oxidation catalyst oxidizes PM (particulate matter) contained in the exhaust gas and the metal filter captures the residual PM and makes it burn for removal from ex- haust gas. The size of the filtration openings has been optimized to eliminate the de- posit of ash (product of combustion) generated in the engine. The filter re- quires no maintenance, including peri- odical cleaning. STRUCTURE AND OPERATION ---===WSE_1505_00010_0284.djvu===--- 15 15-5 Symptoms Reference Gr Possible causes Air cleaner Clogged air cleaner element OO O Turbocharger Defective cartridge a s s e m b l y OOOO O Compressor cover fitted poorly O OOO Intercooler Foreign substances deposited on intercooler front core O Throttle actuator Butterfly valve does not open OOO Gr13E Butterfly valve malfunction OOO Front pipe/diesel particulate filter/tail pipe deformed O Front pipe/diesel particulate filter/tail pipe fitted poorly O Incorrect valve clearances O Gr11 Head gasket defective O Wear/carbon deposits on valves and valve seats O Valve spring weakened O Piston rings worn/damaged O O Piston ring grooves worn/damaged O O Cooling system malfunctioning O Gr14 Engine oil quantity excessive O Gr12 Major moving parts seized O Gr11 Uneven or excessive fuel injection O Gr13E Vacuum system Insufficient vacuum O Gr35 Collapsed piping O Faulty 3-way magnet valve OO G r 5 4 Exhaust shutter valve Faulty valve OO Stuck valve shaft OO Faulty valve chamber O Faulty electric system OO G r 5 4 TROUBLESHOOTING ---===WSE_1505_00010_0285.djvu===--- 15-6 1. Measurement and Adjustment of Turbocharger Boost Pressure CAUTION If boost pressure exceeds the standard value, the engine may malfunction or break down. Boost pressure must be within the specified range. Service standards 1.1 Preparation Shift the transmission to neutral. Hold the steering wheel in neutral position. Turn off lamps and accessory devices not to increase the engine speed. Connect the Multi-Use Tester. (See Gr00.) If any fault exists (corresponding diagnosis code is issued), recti- fy it. Warm up the engine until the engine coolant has been heated to more than 60C. (Determine coolant temperature from service data [32: Water temperature].) Check that the non-load minimum speed (idling speed) is as specified. (See Gr13.) 1.2 Measurement and correction of boost pressure Set the diagnosis switch to OFF (disconnect the fuse). (See Gr00.) Turn the idle adjust dial to any position within the illustrated range of Mode 1. Select [A4: VGT1] in [Actuator Test] of the Multi-Use Tester. Set [Target Value] to 80% and execute. When [A4: VGT1] is executed, the engine speed should be auto- matically increased to 2500 rpm. Maintain the state of [Target Value] having been executed (for 5 to 15 minutes) until boost pressure is stabilized. Measure the following items from among [Service Data]. 20: Atmospheric pressure (measured atmospheric pressure) 21: Boost pressure (measured boost pressure) 30: Intake air temperature (upper stream) (measured air temper- ature) After the measurements, set the diagnosis switch to ON (con- nect the fuse). Obtain boost pressure correction value respectively by calculat- ing above Service Data. [Calculation of intake air temperature correction value] Intake air temperature correction value = --0.3976 (Measured boost temperature --25) [Calculation of atmospheric pressure correction value] Atmospheric temperature correction value = Measured atmo- spheric temperature --100 Location Maintenance item Standard value Limit Remedy -- Boost pressure 147 to 185 kPa -- Inspect or adjust ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0285.djvu===--- 15-6 1. Measurement and Adjustment of Turbocharger Boost Pressure CAUTION If boost pressure exceeds the standard value, the engine may malfunction or break down. Boost pressure must be within the specified range. Service standards 1.1 Preparation Shift the transmission to neutral. Hold the steering wheel in neutral position. Turn off lamps and accessory devices not to increase the engine speed. Connect the Multi-Use Tester. (See Gr00.) If any fault exists (corresponding diagnosis code is issued), recti- fy it. Warm up the engine until the engine coolant has been heated to more than 60C. (Determine coolant temperature from service data [32: Water temperature].) Check that the non-load minimum speed (idling speed) is as specified. (See Gr13.) 1.2 Measurement and correction of boost pressure Set the diagnosis switch to OFF (disconnect the fuse). (See Gr00.) Turn the idle adjust dial to any position within the illustrated range of Mode 1. Select [A4: VGT1] in [Actuator Test] of the Multi-Use Tester. Set [Target Value] to 80% and execute. When [A4: VGT1] is executed, the engine speed should be auto- matically increased to 2500 rpm. Maintain the state of [Target Value] having been executed (for 5 to 15 minutes) until boost pressure is stabilized. Measure the following items from among [Service Data]. 20: Atmospheric pressure (measured atmospheric pressure) 21: Boost pressure (measured boost pressure) 30: Intake air temperature (upper stream) (measured air temper- ature) After the measurements, set the diagnosis switch to ON (con- nect the fuse). Obtain boost pressure correction value respectively by calculat- ing above Service Data. [Calculation of intake air temperature correction value] Intake air temperature correction value = --0.3976 (Measured boost temperature --25) [Calculation of atmospheric pressure correction value] Atmospheric temperature correction value = Measured atmo- spheric temperature --100 Location Maintenance item Standard value Limit Remedy -- Boost pressure 147 to 185 kPa -- Inspect or adjust ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0286.djvu===--- 15 15-7 [Calculation of boost pressure correction value] Obtain the boost pressure correction value using the following equation. Boost pressure correction value = Measured boost pressure -- intake air temperature correction value -- atmospheric tempera- ture correction value If boost pressure correction value deviates from the standard value, adjust the turbocharger. WARNING The turbocharger is hot for a while after the engine is stopped. Take care not to burn yourself during adjustment work. ---===WSE_1505_00010_0287.djvu===--- 15-8 1.3 Turbocharger adjustments Follow the flow chart below when adjustments become necessary on the turbocharger. <Inspection and adjustment sequence> Measure boost pressure Check for contact between control crank and position bolt (see (1) given later) If control crank fails to contact position bolt (see (2) given later) If control crank contacts position bolt (see (3) given later) Adjust actuator shaft length Measure boost pressure Check for contact between control crank and position bolt Adjust position bolt length Adjust actuator shaft length If boost pressure is too low (see (3.1) given later) If boost pressure is too high (see (3.2) given later) Adjust position bolt length Adjust position bolt length Adjust actuator shaft length Measure boost pressure Check turbocharger ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0288.djvu===--- 15 15-9 (1) Checking contact between control crank and position bolt Start the engine. Stop the engine. Set the starter switch to the [ON] position within 40 seconds. Select [A5: EGR, ETV, VGT] from [Actuator Test] on the Multi- Use Tester screen. Set [Target Value] at 100% and have it exe- cuted. The actuator shaft will be put into a full-stroke state. With the actuator shaft maintained in this state, check for contact between the control crank and position bolt. (2) If control crank fails to contact position bolt <Actuator shaft length adjustment> Remove snap rings and pins on the actuator side of the shaft. Loosen the lock nut. Turning the joint part, extend the shaft until the control crank contacts the position bolt. Adjusting guide: Shaft length changes by 1 mm with one turn of the joint. After the adjustment, reinstall the snap rings and pins, and tight- en the lock nut. NOTE If proper control crank-to-position bolt contact cannot be achieved despite full shaft extension, replace the lever and pins. Measure boost pressure again. If boost pressure is out of the standard value, make readjust- ment as follows. <Checking contact between control crank and position bolt> Start the engine. Stop the engine. Set the starter switch to the [ON] position within 40 seconds. Select [A5: EGR, ETV, VGT] from [Actuator Test] on the Multi- Use Tester screen. Set [Target Value] at 100% and have it exe- cuted. The actuator shaft will be put into a full-stroke state. With the actuator shaft maintained in this state, check for contact between the control crank and position bolt. If proper contact is still to be achieved, adjust the actuator shaft length all over again. ---===WSE_1505_00010_0289.djvu===--- 15-10 <Position bolt length adjustment> Loosen the lock nut. Using a hexagon wrench, turn the position bolt in illustrated di- rections to bring it into a position clear of the control crank. Adjusting guide: With the engine running at 2500 rpm, one full turn of the position bolt increases boost pressure by approxi- mately 3 kPa. After the adjustment, tighten the lock nut. Then, proceed to the actuator shaft length adjustment. <Actuator shaft length adjustment> Remove snap rings and pins on the actuator side of the shaft. Loosen the lock nut. Turning the joint part, extend the shaft until the control crank contacts the position bolt. Adjusting guide: Shaft length changes by 1 mm with one turn of the joint. After the adjustment, reinstall the snap rings and pins, and tight- en the lock nut. NOTE If proper control crank-to-position bolt contact cannot be achieved despite full shaft extension, replace the lever and pins. Measure boost pressure again. If boost pressure is out of the standard value, check the turbo- charger. (See later section.) (3) If the control crank contacts the position bolt (3.1) If boost pressure is too low <Position bolt length adjustment> Loosen the lock nut. Using a hexagon wrench, turn the position bolt in illustrated di- rections to bring it into a position clear of the control crank. Adjusting guide: With the engine running at 2500 rpm, one full turn of the position bolt increases boost pressure by approxi- mately 3 kPa. After the adjustment, tighten the lock nut. Then, proceed to the actuator shaft length adjustment. ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0290.djvu===--- 15 15-11 <Actuator shaft length adjustment> Remove snap rings and pins on the actuator side of the shaft. Loosen the lock nut. Turning the joint part, extend the shaft until the control crank contacts the position bolt. Adjusting guide: Shaft length changes by 1 mm with one turn of the joint. After the adjustment, reinstall the snap rings and pins, and tight- en the lock nut. NOTE If proper control crank-to-position bolt contact cannot be achieved despite full shaft extension, replace the lever and pins. Measure boost pressure again. If boost pressure is out of the standard value, check the turbo- charger. (See later section.) (3.2) If boost pressure is too high <Position bolt length adjustment> Loosen the lock nut. Using a hexagon wrench, turn the position bolt in illustrated di- rections to bring it into a position clear of the control crank. (Turn the starter switch ON. If the engine warning lamp stays off for more than 30 seconds, it is in normal condition.) Adjusting guide: With the engine running at 2500 rpm, one full turn of the position bolt increases boost pressure by approxi- mately 3 kPa. After the adjustment, tighten the lock nut. Measure boost pressure again. If boost pressure is out of the standard value, check the turbo- charger. (See later section.) CAUTION If shaft stroke is out of specified standard value (18.5 to 21 mm), the engine electronic control unit detects it as a turbo- charger adjustment error (common rail system diagnosis code P2263: VGT System) and indicates it through engine warning lamp. In such a case, check the turbocharger for responsible fault. Delete the diagnosis code appearing on the Multi-Use Tes- ter screen because it is otherwise memorized in the engine electronic control unit. (See Gr00.) ---===WSE_1505_00010_0291.djvu===--- 15-12 2. Cleaning and Inspection of Air Cleaner Element [Cleaning] Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. [Inspection] Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. [Installation] : Alignment mark 3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "INTAKE MANIFOLD".) 4. Check for Cracks and Gas Leakage in Exhaust Manifold Inspect the exhaust manifold visually. If there is any trace of gas leakage or cracks, replace the exhaust manifold. (See "EXHAUST MANIFOLD".) Check for looseness in the exhaust manifold mounting nuts. If there is looseness, tighten the nuts to the specified torque. (See "EXHAUST MANIFOLD".) 5. Check for Cracks and Gas Leakage in Turbocharger Inspect the turbocharger visually. If there is any trace of gas leakage or cracks, replace the turbocharger. (See "TURBOCHARGER".) Check for looseness in the turbocharger mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "TURBOCHARGER".) ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0291.djvu===--- 15-12 2. Cleaning and Inspection of Air Cleaner Element [Cleaning] Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. [Inspection] Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. [Installation] : Alignment mark 3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "INTAKE MANIFOLD".) 4. Check for Cracks and Gas Leakage in Exhaust Manifold Inspect the exhaust manifold visually. If there is any trace of gas leakage or cracks, replace the exhaust manifold. (See "EXHAUST MANIFOLD".) Check for looseness in the exhaust manifold mounting nuts. If there is looseness, tighten the nuts to the specified torque. (See "EXHAUST MANIFOLD".) 5. Check for Cracks and Gas Leakage in Turbocharger Inspect the turbocharger visually. If there is any trace of gas leakage or cracks, replace the turbocharger. (See "TURBOCHARGER".) Check for looseness in the turbocharger mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "TURBOCHARGER".) ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0291.djvu===--- 15-12 2. Cleaning and Inspection of Air Cleaner Element [Cleaning] Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. [Inspection] Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. [Installation] : Alignment mark 3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "INTAKE MANIFOLD".) 4. Check for Cracks and Gas Leakage in Exhaust Manifold Inspect the exhaust manifold visually. If there is any trace of gas leakage or cracks, replace the exhaust manifold. (See "EXHAUST MANIFOLD".) Check for looseness in the exhaust manifold mounting nuts. If there is looseness, tighten the nuts to the specified torque. (See "EXHAUST MANIFOLD".) 5. Check for Cracks and Gas Leakage in Turbocharger Inspect the turbocharger visually. If there is any trace of gas leakage or cracks, replace the turbocharger. (See "TURBOCHARGER".) Check for looseness in the turbocharger mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "TURBOCHARGER".) ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0291.djvu===--- 15-12 2. Cleaning and Inspection of Air Cleaner Element [Cleaning] Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. [Inspection] Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. [Installation] : Alignment mark 3. Check for Looseness in Intake Manifold Mounting Bolts and Nuts Check for looseness in the intake manifold and air inlet pipe mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "INTAKE MANIFOLD".) 4. Check for Cracks and Gas Leakage in Exhaust Manifold Inspect the exhaust manifold visually. If there is any trace of gas leakage or cracks, replace the exhaust manifold. (See "EXHAUST MANIFOLD".) Check for looseness in the exhaust manifold mounting nuts. If there is looseness, tighten the nuts to the specified torque. (See "EXHAUST MANIFOLD".) 5. Check for Cracks and Gas Leakage in Turbocharger Inspect the turbocharger visually. If there is any trace of gas leakage or cracks, replace the turbocharger. (See "TURBOCHARGER".) Check for looseness in the turbocharger mounting bolts and nuts. If there is looseness, tighten the bolts and nuts to the specified torque. (See "TURBOCHARGER".) ON-VEHICLE INSPECTION AND ADJUSTMENT ---===WSE_1505_00010_0292.djvu===--- 15 15-13 6. Loose Turbocharger Remove the bolts, loosen the clamp securing the air hose and turbocharger and remove the air hose. Turn the compressor wheel by turning the shaft tip with fingers. Check that the compressor wheel rotate smoothly without touch- ing the compressor. If any abnormality is found, disassemble and inspect the turbo- charger. (See "TURBOCHARGER".) ---===WSE_1505_00010_0293.djvu===--- 15-14 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 3.4 {0.3 to 0.35} -- Bolt (air flow sensor mounting) 1.2 to 1.8 {0.12 to 0.18} -- Intake air temperature sensor 10 {1.0} -- 1 Air inlet duct 2 Connector 3 Air hose 4 Insulator 5 Air duct 6 Air flow sensor 7 Connector 8 Mesh filter 9 Intake air temperature sensor 10 Air box 11 Rubber seal 12 Air cleaner cap 13 Air cleaner element 14 Air cleaner case * a: Turbocharger * b: Positive crankcase ventilation hose B : Non-reusable parts AIR DUCT AND AIR CLEANER ---===WSE_1505_00010_0293.djvu===--- 15-14 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 3.4 {0.3 to 0.35} -- Bolt (air flow sensor mounting) 1.2 to 1.8 {0.12 to 0.18} -- Intake air temperature sensor 10 {1.0} -- 1 Air inlet duct 2 Connector 3 Air hose 4 Insulator 5 Air duct 6 Air flow sensor 7 Connector 8 Mesh filter 9 Intake air temperature sensor 10 Air box 11 Rubber seal 12 Air cleaner cap 13 Air cleaner element 14 Air cleaner case * a: Turbocharger * b: Positive crankcase ventilation hose B : Non-reusable parts AIR DUCT AND AIR CLEANER ---===WSE_1505_00010_0293.djvu===--- 15-14 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Clamp 3.0 to 3.4 {0.3 to 0.35} -- Bolt (air flow sensor mounting) 1.2 to 1.8 {0.12 to 0.18} -- Intake air temperature sensor 10 {1.0} -- 1 Air inlet duct 2 Connector 3 Air hose 4 Insulator 5 Air duct 6 Air flow sensor 7 Connector 8 Mesh filter 9 Intake air temperature sensor 10 Air box 11 Rubber seal 12 Air cleaner cap 13 Air cleaner element 14 Air cleaner case * a: Turbocharger * b: Positive crankcase ventilation hose B : Non-reusable parts AIR DUCT AND AIR CLEANER ---===WSE_1505_00010_0294.djvu===--- 15 15-15 Cleaning procedure Cleaning: Element Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. Inspection procedure Inspection: Element Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. Installation procedure Installation: Air cleaner cap : Alignment mark Installation: Rubber seal Align slit of rubber seal with key of air cleaner case. ---===WSE_1505_00010_0294.djvu===--- 15 15-15 Cleaning procedure Cleaning: Element Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. Inspection procedure Inspection: Element Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. Installation procedure Installation: Air cleaner cap : Alignment mark Installation: Rubber seal Align slit of rubber seal with key of air cleaner case. ---===WSE_1505_00010_0294.djvu===--- 15 15-15 Cleaning procedure Cleaning: Element Blow a jet of compressed air at a pressure not higher than 685 kPa {7 kgf/cm 2 } against the inside surfaces of the element. Move the compressed air jet up and down along all pleats of the filter paper element. CAUTION For the frequency and timing of cleaning, see the relevant instruction manual. More frequent cleaning than necessary may damage the element, causing dust and foreign matter to be sucked into the engine. Do not strike the element or hit it against another object to remove dust. Do not blow compressed air against outside surfaces of the element. Inspection procedure Inspection: Element Shine some electric light inside the element. Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is dam- aged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. Installation procedure Installation: Air cleaner cap : Alignment mark Installation: Rubber seal Align slit of rubber seal with key of air cleaner case. ---===WSE_1505_00010_0295.djvu===--- 15-16 Installation: Air box Align slit of air box with key of air cleaner case. Installation: Connector The protruding portion of the connector is put between clamps. Installation is such that the space between the connector and the air cleaner case measures the amount shown in the figure. Installation: Air duct Align the mark " " on air duct with the connector's and push the air duct in until it hits stopper. Installation: Air hose Align the mark " " on air hose with the air duct's and push the air hose in until it hits stopper. Connect the air hose to the turbocharger with the "UP" mark fac- ing up. AIR DUCT AND AIR CLEANER ---===WSE_1505_00010_0296.djvu===--- MEMO 15-17 15 ---===WSE_1505_00010_0297.djvu===--- 15-18 Removal sequence Installation sequence Follow the removal sequence in reverse. 1 Air hose 2 Air inlet hose 3 Turbocharger coupler 4 Gasket 5 Insulator 6 Eyebolt 7 Oil pipe 8 Eyebolt 9 Water pipe 10 Eyebolt 11 Eyebolt 12 Water pipe 13 Eyebolt 14 Water pipe 15 Oil return pipe 16 Gasket 17 Front pipe 18 Gasket 19 Exhaust coupler 20 Gasket 21 Eyebolt 22 By-pass pipe 23 Spacer 24 Bracket 25 Turbocharger (See later section.) 26 Gasket * a: Exhaust manifold : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0297.djvu===--- 15-18 Removal sequence Installation sequence Follow the removal sequence in reverse. 1 Air hose 2 Air inlet hose 3 Turbocharger coupler 4 Gasket 5 Insulator 6 Eyebolt 7 Oil pipe 8 Eyebolt 9 Water pipe 10 Eyebolt 11 Eyebolt 12 Water pipe 13 Eyebolt 14 Water pipe 15 Oil return pipe 16 Gasket 17 Front pipe 18 Gasket 19 Exhaust coupler 20 Gasket 21 Eyebolt 22 By-pass pipe 23 Spacer 24 Bracket 25 Turbocharger (See later section.) 26 Gasket * a: Exhaust manifold : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0297.djvu===--- 15-18 Removal sequence Installation sequence Follow the removal sequence in reverse. 1 Air hose 2 Air inlet hose 3 Turbocharger coupler 4 Gasket 5 Insulator 6 Eyebolt 7 Oil pipe 8 Eyebolt 9 Water pipe 10 Eyebolt 11 Eyebolt 12 Water pipe 13 Eyebolt 14 Water pipe 15 Oil return pipe 16 Gasket 17 Front pipe 18 Gasket 19 Exhaust coupler 20 Gasket 21 Eyebolt 22 By-pass pipe 23 Spacer 24 Bracket 25 Turbocharger (See later section.) 26 Gasket * a: Exhaust manifold : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0298.djvu===--- 15 15-19 Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Installation procedure Installation: Turbocharger Before installing the turbocharger assembly, pour engine oil into the oil hole to ensure smooth operation of the internal parts. Mark Parts to be tightened Tightening torque Remarks Clamp 3 to 3.4 {0.3 to 0.35} -- Clamp 3.9 to 4.9 {0.4 to 0.5} -- Bolt (turbocharger coupler mounting) 23.8 {2.4} -- Bolt (insulator mounting) Bolt (exhaust coupler stay mounting) Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} -- Nut (turbocharger mounting) 42 {4.2} -- Eyebolt (water pipe mounting) 21 {2.1} -- Eyebolt (oil pipe mounting) Eyebolt (by-pass pipe) 39 {4.0} -- Nut (exhaust coupler mounting) 64 {6.5} -- Bolt (exhaust coupler stay mounting) 46 {4.7} -- Mark Points of application Specified lubricant and/or sealant Quantity Pouring into turbocharger Engine oil As required ---===WSE_1505_00010_0299.djvu===--- 15-20 Turbocharger Removal sequence NOTE Do not remove the joint and position bolt from the actuator and turbine assembly unless they are defec- tive. CAUTION The blades on the turbine assembly are easily bent. Make sure that they do not strike the compressor cover. The turbine assembly is a non-disassemble component. When it becomes unsmooth in rotation or has a damaged compressor wheel, replace the turbocharger. Installation sequence Follow the removal sequence in reverse. 1 Snap ring 2 Pin 3 Lever 4 Joint 5 Lock nut 6 Actuator 7 Lock nut 8 Position bolt 9 Snap ring 10 Compressor cover 11 Turbine assembly : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0299.djvu===--- 15-20 Turbocharger Removal sequence NOTE Do not remove the joint and position bolt from the actuator and turbine assembly unless they are defec- tive. CAUTION The blades on the turbine assembly are easily bent. Make sure that they do not strike the compressor cover. The turbine assembly is a non-disassemble component. When it becomes unsmooth in rotation or has a damaged compressor wheel, replace the turbocharger. Installation sequence Follow the removal sequence in reverse. 1 Snap ring 2 Pin 3 Lever 4 Joint 5 Lock nut 6 Actuator 7 Lock nut 8 Position bolt 9 Snap ring 10 Compressor cover 11 Turbine assembly : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0299.djvu===--- 15-20 Turbocharger Removal sequence NOTE Do not remove the joint and position bolt from the actuator and turbine assembly unless they are defec- tive. CAUTION The blades on the turbine assembly are easily bent. Make sure that they do not strike the compressor cover. The turbine assembly is a non-disassemble component. When it becomes unsmooth in rotation or has a damaged compressor wheel, replace the turbocharger. Installation sequence Follow the removal sequence in reverse. 1 Snap ring 2 Pin 3 Lever 4 Joint 5 Lock nut 6 Actuator 7 Lock nut 8 Position bolt 9 Snap ring 10 Compressor cover 11 Turbine assembly : Non-reusable parts TURBOCHARGER ---===WSE_1505_00010_0300.djvu===--- 15 15-21 Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Work before removal Alignment mark Put alignment marks on the pin and lever. CAUTION Be sure to provide alignment marks on the lever and pin to ensure installation of the pins in right places when reused. Pins in wrong position would change boost pressure to re- sult in a malfunctioning or damaged engine. Work after disassembly Cleaning Before cleaning, visually check the disassembled parts for scorches, abrasion and other marks that may be difficult to see after cleaning. Replace any part that appears defective. Immerse the disassembled parts in a non-flammable solvent (a 5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.). Take out the parts and blow them dry with compressed air. Re- move any hard deposits with a stiff brush or plastic scraper. CAUTION Do not immerse the cartridge assembly in the solvent. Do- ing so will cause the O-ring inside the cartridge assembly to sell up, which may adversely affect turbocharger operation. Again, immerse the parts in the solvent. Blow them dry using compressed air. Location Maintenance item Standard value Limit Remedy 2 Pin outer diameter 8 7.5 Replace 3 Lever inner diameter 8 8.5 Replace 4 Joint inner diameter 8 8.5 Replace 6 Actuator shaft stroke 18.5 to 21 18.4 Replace 11 Play in shaft axis direction of turbine assembly 0.39 to 0.67 -- Replace Mark Parts to be tightened Tightening torque Remarks Bolt (bracket mounting) 21.6 to 23.5 {2.2 to 2.4} -- Lock nut 4.9 to 9.8 {0.5 to 1.0} -- Mark Points of application Specified lubricant and/or sealant Quantity Thread area of nuts Seizure preventive compound (FEL-PRO CA-5) As required ---===WSE_1505_00010_0300.djvu===--- 15 15-21 Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Work before removal Alignment mark Put alignment marks on the pin and lever. CAUTION Be sure to provide alignment marks on the lever and pin to ensure installation of the pins in right places when reused. Pins in wrong position would change boost pressure to re- sult in a malfunctioning or damaged engine. Work after disassembly Cleaning Before cleaning, visually check the disassembled parts for scorches, abrasion and other marks that may be difficult to see after cleaning. Replace any part that appears defective. Immerse the disassembled parts in a non-flammable solvent (a 5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.). Take out the parts and blow them dry with compressed air. Re- move any hard deposits with a stiff brush or plastic scraper. CAUTION Do not immerse the cartridge assembly in the solvent. Do- ing so will cause the O-ring inside the cartridge assembly to sell up, which may adversely affect turbocharger operation. Again, immerse the parts in the solvent. Blow them dry using compressed air. Location Maintenance item Standard value Limit Remedy 2 Pin outer diameter 8 7.5 Replace 3 Lever inner diameter 8 8.5 Replace 4 Joint inner diameter 8 8.5 Replace 6 Actuator shaft stroke 18.5 to 21 18.4 Replace 11 Play in shaft axis direction of turbine assembly 0.39 to 0.67 -- Replace Mark Parts to be tightened Tightening torque Remarks Bolt (bracket mounting) 21.6 to 23.5 {2.2 to 2.4} -- Lock nut 4.9 to 9.8 {0.5 to 1.0} -- Mark Points of application Specified lubricant and/or sealant Quantity Thread area of nuts Seizure preventive compound (FEL-PRO CA-5) As required ---===WSE_1505_00010_0301.djvu===--- 15-22 Inspection procedure Inspection: Play in shaft axis direction of turbine assembly With the flange of the turbine assembly attached to a flat plate, measure the play with a dial gauge. If the measurement exceeds the specified limit, replace the tur- bine assembly. Inspection: Pin outer diameter If the measurement is less than the limit, replace the pin. Inspection: Lever inner diameter If the measurement exceeds the limit, replace the lever. Inspection: Joint inner diameter If the measurement exceeds the limit, replace the joint. TURBOCHARGER ---===WSE_1505_00010_0302.djvu===--- 15 15-23 Inspection: Actuator shaft stroke Conduct the actuator check with the turbocharger electronic drive unit mounted on the vehicle. Mark the actuator shaft at the zero stroke point. Select [A5: EGR, ETV, VGT] from [Actuator Test] on the Multi- Use Tester screen and execute it. The actuator shaft will be brought into a full stroke state. Measure the amount of stroke from the full stroke point to the marked point. If the measurement is out of specified standard value, replace the actuator. Installation procedure Installation: Position bolt Move the control crank to the maximum position, and install the position bolt to the turbine assembly. Make sure that the position bolt is in contact with the control crank. In this state, give the position bolt two and half turns, then tight- en the lock nut to secure the position bolt. Installation: Joint With the actuator shaft in a zero stroke state, adjust the distance between the end faces of the actuator and joint to the illustrated value. Adjusting guide: 1 mm with one full turn of joint After the adjustment, tighten the lock nut. Installation: Pin Install the pins in the lever according to alignment marks. CAUTION Be sure to match the alignment marks to ensure installation of the pins in right places when reused. Pins in wrong posi- tion would change the boost pressure to result in a mal- functioning or damaged engine. ---===WSE_1505_00010_0303.djvu===--- 15-24 Disassembly sequence CAUTION Do not remove forcedly the air inlet hose using a screwdriver or other similar tool. Doing so could dam- age the fluorine treatment layer on the inside surface of the hose, deteriorating the resistance to oil of the hose. Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 8 Intercooler air leakage (air pressure: 200 kPa {2.0 kgf/cm 2 } maintained for 30 seconds) 0cm 3 {0 mL} -- Replace Mark Parts to be tightened Tightening torque Remarks Clamp 6.0 to 6.5 {0.6 to 0.7} -- Bolt (bracket mounting) 12 to 15 {1.2 to 1.5} -- Nut (bracket mounting) Bolt (intercooler mounting) Bolt (air inlet pipe LH) 1 Air inlet hose 2 Air inlet pipe LH 3 Air inlet hose 4 Air inlet hose 5 Air inlet pipe RH 6 Air inlet hose 7 Intercooler * a: Air inlet duct * b: Turbocharger coupler INTERCOOLER ---===WSE_1505_00010_0303.djvu===--- 15-24 Disassembly sequence CAUTION Do not remove forcedly the air inlet hose using a screwdriver or other similar tool. Doing so could dam- age the fluorine treatment layer on the inside surface of the hose, deteriorating the resistance to oil of the hose. Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 8 Intercooler air leakage (air pressure: 200 kPa {2.0 kgf/cm 2 } maintained for 30 seconds) 0cm 3 {0 mL} -- Replace Mark Parts to be tightened Tightening torque Remarks Clamp 6.0 to 6.5 {0.6 to 0.7} -- Bolt (bracket mounting) 12 to 15 {1.2 to 1.5} -- Nut (bracket mounting) Bolt (intercooler mounting) Bolt (air inlet pipe LH) 1 Air inlet hose 2 Air inlet pipe LH 3 Air inlet hose 4 Air inlet hose 5 Air inlet pipe RH 6 Air inlet hose 7 Intercooler * a: Air inlet duct * b: Turbocharger coupler INTERCOOLER ---===WSE_1505_00010_0303.djvu===--- 15-24 Disassembly sequence CAUTION Do not remove forcedly the air inlet hose using a screwdriver or other similar tool. Doing so could dam- age the fluorine treatment layer on the inside surface of the hose, deteriorating the resistance to oil of the hose. Assembly sequence Follow the disassembly sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 8 Intercooler air leakage (air pressure: 200 kPa {2.0 kgf/cm 2 } maintained for 30 seconds) 0cm 3 {0 mL} -- Replace Mark Parts to be tightened Tightening torque Remarks Clamp 6.0 to 6.5 {0.6 to 0.7} -- Bolt (bracket mounting) 12 to 15 {1.2 to 1.5} -- Nut (bracket mounting) Bolt (intercooler mounting) Bolt (air inlet pipe LH) 1 Air inlet hose 2 Air inlet pipe LH 3 Air inlet hose 4 Air inlet hose 5 Air inlet pipe RH 6 Air inlet hose 7 Intercooler * a: Air inlet duct * b: Turbocharger coupler INTERCOOLER ---===WSE_1505_00010_0304.djvu===--- 15 15-25 Inspection procedure Inspection: Intercooler Plug one of the air ports of the intercooler and immerse it in a tank of water. Apply the specified air pressure to the intercooler through the other air port and retain pressure for 30 seconds. Replace the intercooler if any air leakage is evident. Installation procedure Installation: Air inlet hose Install the air inlet hose in the intercooler to the dimension shown in the illustration. Install the air inlet hose in the air inlet pipe RH to the dimension shown in the illustration with the pink paint on the hose and the buildup on the pipe aligned. Install the air inlet hose in the turbocharger coupler to the dimen- sion shown in the illustration. ---===WSE_1505_00010_0304.djvu===--- 15 15-25 Inspection procedure Inspection: Intercooler Plug one of the air ports of the intercooler and immerse it in a tank of water. Apply the specified air pressure to the intercooler through the other air port and retain pressure for 30 seconds. Replace the intercooler if any air leakage is evident. Installation procedure Installation: Air inlet hose Install the air inlet hose in the intercooler to the dimension shown in the illustration. Install the air inlet hose in the air inlet pipe RH to the dimension shown in the illustration with the pink paint on the hose and the buildup on the pipe aligned. Install the air inlet hose in the turbocharger coupler to the dimen- sion shown in the illustration. ---===WSE_1505_00010_0305.djvu===--- 15-26 Connect the air inlet hose to the LH air inlet pipe with the white paint on the hose aligned with the buildup on the pipe. Connect the air inlet hoses to the intercooler, LH air inlet pipe and air inlet duct to the dimensions indicated in the illustrations. Connect the air inlet hose to the LH air inlet pipe with the blue paint on the hose aligned with the buildup on the pipe. Installation: Air inlet pipe LH When installing the air inlet pipe LH, tighten the nut on the frame side first. INTERCOOLER ---===WSE_1505_00010_0306.djvu===--- MEMO 15-27 15 ---===WSE_1505_00010_0307.djvu===--- 15-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (boost pressure sensor bracket mounting) 23.2 {2.4} -- Bolt (intake manifold mounting) Bolt (boost pressure sensor mounting) 12.7 {1.3} -- Boost air temperature sensor 25±5{2.5±0.5} -- 1 Intake throttle 2 Gasket 3 Vacuum hose 4 Boost pressure sensor 5 Vacuum hose 6 Vacuum pipe 7 Air inlet pipe 8 Gasket 9 Boost air temperature sensor 10 Intake manifold 11 Gasket : Non-reusable parts INTAKE MANIFOLD ---===WSE_1505_00010_0307.djvu===--- 15-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (boost pressure sensor bracket mounting) 23.2 {2.4} -- Bolt (intake manifold mounting) Bolt (boost pressure sensor mounting) 12.7 {1.3} -- Boost air temperature sensor 25±5{2.5±0.5} -- 1 Intake throttle 2 Gasket 3 Vacuum hose 4 Boost pressure sensor 5 Vacuum hose 6 Vacuum pipe 7 Air inlet pipe 8 Gasket 9 Boost air temperature sensor 10 Intake manifold 11 Gasket : Non-reusable parts INTAKE MANIFOLD ---===WSE_1505_00010_0307.djvu===--- 15-28 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (boost pressure sensor bracket mounting) 23.2 {2.4} -- Bolt (intake manifold mounting) Bolt (boost pressure sensor mounting) 12.7 {1.3} -- Boost air temperature sensor 25±5{2.5±0.5} -- 1 Intake throttle 2 Gasket 3 Vacuum hose 4 Boost pressure sensor 5 Vacuum hose 6 Vacuum pipe 7 Air inlet pipe 8 Gasket 9 Boost air temperature sensor 10 Intake manifold 11 Gasket : Non-reusable parts INTAKE MANIFOLD ---===WSE_1505_00010_0308.djvu===--- 15 15-29 Inspection procedure Inspection: Boost air temperature sensor Check that the sensor portion is free of soot, oily substance, etc. If not, clean the sensor portion as follows. Spray a cleaner on the sensor portion from 2 or 3 cm away. Recommended cleaners: Nonchlorinated solvent In 20 to 30 seconds after spraying, wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth the like. CAUTION Be sure to wait for 20 to 30 seconds before wiping. It takes the cleaner that long to dissolve foreign matter. If the sensor portion is fouled excessively, the positive crankcase ventilation may be faulty. Inspect the positive crankcase ventila- tion valve and filter to locate the cause and remove it. Installation procedure Installation: Gasket Install the gasket on the cylinder head in the illustrated direction. ---===WSE_1505_00010_0308.djvu===--- 15 15-29 Inspection procedure Inspection: Boost air temperature sensor Check that the sensor portion is free of soot, oily substance, etc. If not, clean the sensor portion as follows. Spray a cleaner on the sensor portion from 2 or 3 cm away. Recommended cleaners: Nonchlorinated solvent In 20 to 30 seconds after spraying, wipe the sensor portion clear of the sprayed cleaner using a soft waste cloth the like. CAUTION Be sure to wait for 20 to 30 seconds before wiping. It takes the cleaner that long to dissolve foreign matter. If the sensor portion is fouled excessively, the positive crankcase ventilation may be faulty. Inspect the positive crankcase ventila- tion valve and filter to locate the cause and remove it. Installation procedure Installation: Gasket Install the gasket on the cylinder head in the illustrated direction. ---===WSE_1505_00010_0309.djvu===--- 15-30 Disassembly sequence 1 Insulator 2 Under insulator 3 Exhaust gas recirculation pipe 4 Gasket 5 Distance piece 6 Exhaust manifold 7 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Gasket Install the gasket on the cylinder head with their surfaces facing in the illustrated directions. Mark Parts to be tightened Tightening torque Remarks Bolt (insulator mounting) 11.8 {1.2} -- Nut (exhaust gas recirculation pipe mounting) 20.6 {2.1} -- Nut (exhaust manifold mounting) 41.2 {4.2} -- EXHAUST MANIFOLD ---===WSE_1505_00010_0309.djvu===--- 15-30 Disassembly sequence 1 Insulator 2 Under insulator 3 Exhaust gas recirculation pipe 4 Gasket 5 Distance piece 6 Exhaust manifold 7 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Gasket Install the gasket on the cylinder head with their surfaces facing in the illustrated directions. Mark Parts to be tightened Tightening torque Remarks Bolt (insulator mounting) 11.8 {1.2} -- Nut (exhaust gas recirculation pipe mounting) 20.6 {2.1} -- Nut (exhaust manifold mounting) 41.2 {4.2} -- EXHAUST MANIFOLD ---===WSE_1505_00010_0309.djvu===--- 15-30 Disassembly sequence 1 Insulator 2 Under insulator 3 Exhaust gas recirculation pipe 4 Gasket 5 Distance piece 6 Exhaust manifold 7 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Gasket Install the gasket on the cylinder head with their surfaces facing in the illustrated directions. Mark Parts to be tightened Tightening torque Remarks Bolt (insulator mounting) 11.8 {1.2} -- Nut (exhaust gas recirculation pipe mounting) 20.6 {2.1} -- Nut (exhaust manifold mounting) 41.2 {4.2} -- EXHAUST MANIFOLD ---===WSE_1505_00010_0309.djvu===--- 15-30 Disassembly sequence 1 Insulator 2 Under insulator 3 Exhaust gas recirculation pipe 4 Gasket 5 Distance piece 6 Exhaust manifold 7 Gasket : Non-reusable parts Assembly sequence Follow the disassembly sequence in re- verse. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Gasket Install the gasket on the cylinder head with their surfaces facing in the illustrated directions. Mark Parts to be tightened Tightening torque Remarks Bolt (insulator mounting) 11.8 {1.2} -- Nut (exhaust gas recirculation pipe mounting) 20.6 {2.1} -- Nut (exhaust manifold mounting) 41.2 {4.2} -- EXHAUST MANIFOLD ---===WSE_1505_00010_0310.djvu===--- 15 15-31 Disassembly sequence CAUTION Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Tighten the marked bolt last to prevent undue forces from being applied to the exhaust pipe. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Front pipe Install the front pipe so that the amounts of offset in both vertical and horizontal directions between the pipes in front of and be- hind the bellows are smaller than the dimension indicated in the illustration. CAUTION The bellows on the front pipe have the purpose of reducing the level of noise from the vehicle. It is not intended for compensating for misalignment that may result from im- proper installation of the front pipe. Install the front pipe properly to avoid excessive tension or other stress on the bellows. Mark Parts to be tightened Tightening torque Remarks Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} -- Bolt (exhaust shutter unit mounting) 27 to 29 {2.8 to 3.0} -- 1 Brace bracket 2 Gasket 3 Front pipe 4 Exhaust shutter (See later section.) 5 Front pipe * a: Exhaust manifold : Non-reusable parts EXHAUST PIPE ---===WSE_1505_00010_0310.djvu===--- 15 15-31 Disassembly sequence CAUTION Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Tighten the marked bolt last to prevent undue forces from being applied to the exhaust pipe. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Front pipe Install the front pipe so that the amounts of offset in both vertical and horizontal directions between the pipes in front of and be- hind the bellows are smaller than the dimension indicated in the illustration. CAUTION The bellows on the front pipe have the purpose of reducing the level of noise from the vehicle. It is not intended for compensating for misalignment that may result from im- proper installation of the front pipe. Install the front pipe properly to avoid excessive tension or other stress on the bellows. Mark Parts to be tightened Tightening torque Remarks Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} -- Bolt (exhaust shutter unit mounting) 27 to 29 {2.8 to 3.0} -- 1 Brace bracket 2 Gasket 3 Front pipe 4 Exhaust shutter (See later section.) 5 Front pipe * a: Exhaust manifold : Non-reusable parts EXHAUST PIPE ---===WSE_1505_00010_0310.djvu===--- 15 15-31 Disassembly sequence CAUTION Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Tighten the marked bolt last to prevent undue forces from being applied to the exhaust pipe. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Front pipe Install the front pipe so that the amounts of offset in both vertical and horizontal directions between the pipes in front of and be- hind the bellows are smaller than the dimension indicated in the illustration. CAUTION The bellows on the front pipe have the purpose of reducing the level of noise from the vehicle. It is not intended for compensating for misalignment that may result from im- proper installation of the front pipe. Install the front pipe properly to avoid excessive tension or other stress on the bellows. Mark Parts to be tightened Tightening torque Remarks Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} -- Bolt (exhaust shutter unit mounting) 27 to 29 {2.8 to 3.0} -- 1 Brace bracket 2 Gasket 3 Front pipe 4 Exhaust shutter (See later section.) 5 Front pipe * a: Exhaust manifold : Non-reusable parts EXHAUST PIPE ---===WSE_1505_00010_0310.djvu===--- 15 15-31 Disassembly sequence CAUTION Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe. Assembly sequence Follow the disassembly sequence in reverse. CAUTION Tighten the marked bolt last to prevent undue forces from being applied to the exhaust pipe. Tightening torque (Unit: N·m {kgf·m}) Installation procedure Installation: Front pipe Install the front pipe so that the amounts of offset in both vertical and horizontal directions between the pipes in front of and be- hind the bellows are smaller than the dimension indicated in the illustration. CAUTION The bellows on the front pipe have the purpose of reducing the level of noise from the vehicle. It is not intended for compensating for misalignment that may result from im- proper installation of the front pipe. Install the front pipe properly to avoid excessive tension or other stress on the bellows. Mark Parts to be tightened Tightening torque Remarks Nut (front pipe mounting) 45 to 60 {4.6 to 6.1} -- Bolt (exhaust shutter unit mounting) 27 to 29 {2.8 to 3.0} -- 1 Brace bracket 2 Gasket 3 Front pipe 4 Exhaust shutter (See later section.) 5 Front pipe * a: Exhaust manifold : Non-reusable parts EXHAUST PIPE ---===WSE_1505_00010_0311.djvu===--- 15-32 Exhaust Shutter Disassembly sequence 1 Cover 2 Clevis pin 3 Clevis 4 Power chamber 5 Gasket 6 Bearing 7 Lever 8 Adjust bolt 9 Bracket 10 Seal ring A 11 Seal ring B 12 Valve CAUTION Do not attempt to disassemble the power chamber. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy -- Average of top and bottom clearances between butter- fly valve and body with valve fully closed (with power chamber vacuum of 87 to 93 kPa {650 to 700 mmHg} or above) 0.80 to 0.95 -- Adjust 4 Air-tightness of power chamber (at 15 sec. after vacuum of 67 kPa {500 mmHg} is achieved in chamber) 63 kPa {475 mmHg} or above --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (cover mounting) 4.9 to 6.9 {0.5 to 0.7} -- Lock nut (adjust bolt retention) Nut (power chamber mounting) 11 to 17 {1.10 to 1.70} -- Nut (lever mounting) Bolt (bracket mounting) Lock nut (clevis retention) 9.8 to 16 {1.0 to 1.6} -- EXHAUST PIPE ---===WSE_1505_00010_0311.djvu===--- 15-32 Exhaust Shutter Disassembly sequence 1 Cover 2 Clevis pin 3 Clevis 4 Power chamber 5 Gasket 6 Bearing 7 Lever 8 Adjust bolt 9 Bracket 10 Seal ring A 11 Seal ring B 12 Valve CAUTION Do not attempt to disassemble the power chamber. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy -- Average of top and bottom clearances between butter- fly valve and body with valve fully closed (with power chamber vacuum of 87 to 93 kPa {650 to 700 mmHg} or above) 0.80 to 0.95 -- Adjust 4 Air-tightness of power chamber (at 15 sec. after vacuum of 67 kPa {500 mmHg} is achieved in chamber) 63 kPa {475 mmHg} or above --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (cover mounting) 4.9 to 6.9 {0.5 to 0.7} -- Lock nut (adjust bolt retention) Nut (power chamber mounting) 11 to 17 {1.10 to 1.70} -- Nut (lever mounting) Bolt (bracket mounting) Lock nut (clevis retention) 9.8 to 16 {1.0 to 1.6} -- EXHAUST PIPE ---===WSE_1505_00010_0311.djvu===--- 15-32 Exhaust Shutter Disassembly sequence 1 Cover 2 Clevis pin 3 Clevis 4 Power chamber 5 Gasket 6 Bearing 7 Lever 8 Adjust bolt 9 Bracket 10 Seal ring A 11 Seal ring B 12 Valve CAUTION Do not attempt to disassemble the power chamber. Assembly sequence Follow the disassembly sequence in re- verse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy -- Average of top and bottom clearances between butter- fly valve and body with valve fully closed (with power chamber vacuum of 87 to 93 kPa {650 to 700 mmHg} or above) 0.80 to 0.95 -- Adjust 4 Air-tightness of power chamber (at 15 sec. after vacuum of 67 kPa {500 mmHg} is achieved in chamber) 63 kPa {475 mmHg} or above --R e p l a c e Mark Parts to be tightened Tightening torque Remarks Bolt (cover mounting) 4.9 to 6.9 {0.5 to 0.7} -- Lock nut (adjust bolt retention) Nut (power chamber mounting) 11 to 17 {1.10 to 1.70} -- Nut (lever mounting) Bolt (bracket mounting) Lock nut (clevis retention) 9.8 to 16 {1.0 to 1.6} -- EXHAUST PIPE ---===WSE_1505_00010_0312.djvu===--- 15 15-33 Inspection procedure Inspection: Air-tightness of power chamber Connect the components with piping as illustrated. Apply the specified inspection vacuum or higher to the power chamber and stop the vacuum pump. Fifteen seconds later, the reading on the vacuum gauge should conform to the standard value. If not, replace the power chamber. Adjustment after installation Adjustment: Clevis Assemble the power chamber onto the bracket. Then, adjust the location of the clevis such that the hole in the clevis is aligned by half with the hole in the lever. Adjustment: Butterfly valve (1) Average of top and bottom clearance between butterfly valve and body with valve fully closed. Apply a vacuum of 87 to 93 kPa {650 to 700 mmHg} to the pow- er chamber to fully close the butterfly valve. With the valve fully closed, measure the top and bottom clearances B and A be- tween the valve and the body, and obtain the average of the two. The average value should conform to the standard value. Adjust with the adjust bolt as required. Average clearance = (2) Valve fully-open position Adjust the butterfly valve to the full open position using the ad- just bolt. (A+B) 2 ---===WSE_1505_00010_0312.djvu===--- 15 15-33 Inspection procedure Inspection: Air-tightness of power chamber Connect the components with piping as illustrated. Apply the specified inspection vacuum or higher to the power chamber and stop the vacuum pump. Fifteen seconds later, the reading on the vacuum gauge should conform to the standard value. If not, replace the power chamber. Adjustment after installation Adjustment: Clevis Assemble the power chamber onto the bracket. Then, adjust the location of the clevis such that the hole in the clevis is aligned by half with the hole in the lever. Adjustment: Butterfly valve (1) Average of top and bottom clearance between butterfly valve and body with valve fully closed. Apply a vacuum of 87 to 93 kPa {650 to 700 mmHg} to the pow- er chamber to fully close the butterfly valve. With the valve fully closed, measure the top and bottom clearances B and A be- tween the valve and the body, and obtain the average of the two. The average value should conform to the standard value. Adjust with the adjust bolt as required. Average clearance = (2) Valve fully-open position Adjust the butterfly valve to the full open position using the ad- just bolt. (A+B) 2 ---===WSE_1505_00010_0313.djvu===--- 15-34 <FE85DE, FE85DG> DIESEL PARTICULATE FILTER ---===WSE_1505_00010_0314.djvu===--- 15 15-35 <Except FE85DE, FE85DG> Removal sequence NOTE The color of the diesel particulate filter surface may turn brown. This discoloration is due to the inherent characteristics of stainless steel and does not indicate rusting or any other abnormality. Installation sequence Follow the removal sequence in reverse. 1 Pressure hose 2 Pressure pipe 3 Tail pipe 4 Pressure hose 5 DPF differential pressure sensor 6 Diesel particulate filter band 7 Diesel particulate filter 8 Gasket 9 Cushion rubber 10 Bracket 11 Collar 12 Cushion rubber 13 Stay 14 Cushion rubber 15 Bracket 16 Collar 17 Cushion rubber 18 Stay 19 Bracket 20 Bracket * a: Front pipe : Non-reusable parts DPF: Diesel Particulate Filter ---===WSE_1505_00010_0314.djvu===--- 15 15-35 <Except FE85DE, FE85DG> Removal sequence NOTE The color of the diesel particulate filter surface may turn brown. This discoloration is due to the inherent characteristics of stainless steel and does not indicate rusting or any other abnormality. Installation sequence Follow the removal sequence in reverse. 1 Pressure hose 2 Pressure pipe 3 Tail pipe 4 Pressure hose 5 DPF differential pressure sensor 6 Diesel particulate filter band 7 Diesel particulate filter 8 Gasket 9 Cushion rubber 10 Bracket 11 Collar 12 Cushion rubber 13 Stay 14 Cushion rubber 15 Bracket 16 Collar 17 Cushion rubber 18 Stay 19 Bracket 20 Bracket * a: Front pipe : Non-reusable parts DPF: Diesel Particulate Filter ---===WSE_1505_00010_0315.djvu===--- 15-36 Tightening torque (Unit: N·m {kgf·m}) Inspection procedure Inspection: Pressure pipe and hose Check the pressure pipe and hose for clogging by blowing com- pressed air into the pipe and hose. CAUTION Inspection must be performed on an individual pressure pipe or hose. If compressed air is blown into the pressure pipe or hose with DPF differential pressure sensor still installed, the sen- sor may become damaged. Inspection: Diesel particulate filter Check the inner exhaust channel of diesel particulate filter for clogging with foreign material. If clogged, the inner exhaust channel must be cleaned with com- pressed air or diesel particulate filter must be replaced. If diesel particulate filter is clogged, this may be due to problems with the engine. Check the engine and adjust as required. Also check the engine oil and fuel. Mark Parts to be tightened Tightening torque Remarks Pressure pipe 40 {4.0} -- Nut (tail pipe mounting) 26 to 33 {2.7 to 3.2} -- Nut (diesel particulate filter mounting) Nut (diesel particulate filter band mounting) 20 {2.0} -- DIESEL PARTICULATE FILTER ---===WSE_1505_00010_0316.djvu===--- 15E-1 GROUP 15E TURBOCHARGER CONTROL SYSTEM SPECIFICATIONS....................................................................(See Gr15.) STRUCTURE AND OPERATION 1. Overview .................................................................................... 15E-2 2. Electronic Control System .......................................................... 15E-3 3. Electronic Control Unit Wiring Diagram ...................................... 15E-5 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ........................... (See Gr13E.) 2. Multi-Use Tester Service Data ......................................... (See Gr13E.) 3. Actuator Test Using Multi-Use Tester .............................. (See Gr13E.) 4. Electronic Control Unit Input/Output Table .................... (See Gr13E.) INSPECTION OF ELECTRICAL PARTS ............................... (See Gr54.) INSTALLED LOCATIONS OF PARTS ................................... (See Gr54.) ELECTRIC CIRCUIT DIAGRAM ............................................ (See Gr54.) ---===WSE_1505_00010_0317.djvu===--- 15E-2 1. Overview In the turbocharger control system, various engine-related information (engine speed, coolant temperature, accel- erator position) and driving status are collected by the relevant sensors and are sent to the engine electronic con- trol unit and turbocharger electronic drive unit which then control the engine based on the information received. The turbocharger actuator controls the opening of turbine vanes according to control signals to ensure low fuel consumption and high torque operation over the entire speed range. STRUCTURE AND OPERATION ---===WSE_1505_00010_0317.djvu===--- 15E-2 1. Overview In the turbocharger control system, various engine-related information (engine speed, coolant temperature, accel- erator position) and driving status are collected by the relevant sensors and are sent to the engine electronic con- trol unit and turbocharger electronic drive unit which then control the engine based on the information received. The turbocharger actuator controls the opening of turbine vanes according to control signals to ensure low fuel consumption and high torque operation over the entire speed range. STRUCTURE AND OPERATION ---===WSE_1505_00010_0318.djvu===--- 15E 15E-3 2. Electronic Control System 2.1 System block diagram Part Main function/operation Engine speed sensor Sensing of engine speed Cylinder recognition sensor Cylinder recognition Water temperature sensor Sensing of coolant temperature Boost pressure sensor Sensing of boost pressure Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Engine warning lamp Indication of system abnormalities EDU relay Switching ON/OFF supply of power to exhaust gas recirculation elec- tronic drive unit, throttle and turbocharger electronic drive unit CAN communication (Turbocharger EDU) Engine data recognized by the engine electronic control unit are output- ted to the CAN bus to turbocharger systems to obtain data that they need for control. Turbocharger electronic drive unit issues signals to the engine electronic control unit via the CAN bus to enable it to effect en- gine control appropriate for each type of system control. ---===WSE_1505_00010_0319.djvu===--- 15E-4 2.2 Turbocharger control function In response to output data from various sensors, the engine electronic control unit determines the opening of tur- bine vanes as required by the engine operating status and sends necessary control signals to the turbocharger electronic drive unit. (target opening of turbine vanes) The turbocharger electronic drive unit activates the turbocharger actuator motor to detect the amount of resultant shaft position by means of the position sensor and sends it to the engine electronic control unit. (actual opening of turbine vanes) Thus, the target opening of turbine vanes can be accurately maintained as commanded by the engine electronic control unit. (1) Turbocharger actuator In response to command signals from the turbocharger electron- ic drive unit, the turbocharger actuator moves the shaft up and down by means of its DC motor to open and close the turbine vanes. 2.3 Fault diagnosis function The engine electronic control unit continuously monitors the electronic drive units and sensors for faults. In the event that the engine electronic control unit finds a component faulty, it causes an indication to be made in the meter cluster to alert the driver. At the same time, it memorizes the fault location in the form of a diagnosis code and starts a control during fault. While the engine is running, the turbocharger electronic drive unit continuously monitor communication with the position sensor and motor of the turbocharger actuator communication with the engine electronic control unit. In the event that they identify a fault, they send fault data to the engine electronic control unit. While control necessitated by a fault is taking place, the system's functionality is limited to ensure vehicle and driver safety. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning lamp. The control during fault recovers by servising the faults. However, for some diagnosis codes, the warning lamp stays illuminated until the normal signals are input for several times. Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. The Multi-Use Tester is capable of showing more detailed diagnosis codes. STRUCTURE AND OPERATION ---===WSE_1505_00010_0320.djvu===--- 15E 15E-5 3. Electronic Control Unit Wiring Diagram C10044-ECU-15E Motor(U) Motor(V) Motor(W) Hall IC(U) Hall IC(Power) Shield GND Hall IC(GND) POWER GND Hall IC(V) Shield GND Hall IC(W) Shield GND CAN(H) CAN(L) CAN(H) CAN(L) Contoller area network resistor Turbocharger electronic drive unit Motor Potision sensor Turbocharger actuator Starter switch B LOCK ACC ON START MFS A B5 B6 B40 B15 B58 B56 B54 B57 B55 B53 A10 A9 B35 B49 B34 B46 A20 A40 A41 B1 B2 B39 B14 SIG GND Electronic drive unit relay STARTER SW(M)-1 STARTER SW(M)-2 ECU POWER(+VB)-1 ECU POWER(+VB)-2 ECU POWER(+VB)-3 GND(POWER GND) GND(ANALOG GND) GND(POWER GND) SIG GND +5V +5V Engine electronic control unit Engine speed sensor Accelerator pedal position sensor SENSOR-1 SENSOR-2 B33 B45 GND GND Accelerator pedal switch SENSOR-1 SENSOR-2 +5V GND Water temperature sensor (Red) (Amber) Engine warning lamp (+) (-) 1 8 12 4 11 10 4 7 3 6 2 5 14 13 5 2 3 4 1 6 7 8 15 16 8 12 16 3 7 11 15 2 6 10 14 1 5 9 13 4 1 2 3 8 5 6 7 B A A78 A59 A83 SIG GND +5V Cylinder recognition sensor (Diagnosis code display: Camshaft Position SNSR) A37 A34 A14 SIG +5V GND Boost pressure sensor M9 B9 M2 DC24V Battery Fuse box High-current fuse box 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 13 53 55 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 39 57 54 56 58 52 1 2 3 4 5 6 7 8 9 10 11 12 25 26 27 28 29 30 31 32 33 34 35 36 20 44 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 13 37 61 85 14 38 62 86 15 39 63 87 16 40 64 88 17 41 65 89 18 42 66 90 19 43 67 91 68 92 21 45 69 93 22 46 70 94 23 47 71 95 24 48 72 96 B:GE58A A:GE96A ---===WSE_1505_00010_0321.djvu===--- 17-1 GROUP 17 EMISSION CONTROL STRUCTURE AND OPERATION 1. Exhaust Gas Recirculation System ............................................... 17-2 2. Crankcase Emission Control System............................................ 17-3 EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER .... 17-4 CRANKCASE EMISSION CONTROL SYSTEM................................. 17-6 ---===WSE_1505_00010_0322.djvu===--- 17-2 1. Exhaust Gas Recirculation System In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.). Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx), which are harmful, in the exhaust emissions. Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak combustion temperature. The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas recirculation is maximized. STRUCTURE AND OPERATION ---===WSE_1505_00010_0322.djvu===--- 17-2 1. Exhaust Gas Recirculation System In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.). Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx), which are harmful, in the exhaust emissions. Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak combustion temperature. The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas recirculation is maximized. STRUCTURE AND OPERATION ---===WSE_1505_00010_0323.djvu===--- 17 17-3 2. Crankcase Emission Control System The crankcase emission control system returns blowby gases to an air duct to prevent them from being released to the outside air. The positive crankcase ventilation valve keeps constant the pressure inside the crankcase. ---===WSE_1505_00010_0324.djvu===--- 17-4 Removal sequence Even when all coolant in the crankcase has been drained out, approximately 1 dm 3 {1 L} of coolant remains in the EGR cooler. Before removing the EGR cooler, make ready a container to catch the coolant. Installation sequence Follow the removal sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 13 Air leakage from EGR cooler Leakage into coolant (air pressure: 196 kPa {2.0 kgf/ cm 2 }) 0cm 3 {0 mL} -- Repair Leakage into exhaust gas (air pressure: 294 kPa {3.0 kgf/cm 2 }) 0cm 3 {0 mL} Mark Parts to be tightened Tightening torque Remarks Connector 59 {6.0} -- Nut (mounting of EGR pipe A) 20.6 {2.1} -- Bolt (mounting of EGR pipe A) 23.8 {2.4} -- By-pass pipe 60 {6.1} -- 1 By-pass pipe 2 Connector 3 EGRpipeC 4 EGR gasket 5 EGR gasket A 6 EGRpipeA 7 EGR pipe gasket 8 EGR gasket 9 EGR valve 10 EGR gasket B 11 EGR pipe B 12 EGR gasket 13 EGR cooler 14 EGR cooler bracket 15 O-ring * a: Air inlet pipe * b: Exhaust manifold : Non-reusable parts EGR: Exhaust gas recirculation EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER ---===WSE_1505_00010_0324.djvu===--- 17-4 Removal sequence Even when all coolant in the crankcase has been drained out, approximately 1 dm 3 {1 L} of coolant remains in the EGR cooler. Before removing the EGR cooler, make ready a container to catch the coolant. Installation sequence Follow the removal sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 13 Air leakage from EGR cooler Leakage into coolant (air pressure: 196 kPa {2.0 kgf/ cm 2 }) 0cm 3 {0 mL} -- Repair Leakage into exhaust gas (air pressure: 294 kPa {3.0 kgf/cm 2 }) 0cm 3 {0 mL} Mark Parts to be tightened Tightening torque Remarks Connector 59 {6.0} -- Nut (mounting of EGR pipe A) 20.6 {2.1} -- Bolt (mounting of EGR pipe A) 23.8 {2.4} -- By-pass pipe 60 {6.1} -- 1 By-pass pipe 2 Connector 3 EGRpipeC 4 EGR gasket 5 EGR gasket A 6 EGRpipeA 7 EGR pipe gasket 8 EGR gasket 9 EGR valve 10 EGR gasket B 11 EGR pipe B 12 EGR gasket 13 EGR cooler 14 EGR cooler bracket 15 O-ring * a: Air inlet pipe * b: Exhaust manifold : Non-reusable parts EGR: Exhaust gas recirculation EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER ---===WSE_1505_00010_0324.djvu===--- 17-4 Removal sequence Even when all coolant in the crankcase has been drained out, approximately 1 dm 3 {1 L} of coolant remains in the EGR cooler. Before removing the EGR cooler, make ready a container to catch the coolant. Installation sequence Follow the removal sequence in reverse. Service standards Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy 13 Air leakage from EGR cooler Leakage into coolant (air pressure: 196 kPa {2.0 kgf/ cm 2 }) 0cm 3 {0 mL} -- Repair Leakage into exhaust gas (air pressure: 294 kPa {3.0 kgf/cm 2 }) 0cm 3 {0 mL} Mark Parts to be tightened Tightening torque Remarks Connector 59 {6.0} -- Nut (mounting of EGR pipe A) 20.6 {2.1} -- Bolt (mounting of EGR pipe A) 23.8 {2.4} -- By-pass pipe 60 {6.1} -- 1 By-pass pipe 2 Connector 3 EGRpipeC 4 EGR gasket 5 EGR gasket A 6 EGRpipeA 7 EGR pipe gasket 8 EGR gasket 9 EGR valve 10 EGR gasket B 11 EGR pipe B 12 EGR gasket 13 EGR cooler 14 EGR cooler bracket 15 O-ring * a: Air inlet pipe * b: Exhaust manifold : Non-reusable parts EGR: Exhaust gas recirculation EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER ---===WSE_1505_00010_0325.djvu===--- 17 17-5 Inspection procedures Inspection: Air leakage from EGR cooler Perform the following inspection. If any abnormality is found, re- place the exhaust gas recirculation cooler. (1) Exhaust gas passage side Fit a cover over the exhaust gas outlet of the exhaust gas recir- culation cooler, and connect a hose to the exhaust gas inlet. Then, submerge the exhaust gas recirculation cooler in a con- tainer of water. Make sure the coolant passage is full of water. Apply air pressure of 294 kPa {3 kgf/cm 2 } through the hose. Check that air does not leak from any part of the exhaust gas re- circulation cooler. (2) Coolant passage side Fit covers over the exhaust gas recirculation cooler's exhaust gas inlet, exhaust gas outlet, and coolant outlet, and connect a hose to the coolant inlet. Then, submerge the exhaust gas recir- culation cooler in a container of water. Apply air pressure of 196 kPa {2 kgf/cm 2 } through the hose. Check that air does not leak from any part of the exhaust gas re- circulation cooler. ---===WSE_1505_00010_0326.djvu===--- 17-6 Removal sequence Installation sequence Perform installation by following the removal sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (mounting of breather cover) 23.2 {2.4} -- Bolt (mounting of PCV valve) Bolt (mounting of breather cover) 9.8 {1.0} -- Screw (mounting of breather cover A) 2to3{0.2to0.3} -- Clamp 4 {0.4} -- 1 Washer 2 Rubber bushing 3 Spacer 4 Breather cover A 5 Separator plate 6 Breather cover B 7 Gasket 8 Breather gasket 9 PCVhoseB 10 PCV pipe 11 PCV hose 12 PCV valve 13 O-ring * a: Front case : Non-reusable parts PCV: Positive crankcase ventilation CRANKCASE EMISSION CONTROL SYSTEM ---===WSE_1505_00010_0326.djvu===--- 17-6 Removal sequence Installation sequence Perform installation by following the removal sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (mounting of breather cover) 23.2 {2.4} -- Bolt (mounting of PCV valve) Bolt (mounting of breather cover) 9.8 {1.0} -- Screw (mounting of breather cover A) 2to3{0.2to0.3} -- Clamp 4 {0.4} -- 1 Washer 2 Rubber bushing 3 Spacer 4 Breather cover A 5 Separator plate 6 Breather cover B 7 Gasket 8 Breather gasket 9 PCVhoseB 10 PCV pipe 11 PCV hose 12 PCV valve 13 O-ring * a: Front case : Non-reusable parts PCV: Positive crankcase ventilation CRANKCASE EMISSION CONTROL SYSTEM ---===WSE_1505_00010_0326.djvu===--- 17-6 Removal sequence Installation sequence Perform installation by following the removal sequence in reverse. Tightening torque (Unit: N·m {kgf·m}) Mark Parts to be tightened Tightening torque Remarks Bolt (mounting of breather cover) 23.2 {2.4} -- Bolt (mounting of PCV valve) Bolt (mounting of breather cover) 9.8 {1.0} -- Screw (mounting of breather cover A) 2to3{0.2to0.3} -- Clamp 4 {0.4} -- 1 Washer 2 Rubber bushing 3 Spacer 4 Breather cover A 5 Separator plate 6 Breather cover B 7 Gasket 8 Breather gasket 9 PCVhoseB 10 PCV pipe 11 PCV hose 12 PCV valve 13 O-ring * a: Front case : Non-reusable parts PCV: Positive crankcase ventilation CRANKCASE EMISSION CONTROL SYSTEM ---===WSE_1505_00010_0327.djvu===--- 17 17-7 Lubricant and/or sealant Installation procedures Installation: PCV hose Install the PCV hose to the PCV pipe with the white paint on the hose and the black paint on the pipe aligned as shown in the il- lustration. Installation: PCV hose B Install the PCV hose B to the PCV pipe with the white paint on the hose and the black paint on the pipe aligned as shown in the illustration. Installation: Breather cover A Clean the sealant application surfaces of each part. Apply a bead of sealant to the breather cover A evenly and with- out any breaks as shown in the illustration. Install the lower crankcase within three minutes of applying the sealant to the upper crankcase, being careful not to dislodge the sealant. Mark Points of application Specified lubricant and/or sealant Quantity O-ring Engine oil As required Mating surface of breather cover A or B ThreeBond 1216 As required ---===WSE_1505_00010_0328.djvu===--- 17E-1 GROUP 17E EXHAUST GAS RECIRCULATION SYSTEM AND DIESEL PARTICULATE FILTER SPECIFICATIONS....................................................................(See Gr17.) STRUCTURE AND OPERATION 1. Overview .................................................................................... 17E-2 2. Electronic Control System .......................................................... 17E-4 3. Electronic Control Unit Connection Diagram .............................. 17E-7 TROUBLESHOOTING 1. Inspection Based on Diagnosis Codes ........................... (See Gr13E.) 2. Multi-Use Tester Service Data ......................................... (See Gr13E.) 3. Actuator Test Using Multi-Use Tester .............................. (See Gr13E.) 4. Electronic Control Unit Input/Output Table ..................... (See Gr13E.) INSPECTION OF ELECTRICAL PARTS ............................... (See Gr54.) INSTALLED LOCATIONS OF PARTS ................................... (See Gr54.) ELECTRIC CIRCUIT DIAGRAM ............................................ (See Gr54.) ---===WSE_1505_00010_0329.djvu===--- 17E-2 1. Overview 1.1 Exhaust gas recirculation system In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.). Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx), which are harmful, in the exhaust emissions. Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak combustion temperature. The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas recirculation is maximized. STRUCTURE AND OPERATION ---===WSE_1505_00010_0329.djvu===--- 17E-2 1. Overview 1.1 Exhaust gas recirculation system In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con- trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various aspects of the engine (engine speed, intake air quantity, coolant temperature, throttle opening, etc.). Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx), which are harmful, in the exhaust emissions. Further, an exhaust gas recirculation cooler cools the recirculated exhaust emissions, thereby reducing the peak combustion temperature. The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas recirculation is maximized. STRUCTURE AND OPERATION ---===WSE_1505_00010_0330.djvu===--- 17E 17E-3 1.2 Diesel particulate filter Diesel particulate filter is a large-ca- pacity system consisting of an ultra-ef- ficient oxidation catalyst and a filter. Diesel particulate filter is designed to efficiently break and capture PM emit- ted by engines running on low-sulfur fuel, and the filter is continuously re- generated. The new environmentally-friendly en- gine has drastically-reduced PM emis- sion levels. In addition, the ultra- efficient oxidation catalyst breaks and treats most of PM emitted from the en- gine, minimizing PM loading/deposit onto the subsequent filter. As a result, the filter is unlikely to clog up even un- der the driving conditions that require long hours of drive with relatively low exhaust gas temperature. Also, active regeneration, which increases fuel consumption, is not required. The size of the filtration openings has been optimized to eliminate the de- posit of ash (product of combustion) generated in the engine. The filter re- quires no maintenance, including peri- odical cleaning. The diesel particulate filter differential pressure sensor compares diesel par- ticulate filter pressure with atmospher- ic pressure and outputs difference data to the engine electronic control unit. ---===WSE_1505_00010_0331.djvu===--- 17E-4 2. Electronic Control System 2.1 System block diagram Part Main function/operation Engine speed sensor Sensing of engine speed Water temperature sensor Sensing of coolant temperature Accelerator pedal position sensor Sensing of extent of accelerator pedal depression Intake air temperature sensor 1 Sensing of intake air temperature Intake air temperature sensor 2 Sensing of boost air temperature Air flow sensor Sensing of intake air flow rate DPF differential pressure sensor Detection of pressure differential between DPF inlet pressure and at- mospheric pressure Engine warning lamp Indication of system abnormalities Exhaust shutter 3-way magnetic valve ON/OFF control of exhaust shutter valve EDU relay Switching ON/OFF supply of power to exhaust gas recirculation elec- tronic drive unit, throttle and turbocharger electronic drive unit CAN communication (EGR EDU, Throttle EDU) Engine data recognized by the engine electronic control unit are output- ted to the CAN bus to enable systems to obtain data that they need for control. Each electronic drive unit issues signals to the engine electron- ic control unit via the CAN bus to enable it to effect engine control ap- propriate for each type of system control. STRUCTURE AND OPERATION ---===WSE_1505_00010_0332.djvu===--- 17E 17E-5 2.2 Exhaust gas recirculation (1) Exhaust gas recirculation valve control function In accordance with data from sensors, the engine electronic control unit determines the exhaust gas recirculation valve opening that suits the operating condition and sends a control signal (this indicates the target exhaust gas recirculation valve opening) to the exhaust gas recirculation electronic drive unit. When necessary to prevent black smoke emissions and engine speed instability (for example, when the engine is heavily loaded, when the engine is lightly loaded, and when the exhaust brake is operating), the engine electronic control unit stops exhaust gas recirculation valve control. The exhaust gas recirculation electronic drive unit activates the exhaust gas recirculation valve motor. At the same time, it monitors the extent of valve lift using a position sensor and sends this information (this indicates the actual exhaust gas recirculation valve opening) to the engine electronic control unit. This operation makes it possible for the target exhaust gas recirculation valve opening indicated by the engine electronic control unit to be precisely maintained. (1.1) Exhaust gas recirculation valve DC motor in the exhaust gas recirculation valve is driven by con- trol signals from the exhaust gas recirculation electronic drive unit. Via a rod, the motor's operation opens and closes the valve. (2) Intake throttle control function When the engine electronic control unit determines from sensor data on the engine speed and engine loading that the vacuum pressure in the intake manifold is low, it increases the amount of exhaust emissions introduced into the intake manifold by determining an appropriate butterfly valve opening and by sending corresponding control signals (these indicate the target throttle opening) to the throttle electronic drive unit. The throttle electronic drive unit activates the valve motor. At the same time, it monitors the valve opening using a position sensor and sends this information (this indicates the actual throttle opening) to the engine electronic con- trol unit. This operation makes it possible for the target throttle opening indicated by the engine electronic control unit to be precisely maintained. ---===WSE_1505_00010_0333.djvu===--- 17E-6 (2.1) Intake throttle In accordance with signals from the throttle electronic drive unit, the motor opens and closes the butterfly valve, thereby adjusting the intake air amount such that the effectiveness of exhaust gas recirculation is maximized. (3) Fault diagnosis function The engine electronic control unit continuously monitors the electronic drive units and sensors for faults. In the event that the engine electronic control unit finds a component faulty, it causes an indication to be made in the meter cluster to alert the driver. At the same time, it memorizes the fault location in the form of a diagnosis code and starts a control during fault. While the engine is running, the exhaust gas recirculation electronic drive unit and throttle electronic drive unit continuously monitor communication with the position sensor and motor of the exhaust gas recirculation valve, communication with the position sensor and motor of the throttle actuator, and communication with the engine electronic control unit. In the event that they identify a fault, they send fault data to the engine electronic control unit. While control necessitated by a fault is taking place, the system's functionality is limited to ensure vehicle and driver safety. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning lamp. The control during fault recovers by servising the faults. However, for some diagnosis codes, the warning lamp stays illuminated until the normal signals are input for several times. Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are different. The Multi-Use Tester is capable of showing more detailed diagnosis codes. 2.3 Diesel particulate filter (1) Diesel particulate filter clogged warning function The function works to alert the driver that the filter is clogged with accumulated particulate matter when the engine electronic control unit so determines. The engine electronic control unit determines whether or not the diesel particulate filter is clogged according to the difference between diesel particulate filter pressure and atmospheric pressure received from the diesel partic- ulate filter differential pressure sensor. (1.1) Diesel particulate filter differential pressure sensor The sensor compares diesel particulate filter pressure with at- mospheric pressure and outputs difference data to the engine electronic control unit. When the pressure difference exceeds the specified limit, the engine electronic control unit turns on the warning lamp in the meter cluster and the buzzer, thereby warning the driver of the existing condition. (2) Diagnostic function The engine electronic control unit monitors the condition of the sensors for failure. In the event that the engine electronic control unit finds a component faulty, it causes an indication to be made in the meter cluster to alert the driver. At the same time, it memorizes the fault location in the form of a diagnosis code. Then, a control during fault is started. When control-during-fault is started, system function is restricted to ensure safety of the vehicle and driver. Stored diagnosis codes can be retrieved on the Multi-Use Tester or the meter cluster. STRUCTURE AND OPERATION ---===WSE_1505_00010_0334.djvu===--- 17E 17E-7 3. Electronic Control Unit Connection Diagram C10044-ECU-17E Motor(U) Motor(V) Motor(W) Hall IC(U) Hall IC(power supply) Shield GND Hall IC(GND) POWER GND POWER THROTTLE ACT(M1) THROTTLE SENSOR(+5V) THROTTLE SENSOR(GND) THROTTLE SENSOR(SIG) THROTTLE ACT(M2) Hall IC(V) Shield GND Hall IC(W) Shield GND CAN(H) CAN(L) CAN(H) CAN(H) CAN(L) CAN(L) GND SIG Controller area network resistor Exhaust gas recirculation electronic drive unit Throttle electronic drive unit Motor Motor Exhaust gas recirculation valve 1 8 12 11 10 4 7 3 6 2 2 3 4 10 11 5 14 13 14 13 5 2 2 3 4 6 5 3 4 1 6 7 8 15 16 15 16 Intake throttle (Diagnosis code display: TVA SNSR) GND B27 B5 B6 B44 B43 B40 B15 B58 B56 B54 B57 B55 B53 A10 A9 B35 B49 B34 B46 A20 A40 A41 A63 A32 B1 B2 B39 B14 SIG GND SIG GND Electronic drive unit relay Air flow sensor STARTER SW(S) STARTER SW(M)-1 STARTER SW(M)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-1 ELECTRONIC CONTROL UNIT POWER(+VB)-2 ELECTRONIC CONTROL UNIT POWER(+VB)-3 GND(POWER GND) GND(ANALOG GND) GND(POWER GND) SIG GND Engine speed sensor B33 B45 B30 B29 SIG GND Intake air temperature sensor 2 (Diagnosis code display: EGR Gas Temp Sensor) Water temperature sensor Intake air temperature sensor 1 (Red) (Amber) Engine warning lamp (+) (-) Position sensor Position sensor (Opened when pressed : closed when released) Accelerator pedal position sensor Accelerator pedal switch Sensor 1 Sensor 2 +5V SIG GND +5V SIG GND A76 A6 Exhaust shutter 3-way magnetic valve (Diagnosis code display: Exhaust Brake PWR Service data and actuator test display: Auxiliary Brake M/V 1) (+) (-) Twist pair B A 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 13 53 55 26 27 28 29 30 31 32 33 34 35 36 37 38 40 41 42 43 44 45 46 47 48 49 50 51 39 57 54 56 58 52 B:GE58A 1 2 3 4 5 6 7 8 9 10 11 12 25 26 27 28 29 30 31 32 33 34 35 36 20 44 49 50 51 52 53 54 55 56 57 58 59 60 73 74 75 76 77 78 79 80 81 82 83 84 13 37 61 85 14 38 62 86 15 39 63 87 16 40 64 88 17 41 65 89 18 42 66 90 19 43 67 91 68 92 21 45 69 93 22 46 70 94 23 47 71 95 24 48 72 96 A:GE96A Engine electronic control unit 4 8 12 16 3 7 11 15 2 6 10 14 1 5 9 13 4 8 12 16 3 7 11 15 2 6 10 14 1 5 9 13 654 2 3 4 1 2 3 8 5 6 7 Starter switch B LOCK ACC ON START MFS A M9 S1 B9 M2 DC24V Battery A61 A84 A85 SIG +5V GND Diesel particurate filter differential pressure sensor (Diagnosis code display: DPF Diff SNSR) Fuse box High-current fuse box POWER OUT 9 ---===WSE_1505_00010_0335.djvu===--- Revision history 00ELT0085 Date Bulletin No. Subject JUNE 1, 2015 S15-T021-13 Addition of maintenance procedure for pressure limiting valve ---===WSE_1505_00010_0336.djvu===--- ( EURO 4 ) ---===WSE_1505_00010_0337.djvu===--- Pub.No.00ELT0085, MARCH 2015