Professional Documents
Culture Documents
12MY L200 EU Workshop Manual PDF
12MY L200 EU Workshop Manual PDF
GROUP 00
GENERAL
CONTENTS
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00
GROUP 00
GENERAL
CONTENTS
Indicates the
Denotes tightening torque. section title.
For bolts and nuts which do
not have a tightening torque
listed, refer to the "Standard Indicates the Indicates the
Parts tightening-torque Table" group title. group number.
Component diagram
A diagram of the component parts is pro-
vided near the front of each section in order
to give the reader a better understanding of
the installed condition of component parts.
>>A<<
>>B<<
AC311238 AE
GENERAL
HOW TO USE THIS MANUAL
00-5
35A-21
Operating procedures,
cautions, etc. on removal,
installation, disassembly and
reassembly are described
AC509265AF
00-6 GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
CAUTION
During diagnosis, a diagnosis code associated
with other system may be set when the ignition
switch is turned on with connector(s) discon-
nected. On completion, confirm all systems for
diagnosis code(s). If diagnosis code(s) are set,
erase them all.
WARNING
Since the radiator fan rotates during CAN
bus line diagnostics, make sure that no one
is servicing the engine compartment before
diagnosing the CAN bus line. Since the CAN
communication stops when diagnosing the
CAN bus line, the ETACS-ECU detects the
time-out of the engine-ECU, and activates
the radiator fan to prevent overheating as
fail-safe.
Troubleshooting of electronic control systems for
which the M.U.T.-III can be used follows the basic
outline described below. Even in systems for which
the M.U.T.-III cannot be used, some of these sys-
tems still follow this outline.
Gathering information
from the customer.
NG
CAN bus diagnosis* 1 CAN bus diagnosis chart* 2
OK
Diagnosis code Diagnosis code
Read the diagnosis code. displayed. displayed. Read the diagnosis code.
(Current trouble)* 3 (Current trouble)* 3
No diagnosis code Diagnosis code After taking note of the Diagnosis code No diagnosis
or communication displayed. malfunction code, erase the displayed. code.
with M.U.T.-III not (Past trouble)* 3 diagnosis code memory. (Past trouble)* 3
possible
Refer to the INSPECTION CHART Refer to the INSPECTION CHART INTERMITTENT MALFUNCTIONS* 5
FOR TROUBLE SYMPTOMS FOR DIAGNOSIS CODES
(Refer to applicable group). (Refer to applicable group).
AC501888
1
• * : For how to diagnose CAN bus lines, refer to GROUP 54C .
• *2: For the CAN bus diagnosis chart, refer to GROUP 54C .
• *3: When the M.U.T.-III detects a diagnosis code, its display informs users whether a mechanical problem
currently exists or whether it existed before. The message for the former state identifies it as a "Active"
and the message for the latter identifies it as a "Stored".
• *4: For how to treat past trouble, refer to P.00-15.
• *5: For how to cope with intermittent malfunctions, refer to P.00-14.
MB991827 AC501413AC
Grey
AC301964AC
GENERAL
HOW TO USE TROUBLESHOOTING/INSPECTION SERVICE POINTS
00-11
Explains about
technical details.
Describes the
conditions for that
diagnosis code being
set.
Describes possible
causes(s) for that
diagnosis code.
AC313955AC
CONNECTOR MEASUREMENT SERVICE Inspect by inserting a test probe from the harness
POINTS side. If the connector is too small to insert a test
M1001013600386 probe (e.g. control unit connector), do not insert it
CAUTION forcibly. Use special tool extra fine probe
During diagnosis, a diagnosis code associated (MB992006).
with other system may be set when the ignition IF INSPECTING WITH THE CONNECTOR
switch is turned on with connector(s) discon- DISCONNECTED <WHEN INSPECTING A
nected. On completion, confirm all systems for FEMALE PIN>
diagnosis code(s). If diagnosis code(s) are set,
erase them all. CAUTION
Turn the ignition switch to the "LOCK" (OFF) position • Use special tool inspection harness
when connecting and disconnecting the connectors. (MB991219). If the test bar is inserted forcibly,
Turn the ignition switch to "ON" when measuring, it will cause a poor contact.
unless there are instructions to the contrary. • If the connector is disconnected, a diagnosis
IF INSPECTING WITH THE CONNECTOR code may be stored for the system to be
CONNECTED <WATERPROOF CONNECTORS> checked or other systems.
CAUTION MB991219
Never insert a test probe from the harness side,
as this will reduce the waterproof performance
and result in corrosion.
AC105599 AB
MB992006
AC105598AH
AC105600
AC300899AB
CAUTION
A diagnosis code may be stored due to a blown
fuse.
Battery
Fuse
Short-circuit
Load occurrence
switch section
Load
AC300900AB
• Gently shake the wiring harness up, down and to Since the trouble may still be present even the status
the left and right. is "Stored", set the vehicle to the diagnosis code
• Gently rock each sensor and relay, etc. by hand. detection condition and check that the status
• Gently shake the wiring harness at suspensions changes to "Active". If the status does not change
and other moving parts. from "Stored", carry out the following procedure.
1. Establish from the customer whether a fuse or
NOTE: If determining the cause is difficult, the drive
connector has been replaced or disconnected.
recorder function of the M.U.T.-III can also be used.
(For details on how to use the M.U.T.-III, refer to the 2. If yes, erase the diagnosis code, and then check
"M.U.T.-III operation manual). that no diagnostic code is reset. If no diagnosis
code is reset, the diagnosis is complete.
3. If no, follow the applicable Diagnostic Trouble
Code Chart. Then check the wiring harness and
connector, and refer to "How to Cope with
Intermittent Malfunction P.00-14 ."
VEHICLE IDENTIFICATION
MODELS
M1001000306510
VEHICLES FOR EUROPE
<SINGLE CAB>
Model code Engine model Transmission model Fuel supply system
KA4T NENMZL6 4D56 (2,477 mL) R5MB1 (Rear wheel drive Common rail fuel
DOHC DI-D (Direct Injection- 2WD, 5M/T) injection (Electrical
KB4T NENMZL6/R6 Diesel) engine with V5MB1 (Easy select 4WD, fuel injection)
intercooled turbocharger 5M/T)
<CLUB CAB>
Model code Engine model Transmission model Fuel supply system
KB4T NCNUZL6/R6 4D56 (2,477 mL) V5MB1 (Easy select 4WD, Common rail fuel
DOHC DI-D (Direct Injection- 5M/T) injection (Electrical
GCNXZL6 Diesel) engine with V5MB1 (Super select fuel injection)
intercooled turbocharger 4WD, 5M/T)
GCNXZPL6 4D56 (2,477 mL)
DOHC DI-D (Direct Injection-
Diesel) high-power engine
with intercooled turbocharger
00-16 GENERAL
VEHICLE IDENTIFICATION
<DOUBLE CAB>
Model code Engine model Transmission model Fuel supply system
KA4T NJNUZL6 4D56 (2,477 mL) R5MB1 (Rear wheel drive Common rail fuel
HJNUZL6 DOHC DI-D (Direct Injection- 2WD, 5M/T) injection (Electrical
Diesel) engine with fuel injection)
HJRUZL6 intercooled turbocharger R4A5A (Rear wheel drive
2WD, 4A/T)
KB4T NJNUZL6/R6 V5MB1 (Easy select 4WD,
5M/T)
NJRUZL6 V4A5A (Easy select 4WD,
4A/T)
GJNXZL6 V5MB1 (Super select
4WD, 5M/T)
GJRXZR6 V4A5A (Super select 4WD,
4A/T)
GJNXZPL6/R6 4D56 (2,477 mL) V5MB1 (Super select
DOHC DI-D (Direct Injection- 4WD, 5M/T)
GJYXZPL6/R6 Diesel) high-power engine
V5A5A (Super select 4WD,
with intercooled turbocharger
5A/T)
VEHICLES FOR RUSSIA (EASTERN EUROPE COUNTRIES)
Model code Engine model Transmission model Fuel supply system
KB4T NJNUZL6Z 4D56 (2,477 mL) V5MB1 (Easy select 4WD, Common rail fuel
DOHC DI-D (Direct Injection- 5M/T) injection (Electrical
GJNXZL6Z Diesel) engine with V5MB1 (Super select fuel injection)
intercooled turbocharger 4WD, 5M/T)
GJRXZL6Z V4A5A (Super select 4WD,
4A/T)
MODEL CODE <VEHICLES FOR EUROPE AND RUSSIA (EASTERN EUROPE COUNTRIES)>
B L 6Z
1 2 3 4 5 6 7 8 9 10 11
AC407365AK
E M 6BA
1 2 3 4 5 6 7 8 9 10
ACA00801AC
Frame
AC501503AB
C 0 00001
1 2 3 4 5 6 7 8 9 10 11 12 13
AC804908 AD
AC508917AB
AC507828AB
C Club cab
J Double cab
No. Item Example Content
5 Transmission N 5-speed manual
1 MODEL KB4T Vehicle model type transmission
GJRXZL6 Model series R 4-speed automatic
2 ENGINE 4D56 Engine model transmission
3 TRANS V4A5A Transmission model Y 5-speed automatic
AXLE 4100 and final gear ratio transmission
4 COLOUR W32 Body colour code 6 Vehicle line K MITSUBISHI L200
5 TRIM 10X Interior code 7 Drive system B 4WD
6 OPT S31 Option code 8 Engine 4 2.5L diesel engine (4D56)
9 MMTh internal 0 No meaning
VEHICLE IDENTIFICATION NUMBER (VIN) purpose
PLATE <VEHICLES FOR RHD> 10 Model year C 2012
M1001005501945
11 Plants D Laemchabang-2 (Thailand
motor vehicle works)
F Laemchabang-1 (Thailand
motor vehicle works)
12 Emission step 0 Euro-5
13 Serial number 00001 to 99999
AC507971AB
00-20 GENERAL
VEHICLE IDENTIFICATION
AC508918AB
AC511709AB
The engine serial number is stamped near the
engine model number.
No. Content Engine serial number AA0201 to YY9999
1 Chassis No. (Vehicle identification number)
2 Gross vehicle weight
3 Gross combination weight
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-21
GENERAL DATA AND SPECIFICATIONS
GENERAL DATA AND SPECIFICATIONS
<VEHICLES FOR EUROPE>
M1001000906642
SINGLE CAB
11
10 12
8
13
1 3 4 5 7
2 6 9
AC805672
CLUB CAB
11
10 12
13
1 3 4 5 7
2 6 9
AC805455
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-23
Item KB4T
NCNUZL6/NCNUZR6 GCNXZL6
Vehicle Front track 1 1,505 1,520
dimension mm Overall width 2 1,750 1,815
Front overhang 3 795 795
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,325 1,325
overhang With rear bumper 1,400 1,400
Overall Without rear bumper 6 5,120 5,120
length With rear bumper 5,195 5,195
Ground clearance (unladen) 7 200 205
Overall height (unladen) 8 1,775/1,790* 1,780
Rear track 9 1,500 1,515
Cargo bed interior length 10 1,805 1,805
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 460 460
Cargo floor height (unladen) 13 855 860
Vehicle weight Kerb Without optional parts 1,800 1,815
kg weight With full optional parts 1,900 <LHD> 1,910
1,880 <RHD>
Max. gross vehicle weight 2,850 2,850
Max. axle weight rating-front 1,260 1,260
Max. axle weight rating-rear 1,800 1,800
Max. towable With brake 2,700 2,700
weight Without brake 750 750
Max. trailer-nose weight 115 115
Max. gross combination weight 5,500 5,500
Seating capacity (including a driver) 4 4
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 100/4,000 100/4,000
Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000
Transmission Model code V5MB1 V5MB1
Type 5M/T 5M/T
Drive system Easy select 4WD Super select 4WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.3 6.3
m Wheel 5.9 5.9
00-24 GENERAL
GENERAL DATA AND SPECIFICATIONS
NOTE: .
• *:Vehicles with rear body ground frame.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
Item KB4T
GCNXZPL6
Vehicle Front track 1 1,520
dimension mm Overall width 2 1,815
Front overhang 3 795
Wheel base 4 3,000
Rear Without rear bumper 5 1,325
overhang With rear bumper 1,400
Overall Without rear bumper 6 5,120
length With rear bumper 5,195
Ground clearance (unladen) 7 205
Overall height (unladen) 8 1,780
Rear track 9 1,515
Cargo bed interior length 10 1,805
Cargo bed interior width 11 1,470
Cargo bed interior height 12 460
Cargo floor height (unladen) 13 860
Vehicle weight Kerb Without optional parts 1,825
kg weight With full optional parts 1,920
Max. gross vehicle weight 2,850
Max. axle weight rating-front 1,260
Max. axle weight rating-rear 1,800
Max. towable With brake 2,700
weight Without brake 750
Max. trailer-nose weight 115
Max. gross combination weight 5,500
Seating capacity (including a driver) 4
Engine Model code 4D56
Total displacement mL 2,477
Type DOHC High-power diesel Intercooled,
Turbocharger
Max. output kW/rpm (EEC net) 131/3,750
Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850
Transmission Model code V5MB1
Type 5M/T
Drive system Super select 4WD
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-25
Item KB4T
GCNXZPL6
Fuel system Fuel supply system Electrical fuel injection
Turning radius Body 6.3
m Wheel 5.9
NOTE: .
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
DOUBLE CAB
11
10
12
8
13
1 3 4 5 7
2 6 9
AC809340 AB
<2WD>
Item KA4T
NJNUZL6 HJNUZL6
Vehicle Front track 1 1,505 1,505
dimension mm Overall width 2 1,750 1,750
Front overhang 3 830 795
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390* 1,210/1,390*
overhang With rear bumper − 1,285/1,465*
Overall Without rear bumper 6 5,040/5,220 5,005/5,185*
length With rear bumper − 5,080/5,260*
Ground clearance (unladen) 7 200 200
Overall height (unladen) 8 1655 1,775
Rear track 9 1,500 1,500
Cargo bed interior length 10 1,325/1,505* 1,325/1,505*
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405/460* 405/460*
Cargo floor height (unladen) 13 715 845
00-26 GENERAL
GENERAL DATA AND SPECIFICATIONS
Item KA4T
NJNUZL6 HJNUZL6
Vehicle weight Kerb Without optional parts 1,665 1,770
kg weight With full optional parts 1,735 1,900
Max. gross vehicle weight 2,630 2,800
Max. axle weight rating-front 1,030 1,260
Max. axle weight rating-rear 1,700 1,800
Max. towable With brake 1,800 2,700
weight Without brake 750 750
Max. trailer-nose weight 75 112
Max. gross combination weight 4,400 5,465
Seating capacity (including a driver) 5 5
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 94/4,000 100/4,000
Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500 314/2,000
Transmission Model code R5MB1 R5MB1
Type 5M/T 5M/T
Drive system Rear wheel drive 2WD Rear wheel drive 2WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.1 6.3
m Wheel 5.7 5.9
NOTE: .
• *:Vehicles with long cargo bed.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-27
Item KA4T
HJRUZL6
Vehicle Front track 1 1,505
dimension mm Overall width 2 1,750
Front overhang 3 795
Wheel base 4 3,000
Rear Without rear bumper 5 1,210/1,390*
overhang With rear bumper 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185*
length With rear bumper 5,080/5,260*
Ground clearance (unladen) 7 200
Overall height (unladen) 8 1,775
Rear track 9 1,500
Cargo bed interior length 10 1,325/1,505*
Cargo bed interior width 11 1,470
Cargo bed interior height 12 405/460*
Cargo floor height (unladen) 13 845
Vehicle weight Kerb Without optional parts 1,780
kg weight With full optional parts 1,910
Max. gross vehicle weight 2,800
Max. axle weight rating-front 1,260
Max. axle weight rating-rear 1,800
Max. towable With brake 2,700
weight Without brake 750
Max. trailer-nose weight 112
Max. gross combination weight 5,465
Seating capacity (including a driver) 5
Engine Model code 4D56
Total displacement mL 2,477
Type DOHC diesel Intercooled, Turbocharger
Max. output kW/rpm (EEC net) 100/4,000
Max. torque N⋅m/rpm (EEC net) 314/2,000
Transmission Model code R4A5A
Type 4A/T
Drive system Rear wheel drive 2WD
Fuel system Fuel supply system Electrical fuel injection
Turning radius Body 6.3
m Wheel 5.9
00-28 GENERAL
GENERAL DATA AND SPECIFICATIONS
NOTE: .
• *:Vehicles with long cargo bed.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
<4WD>
Item KB4T
NJNUZL6/NJNUZR6 NJRUZL6
Vehicle Front track 1 1,505 1,505
dimension mm Overall width 2 1,750 1,750
Front overhang 3 795 795
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390* 1,210/1,390*
overhang With rear bumper 1,285/1,465* 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185* 5,005/5,185*
length With rear bumper 5,080/5,260* 5,080/5,260*
Ground clearance (unladen) 7 200 200
Overall height (unladen) 8 1,775 1,775
Rear track 9 1,500 1,500
Cargo bed interior length 10 1,325/1,505* 1,325/1,505*
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405/460* 405/460*
Cargo floor height (unladen) 13 845 845
Vehicle weight Kerb Without optional parts 1,870 <LHD> 1,880
kg weight 1,850 <RHD>
With full optional parts 2,000 <LHD> 2,010
1,980 <RHD>
Max. gross vehicle weight 2,850 <LHD> 2,850
2,900 <RHD>
Max. axle weight rating-front 1,260 1,260
Max. axle weight rating-rear 1,800 1,800
Max. towable With brake 2,700 2,700
weight Without brake 750 750
Max. trailer-nose weight 115 115
Max. gross combination weight 5,500 <LHD> 5,500
5,550 <RHD>
Seating capacity (including a driver) 5 5
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-29
Item KB4T
NJNUZL6/NJNUZR6 NJRUZL6
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 100/4,000 100/4,000
Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000
Transmission Model code V5MB1 V4A5A
Type 5M/T 4A/T
Drive system Easy select 4WD Easy select 4WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.3 6.3
m Wheel 5.9 5.9
NOTE: .
• *:Vehicles with long cargo bed.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
Item KB4T
GJNXZL6 GJRXZR6
Vehicle Front track 1 1,520 1,520
dimension mm Overall width 2 1,815 1,815
Front overhang 3 795 795
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390* 1,210/1,390*
overhang With rear bumper 1,285/1,465* 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185* 5,005/5,185*
length With rear bumper 5,080/5,260* 5,080/5,260*
Ground clearance (unladen) 7 205 205
Overall height (unladen) 8 1,780 1,780
Rear track 9 1,515 1,515
Cargo bed interior length 10 1,325/1,505* 1,325/1,505*
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405/460* 405/460*
Cargo floor height (unladen) 13 850 850
00-30 GENERAL
GENERAL DATA AND SPECIFICATIONS
Item KB4T
GJNXZL6 GJRXZR6
Vehicle weight Kerb Without optional parts 1,890 1,885
kg weight With full optional parts 2,030 2,030
Max. gross vehicle weight 2,850 2,930
Max. axle weight rating-front 1,260 1,260
Max. axle weight rating-rear 1,800 1,800
Max. towable With brake 2,700 2,700
weight Without brake 750 750
Max. trailer-nose weight 115 115
Max. gross combination weight 5,500 5,580
Seating capacity (including a driver) 5 5
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 100/4,000 100/4,000
Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000
Transmission Model code V5MB1 V4A5A
Type 5M/T 4A/T
Drive system Super select 4WD Super select 4WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.3 6.3
m Wheel 5.9 5.9
NOTE: .
• *:Vehicles with long cargo bed.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-31
Item KB4T
GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6
Vehicle Front track 1 1,520 1,520
dimension mm Overall width 2 1,815 1,815
Front overhang 3 795 795
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390* 1,210/1,390*
overhang With rear bumper 1,285/1,465* 1,285/1,465*
Overall Without rear bumper 6 5,005/5,185* 5,005/5,185*
length With rear bumper 5,080/5,260* 5,080/5,260*
Ground clearance (unladen) 7 205 205
Overall height (unladen) 8 1,780 1,780
Rear track 9 1,515 1,515
Cargo bed interior length 10 1,325/1,505* 1,325/1,505*
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405/460* 405/460*
Cargo floor height (unladen) 13 850 850
Vehicle weight Kerb Without optional parts 1,900 <LHD> 1,915 <LHD>
kg weight 1,885 <RHD> 1,900 <RHD>
With full optional parts 2,040 <LHD> 2,045
2,030 <RHD>
Max. gross vehicle weight 2,850 <LHD> 2,850 <LHD>
2,930 <RHD> 2,945 <RHD>
Max. axle weight rating-front 1,260 1,260
Max. axle weight rating-rear 1,800 1,800
Max. towable With brake 2,700 2,700
weight Without brake 750 750
Max. trailer-nose weight 115 115
Max. gross combination weight 5,500 <LHD> 5,500 <LHD>
5,580 <RHD> 5,595 <RHD>
Seating capacity (including a driver) 5 5
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC High-power DOHC High-power
diesel Intercooled, diesel Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 131/3,750 131/3,750
Max. torque N⋅m/rpm (EEC net) 400/2,000 − 2,850 350/1,800 − 3,500
Transmission Model code V5MB1 V5A5A
Type 5M/T 5A/T
Drive system Super select 4WD Super select 4WD
00-32 GENERAL
GENERAL DATA AND SPECIFICATIONS
Item KB4T
GJNXZPL6/GJNXZPR6 GJYXZPL6/GJYXZPR6
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.3 6.3
m Wheel 5.9 5.9
NOTE: .
• *:Vehicles with long cargo bed.
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
11
10
12
13
1 3 4 5 7
2 6 9
AC502186AB
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-33
Item KB4T
NJNUZL6Z GJNXZL6Z
Vehicle Front track 1 1,505 1,520
dimension mm Overall width 2 1,750 1,800
Front overhang 3 830 830
Wheel base 4 3,000 3,000
Rear Without rear bumper 5 1,210/1,390*1 1,210/1,390*1
overhang
With rear bumper 1,285/1,465*1 1,285/1,465*1
Overall Without rear bumper 6 5,040/5,220*1 5,040/5,220*1
length
With rear bumper 5,115/5,295*1 5,115/5,295*1
Ground clearance (unladen) 7 200 205
Overall height (unladen) 8 1,775 1,780
Rear track 9 1,500 1,515
Cargo bed interior length 10 1,325/1,505*1 1,325/1,505*1
Cargo bed interior width 11 1,470 1,470
Cargo bed interior height 12 405/460*1 405/460*1
Cargo floor height (unladen) 13 845 850
Vehicle weight Kerb Without optional parts 1,860 1,880
kg weight With full optional parts 1,980 2,015
Max. gross vehicle weight 2,850 2,850
Max. axle weight rating-front 1,260 1,260
Max. axle weight rating-rear 1,800 1,800
Max. towable With brake 2,700 2,700
weight Without brake 750 750
Max. trailer-nose weight 115 115
Max. gross combination weight 5,500 5,500
Seating capacity (including a driver) 5 5
Engine Model code 4D56 4D56
Total displacement mL 2,477 2,477
Type DOHC diesel DOHC diesel
Intercooled, Intercooled,
Turbocharger Turbocharger
Max. output kW/rpm (EEC net) 100/3,500 100/3,500
Max. torque N⋅m/rpm (EEC net) 314/2,000 314/2,000
Transmission Model code V5MB1 V5MB1
Type 5M/T 5M/T
Drive system Easy select 4WD Super select 4WD
Fuel system Fuel supply system Electrical fuel injection Electrical fuel injection
Turning radius Body 6.3 6.3
m Wheel 5.9 5.9
00-34 GENERAL
GENERAL DATA AND SPECIFICATIONS
Item KB4T
GJRXZL6Z
Vehicle Front track 1 1,520
dimension mm Overall width 2 1,800
Front overhang 3 830
Wheel base 4 3,000
Rear Without rear bumper 5 1,210/1,390*1
overhang
With rear bumper 1,285/1,465*1
Overall Without rear bumper 6 5,040/5,220*1
length
With rear bumper 5,115/5,295*1
Ground clearance (unladen) 7 205
Overall height (unladen) 8 1,780
Rear track 9 1,515
Cargo bed interior length 10 1,325/1,505*1
Cargo bed interior width 11 1,470
Cargo bed interior height 12 405/460*1
Cargo floor height (unladen) 13 850
Vehicle weight Kerb Without optional parts 1,890
kg weight With full optional parts 2,025
Max. gross vehicle weight 2,850
Max. axle weight rating-front 1,260
Max. axle weight rating-rear 1,800
Max. towable With brake 2,700
weight Without brake 750
Max. trailer-nose weight 115
Max. gross combination weight 5,500
Seating capacity (including a driver) 5
Engine Model code 4D56
Total displacement mL 2,477
Type DOHC diesel
Intercooled, Turbocharger
Max. output kW/rpm (EEC net) 100/3,500
Max. torque N⋅m/rpm (EEC net) 314/2,000
Transmission Model code V4A5A
Type 4A/T
Drive system Super select 4WD
Fuel system Fuel supply system Electrical fuel injection
Turning radius Body 6.3
m Wheel 5.9
GENERAL
GENERAL DATA AND SPECIFICATIONS
00-35
NOTE: .
• *1: Vehicle with extended cargo bed (optional)
• Trailer specifications indicate the manufacturer’s recommendation.
• When loading luggage and/or towing a trailer, make sure not to exceed any of the above maximum
weights all the time.
11
10 12
8
13
1 3 4 5 7
2 6 9
AC805672
Item KA4T
NENMZ6BA
Vehicle dimension Front track 1 1,505
mm Overall width 2 1,750
Front overhang 3 830
Wheel base 4 3,000
Rear overhang 5 1,210/1,385*1
Overall length 6 5,040/5,215*1
Ground clearance (unladen) 7 200
Overall height (unladen) 8 1,655
Rear track 9 1,500
Cargo bed interior length 10 2,220
Cargo bed interior width 11 1,470
Cargo bed interior height 12 405
Cargo floor height (unladen) 13 715
Vehicle weight kg Kerb weight Without optional parts 1,550
With full optional parts 1,600
Max. gross vehicle weight 2,630
Max. axle weight rating-front 1,030
Max. axle weight rating-rear 1,700
Seating capacity (including a driver) 2
00-36 GENERAL
PRECAUTIONS BEFORE SERVICE
Item KA4T
NENMZ6BA
Engine Model code 4D56
Total displacement mL 2,477
Type DOHC diesel
Intercooled, Turbocharger
Max. output kW/rpm (EEC net) 94/4,000
Max. torque N⋅m/rpm (EEC net) 240/1,500 − 3,500
Transmission Model code R5MB1
Type 5M/T
Drive system Rear wheel drive 2WD
Fuel system Fuel supply system Electrical fuel injection
Turning radius m Body 6.1
Wheel 5.7
NOTE: .
• *1: Vehicles with rear step bumper assembly.
Diagnosis
MB991824 connector
M.U.T.-III USB cable
MB991910
MB991824
MB991827
Do not use
MB991911
MB991824
MB991825
MB991827 AC501413AC
MB991826
AC305090AK
Connect the M.U.T.-III to the diagnosis connector as
Refer to the "M.U.T.-III OPERATION MANUAL" for shown in the illustration.
instructions on handling the M.U.T.-III.
HOW TO PERFORM CHASSIS NUMBER
(CHASSIS NO.) WRITING
M1001015200715
Write the Chassis Number (Chassis No.) of immobi-
liser system as following procedure.
GENERAL
PRECAUTIONS BEFORE SERVICE
00-39
The Chassis Number (Chassis No.) is stored in the No. malfunction) is shown. When the engine-ECU or
engine-ECU or ETACS-ECU by the vehicle manufac- ETACS-ECU is replaced, and entry of the Chassis
ture. If the Chassis No. to be stored in the engine- No. necessary due to diagnosis code No. P0630
ECU or ETACS-ECU is eliminated fraudulently, the (Chassis No. malfunction). Enter the Chassis No. in
engine warning lamp illuminates and Diagnostic accordance with the procedure as follows:
Trouble Code (diagnosis code) No.P0630 (Chassis
SCREEN FLOW OF M.U.T.-III
AC510087AE
00-40 GENERAL
PRECAUTIONS BEFORE SERVICE
CHASSIS NUMBER REGISTRATION PRO- Connect the M.U.T.-III to the 16-pin diagnosis con-
CEDURE FOR ENGINE-ECU nector, and read the diagnosis code.
NOTE: For details on how to use the M.U.T.-III, refer
CAUTION
to the "M.U.T.-III operation manual."
• Check that diagnosis code No.P0603 (EEP-
1. Ensure that the ignition switch is at the "LOCK"
ROM malfunction) is not set. If diagnosis
(OFF) position.
code No.P0603 (EEPROM malfunction) is set,
entered Chassis No. cannot be stored. There- 2. Start up the personal computer.
fore, carry out troubleshooting and repair the 3. Connect special tool M.U.T.-III USB cable
malfunction when this code is set. (MB991827) to V.C.I. (MB991824) and the
<LH drive vehicles>
•
personal computer.
4. Connect special tool M.U.T.-III main harness A
(MB991910) to the V.C.I.
5. Connect the M.U.T.-III main harness A to the
diagnosis connector.
6. Turn the V.C.I. power switch to the "ON" position.
Diagnosis
connector NOTE: When the V.C.I. is energized, the V.C.I.
indicator lamp will be illuminated in a green col-
MB991910 our.
7. Start the M.U.T.-III system on the personal
MB991824
computer and turn the ignition switch to the "ON"
position.
MB991827 AC509179AB
MB991824
OK button
AC510063AB
MB991827 AC501413AC
To prevent damage to M.U.T.-III, always turn the 9. Push the OK button after "Key Code Registration"
ignition switch to the "LOCK" (OFF) position is displayed.
before connecting or disconnecting M.U.T.-III.
GENERAL
PRECAUTIONS BEFORE SERVICE
00-41
10.Push the OK button after "Completed. Press the CHASSIS NUMBER REGISTRATION PRO-
OK button and move to Chassis No. writing CEDURE FOR ETACS-ECU.
function." is displayed.
<LH drive vehicles>
*****************
*****************
Diagnosis
connector
MB991910
AC510064AB
MB991824
11.Enter the Chassis No. of registering vehicle and
push the OK button.
12.Push the OK button after "Chassis No. Writing will
start. Are you sure?" is displayed.
13.Return to the previous screen and "In Progress" is
displayed at the lower-left corner on the screen.
14.Push the OK button after "Completed." is
displayed. MB991827 AC509179AB
Result of Writing
Item Current Before Writing
Chassis No. ***************** *****************
MB991910
AC510065AB
PRE-INSPECTION CONDITION
M1001012100388
"Pre-inspection condition" refers to the condition that
the vehicle must be in before proper engine inspec-
AC510062
tion can be carried out. If you see the words "Set the
8. Select "IMMOBILIZER" in the "System Select" vehicle to the pre-inspection condition" in this man-
tag. Select the model year and push the OK ual. It means to set the vehicle to the following condi-
button (Check each model if there is an tion.
option).Select "Coding" on the next screen, and • Engine coolant temperature 80 to 90°C
select "Chassis No. Writing" on the further screen. • Lamps, electric cooling fan and all accessories:
OFF
• M/T: Neutral
***************** • A/T: P range
ENGINE OILS
M1001011200155
HEALTH WARNING
OK button Prolonged and repeated contact with mineral oil will
result in the removal of natural fats from the skin,
leading to dryness, irritation and dermatitis. In addi-
AC510066 AC tion, used engine oil contains potentially harmful con-
taminants which may cause skin cancer. Adequate
9. Enter the Chassis No. of registering vehicle and
means of skin protection and washing facilities must
push the OK button.
be provided.
10.Push the OK button after "Chassis No. Writing will
start. Are you sure?" is displayed. RECOMMENDED PRECAUTIONS
11.Return to the previous screen and "In Progress" is The most effective precaution is to adapt working
displayed at the lower-left corner on the screen. practices which prevent, as far as practicable, the
12.Push the OK button after "Completed." is risk of skin contact with mineral oils, for example by
displayed. using enclosed systems for handling used engine oil
and by degreasing components, where practicable,
before handling them.
Other precautions:
• Avoid prolonged and repeated contact with oils,
particularly used engine oils.
GENERAL
PRECAUTIONS BEFORE SERVICE
00-43
• Wear protective clothing, including impervious • Obtain first aid treatment immediately for open
gloves where practicable. cuts and wounds.
• Avoid contaminating clothes, particularly under- • Wash regularly with soap and water to ensure all
pants, with oil. oil is removed, especially before meals (skin
• Do not put oily rags in pockets, the use of overalls cleansers and nail brushes will help). After clean-
without pockets will avoid this. ing, the application of preparations containing
• Do not wear heavily soiled clothing and oil- lanolin to replace the natural skin oils is advised.
impregnated foot-wear. Overalls must be cleaned • Do not use petrol, kerosine, diesel fuel, gas oil,
regularly and kept separately from personal cloth- thinners or solvents for cleaning skin.
ing. • Use barrier creams, applying them before each
• Where there is a risk of eye contact, eye protec- work period, to help the removal of oil from the
tion should be worn, for example, chemical gog- skin after work.
gles or face shields; in addition an eye wash • If skin disorders develop, obtain medical advice
facility should be provided. without delay.
CAUTION
1. If the injector identification code is not regis- Identification code
tered, the engine warning lamp goes on and
diagnosis code No. P1626 is logged.
2. Failure to register the injector identification
code correctly will cause rough idling, abnor-
mal noise, and emission deterioration.
PURPOSE
AK501491 AB
For this reason, when the injector or engine-ECU is 6. If the injector has been replaced or data has not
replaced, injector correction data must be registered been read from the current engine-ECU, register
afterwards in the engine-ECU using the Multi Use the injector identification code as follows:
Tester III (M.U.T.-III). (1) Select Write Injector ID Code from the
Correction data is converted into an identification SPECIAL FUNCTION menu.
code consisting of 30 alphanumeric characters and (2) If the injector was replaced, specify whether to
printed on the injector connector. write to every cylinder or a specific cylinder.
REGISTRATION PROCEDURE Frame 1 Frame 2
(4 digits) (4 digits)
1. When replacing the engine-ECU, connect the
current engine-ECU to the body harness. Frame 3 Frame 4
NOTE: This operation is purposed to read the injec- (4 digits) (4 digits)
tor identification code stored in the engine-ECU. Frame 5 Frame 6
Reading the identification code in this way before (4 digits) (4 digits)
replacement can eliminate manual input of the identi-
Frame 7 Frame 8
fication code after replacement. (4 digits) (2 digits)
2. After the ignition switch is in "LOCK" (OFF) AK501492 AB
position, connect the M.U.T.-III to the diagnosis
(3) Select the write mode from the menu, enter
connector.
the identification code printed on the injector,
3. Turn the ignition switch to "ON" position. and execute writing.
4. Select SPECIAL FUNCTION from the function
CAUTION
menu.
Even if the number of the cylinder to be regis-
5. When the current engine-ECU is still mounted, tered does not match the actual injector mount-
read and register the injector identification code ing location, registration ends normally. Specify
as follows: the cylinder number correctly.
(1) Select Read Injector ID Code (for engine-ECU
NOTE: The identification code is displayed in order
replacement) from the SPECIAL FUNCTION
of the frame numbers when it is read.
menu.
7. Makes sure that the engine warning lamp that is
(2) Select Write and Save Injector ID Code from
on changes to blinking, indicating the registration
the menu to read data from the current engine-
is complete.
ECU and save the data if it could be read
normally. NOTE: When the injector is replaced, executing the
write operation also clears the values of small injec-
(3) Mount the new engine-ECU on the vehicle.
tion quantity learning.
(4) Select SPECIAL FUNCTION from the function
8. Execute small injection quantity learning.
menu.
(5) Select Write Injector ID Code (for engine-ECU Refer to P.00-45, the SMALL INJECTION
replacement) from the SPECIAL FUNCTION QUANTITY LEARNING PROCEDURE for the
menu. learning procedure.
(6) Select SAVED INJECTOR ID WRITING from 9. Confirm that the engine warning lamp is off.
the Write Injector ID Code menu to write the Confirm also that the diagnosis code is not stored.
data, which was saved previously, to the
engine-ECU.
GENERAL
PRECAUTIONS BEFORE SERVICE
00-45
SMALL INJECTION QUANTITY LEARNING PROCEDURE
M1001014300322
APS harness
side connector
MB991894
MB991910
MB991791
MB991824 AC103781AC
AC300832AC
Frequency Maximum Modulation
(MHz) output power
If high-pressure car-washing equipment or steam
(W)
car-washing equipment is used to wash the vehicle,
be sure to note the following information in order to 3.5 50 CW, FM, AM,
avoid damage to plastic components, etc. 7 SSB
• Spray nozzle distance: Approx. 40 cm or more 14
• Spray pressure: 3,900 kPa or less
• Spray temperature: 82°C or less 21
• Time of concentrated spray to one point: within 28
30 sec. 50
PRECAUTIONS FOR INSTALLATION OF 144
ON-VEHICLE RADIO TRANSMISSION 430
EQUIPMENT 1,260 2
M1001015500095 •
Clock spring
<M/T> SRS warning lamp
Passenger's air bag
cut off switch
SRS-ECU
Side-airbag module
Curtain air bag module
SRS-ECU
DANGER CAUTION
In order to avoid injury to yourself or others SRS-ECU connector
from accidental deployment of the air bag <Vehicles without side-airbag and curtain air bag>
during servicing, read and carefully follow all
the precautions and procedures described in
this manual.
CAUTION <Vehicles with side-airbag and curtain air bag>
Do not use any electrical test equipment on or
near SRS components, except those specified on
.
AC800836 AB
CAUTION
Never attempt to repair the following compo- Do not attempt to repair the wiring harness con-
nents: nectors of the SRS. If a defective wiring harness
1. SRS-ECU is found, repair or replace it by referring to the
table below.
2. Front impact sensor
3. Clock spring
4. Driver's and passenger's (front) air bag mod-
ules
5. Seat belt with pre-tensioner
6. Side impact sensor
7. Front seatback assembly incorporating side-
airbag module
8. Curtain air bag module
NOTE: If any of these components are diagnosed as
faulty, they should only be replaced, in accordance
with the INDIVIDUAL COMPONENTS SERVICE pro-
cedures in this manual, starting at page .
<Vehicle without side-airbag and curtain air bag>
SRS-ECU terminal No. Destination of harness Remedy
1, 2 Instrument panel wiring harness → Correct or replace each wiring harness.
Front wiring harness → Front impact
sensor (RH)
3, 4 Instrument panel wiring harness → Correct or replace each wiring harness.
Front wiring harness → Front impact
sensor (LH)
8 Instrument panel wiring harness → Correct or replace the Instrument panel
SRS warning lamp wiring harness.
9, 10 Instrument panel wiring harness → Correct or replace the instrument panel
Passenger's air bag cut off switch → wiring harness.
Passenger's (front) air bag module
11, 12 Instrument panel wiring harness → Correct or replace instrument panel
Clock spring → Driver's air bag module wiring harness. Replace the clock
spring.
13 Instrument panel wiring harness → Correct or replace the instrument panel
Junction block (fuse No.21) wiring harness.
GENERAL
SRS SERVICE PRECAUTIONS
00-51
SRS-ECU terminal No. Destination of harness Remedy
16 Instrument panel wiring harness → Correct or replace the instrument panel
Junction block (fuse No.15) wiring harness.
18 Instrument panel wiring harness → Correct or replace the instrument panel
Earth wiring harness.
20 Instrument panel wiring harness → Correct or replace the instrument panel
Diagnosis connector wiring harness.
27, 28 Instrument panel wiring harness → Correct or replace each wiring harness.
Floor wiring harness → Seat belt pre-
tensioner (passenger’s side)
29, 30 Instrument panel wiring harness → Correct or replace each wiring harness.
Floor wiring harness → Seat belt pre-
tensioner (driver’s side)
Insulating tape
Battery
Battery cable
AC300580AB
SRS-harness connector
MB992006
AC801105AB
AXLE STANDS
<Front> <Rear> <Rear>
GARAGE JACK
<Front> <Rear>
crossmember
AC502069 AC502070
AC502553AF
GENERAL
SUPPORT LOCATIONS FOR LIFTING AND JACKING
00-55
SUPPORT POSITIONS FOR A SINGLE-POST LIFT OR DOUBLE-POST LIFT
CAUTION
When service procedures require removing rear suspension, spare tyre and rear bumper, place addi-
tional weight on rear end of vehicle or anchor vehicle to hoist to prevent tipping of centre of gravity
changes.
<Front> <Rear>
AC505968 AC502653
AC502572 AC
00E-1
GROUP 00E
GENERAL
<ELECTRICAL>
CONTENTS
HOW TO READ WIRING DIAGRAMS 00E-2 HOW TO READ CIRCUIT DIAGRAMS . . . . 00E-4
COMPOSITION AND CONTENTS OF WIRING MARKINGS FOR CONNECTOR AND EARTHING
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 00E-2 ...................................... 00E-5
HOW TO READ CONFIGURATION DIAGRAMS WIRE COLOUR CODES . . . . . . . . . . . . . . . 00E-7
...................................... 00E-2 ABBREVIATION SYMBOLS . . . . . . . . . . . . 00E-8
00E-2 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
A-19
Denotes earth point.
Same earth number is used throughout circuit
diagrams to facilitate search of earth point.
Refer to GROUP 70 COMPONENT LOCATIONS
- EARTH MOUNTING LOCATIONS 1
for details of earth points.
Front
wiring
harness
(RH)
Denotes harness name.
A-18
AC208446 AP
00E-4 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
Indicates power source. Indicates connector number. Indicates input/output Indicates a wiring connector which is inside
The same numbers are used in the to/from control unit the equipment and which is not shown in
wiring harness diagram. (current flow direction). the wiring harness configuration diagram.
Connector and connector numbers
are shown at the lower part of the Input Output Input/ Example C-15-2 Indicates a connector
Indicates that terminal is conne- output
cted via a plate in the relay box. page. which is inside the
Connector numbers not enclosed equipment, numbered Indicates that the diagram comes
by frame indicate the device incor- in order starting from 1. from which belongs to the
porated into wiring harness. block in the same circuit.
Indicates the connector number shown in
Each circuit diagram consists of the wiring harness configuration diagram.
block(s).
Indicates that these connectors
are the same intermediate
connectors.
Indicates harness junction point
numbers for another system.
The number corresponds to the
junction point number indicated
on another circuit diagram. Indicates terminal number.
AC502479AB
AC502479
GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
00E-5
MARKINGS FOR CONNECTOR AND
EARTHING
M1001007900162
IGNITION FUSIBLE
SWITCH (IG1) LINK 1
SOLENOID
VALVE 5
1
8 ECU
4
SENSOR
MOTOR
INSPECTION
CONNECTOR
AC208460 AB
7
2
00E-6 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
ACX01253 AI
ACX01251AE
Female terminal
Female connector
ACX01255AD
Female connector
Female terminal
ACX01256 AH
ACX01254 AD
ACX01256
ACX01816 AD
GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
00E-7
Item No. Connector/Earthing Symbol Contents
Connector 3 Direct connection type Connection between a device
connection and the harness is either by
marking direct insertion in the device
(direct connection type) or by
connection with a harness
connector furnished on the
ACX01261
ACX01260 AD device side (harness
connection type). The two types
4 Harness connection type are indicated as illustrated.
ACX01263
ACX01262 AD
5 Intermediate connector
ACX01265
ACX01264AD
AC208448AB ACX01274
7 Device earth
AC208449AB ACX01276
ACX01278
AC208450AB
Code Wire colour Code Wire colour Code Wire colour Code Wire colour
B Black L Blue PU Purple V Violet
BR Brown LG Light green R Red W White
G Green O Orange SB Sky blue Y Yellow
GR Grey P Pink SI Silver − −
If a cable has two colours, the first of the two colour
code characters indicates the basic colour (colour of
Example: <F> 1.25 G B
the cable coating) and the second indicates the
1 2 3 4 marking colour.
ACX01279 AE
No. Meaning
1 <F>: Flexible wire
<T>: Twisted wire
2 Wire size (mm2)*
3 Basic colour (colour of the cable coating)
4 Marking colour
NOTE: ABBREVIATION SYMBOLS
2
*: No code indicates 0.5 mm . Cable colour code in M1001008101593
4. FOR OTHERS
Abbreviation Meaning Abbreviation Meaning
symbol symbol
2WD 2 wheel-drive vehicles HI High
4WD 4 wheel-drive vehicles IC Integrated circuit
A/C Air conditioner ILL Illumination lamp
A/T Automatic transmission IND Indicator lamp
CPU Central processing unit LIN Local interconnect network
D.C Direct current LH Left hand
ECU Electronic control unit LO Low
00E-12 GENERAL <ELECTRICAL>
HOW TO READ WIRING DIAGRAMS
GROUP 11
ENGINE
CONTENTS
GROUP 11A
ENGINE
MECHANICAL
CONTENTS
GENERAL INFORMATION
M1111000102222
SERVICE SPECIFICATIONS
M1111000302118
SEALANTS
M1111000500956
SPECIAL TOOLS
M1111000602799
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MB992046
ENGINE MECHANICAL
SPECIAL TOOLS
11A-5
Tool Number Name Use
MB991800 Pulley holder Holding the crankshaft pulley
MB991800
B992100
B992099
MD998772
D998713
D998727
B990767
MD998719 Pin
D998719
D998383
D998382
B991683
ENGINE MECHANICAL
ON-VEHICLE SERVICE
11A-7
ON-VEHICLE SERVICE
ALTERNATOR AND POWER STEERING WHEN THE VIBRATION FREQUENCY IS
OIL PUMP DRIVE BELT TENSION CHECK MEASURED (SPECIAL TOOL MB992080 IS
M1111001200033 USED): RECOMMENDATION
CAUTION NOTE: The vibration frequency measuring method is
Check the drive belt tension after turning the recommended for check and adjustment of the drive
crankshaft clockwise one turn or more. belt tension.
Belt tension meter set (MB992080)
A
MB992081
Indicator mark
MB992082
Auto tensioner
AC501803AB AC507219AB
1. Make sure that the indicator mark is within the 1. Connect special tool microphone assembly
area marked with A in the illustration. (MB992082) to special tool belt tension meter
2. If the mark is out of the area, replace the drive (MB992081) of special tool belt tension meter set
belt. (Refer to P.11A-17). (MB992080).
NOTE: The drive belt tension check is not neces- 2. Press the "POWER" button to turn on the power
sary as auto tensioner is adopted. supply.
3. Press the numeral key of "1" and check that
A/C COMPRESSOR DRIVE BELT "No.1" appears on the upper left of the display.
TENSION CHECK AND ADJUSTMENT NOTE: This operation is to temporarily set the
M1111001000363
preset data such as the belt specifications,
Check the drive belt tension by the following proce- because if the measurement is taken without input
dures. of the belt specifications, conversion to tension
STANDARD VALUE: value (N) cannot be made, resulting in judgement
Item When When When of error.
checked adjusted replaced 4. Press "Hz" button twice to change the display to
Vibration 222.5 − 222.5 − 259.8 − the frequency display (Hz).
frequency Hz 251.0 251.0 300.0
Tension N 363 − 462 363 − 462 495 − 660
Deflection 6.8 − 8.0 6.8 − 8.0 5.1 − 6.4
mm
(Reference)
11A-8 ENGINE MECHANICAL
ON-VEHICLE SERVICE
• If the microphone is touching the belt while Use a belt tension gauge in the middle of the belt
the measurement is being made, the values between the pulleys shown in the figure (at the place
measured by the microphone may not corre- indicated by the arrow) to check that the belt tension
spond to actual values. is within the standard value.
• Do not take the measurement while the vehi-
cle's engine is running. BELT DEFLECTION CHECK
10 – 15 mm 15˚
Tensioner pulley Tensioner pulley
Approximately
15˚ 100N
MB992080
(Microphone)
Deflection
Crankshaft A/C compressor pulley Crankshaft A/C compressor pulley
pulley AC903689 AB pulley AC506004AB
5. Hold special tool MB992080 to the middle of the Apply approximately 100 N of pressure against the
belt between the pulleys (at the place indicated by location between the pulleys shown by the arrow in
arrow) where it does not contact the belt the illustration and then measure the deflection.
(approximately 10 − 15 mm away from the rear When the belt tension is adjusted by measuring the
surface of the belt) so that it is perpendicular to belt deflection, adjust it with a tool for vibration fre-
the belt (within an angle of ± 15 °). quency measurement or tension measurement after-
6. Press the "MEASURE" button. ward.
7. Gently tap the middle of the belt between the
BELT TENSION ADJUSTMENT
pulleys (the place indicated by the arrow) with
If not within the standard value, adjust the belt ten-
your finger as shown in the illustration, and check
sion by the following procedure.
that the vibration frequency of the belt is within the
standard value.
Adjusting bolt
NOTE: To take the measurement repeatedly, fillip Tensioner pulley
the belt again. Locking nut
AC505988AB
OPERATION CHECK
1. Turn off the engine from the idle state then check
to see that the drive belt is not protruding from the
pulley width of the auto tensioner.
MB992082
2. Remove the drive belt (Refer to P.11A-17).
AC507219AB
AC501804
Auto tensioner (1) Connect special tool microphone assembly
(MB992082) to special tool belt tension meter
(MB992081) of special tool belt tension meter
set (MB992080).
(2) Press the "POWER" button to turn on the
power supply.
(3) Press the numeral key of "1" and check that
"No.1" appears on the upper left of the display.
AC507703AB NOTE: This operation is to temporarily set the
preset data such as the belt specifications,
3. Install the tool to the auto tensioner, and check
because if the measurement is taken without
that no binding is present by turning the auto
input of the belt specifications, conversion to
tensioner in the left and right directions.
tension value (N) cannot be made, resulting in
4. If there are any problems in the procedure 1 or 3, judgement of error.
replace the auto tensioner (Refer to P.11A-43).
(4) Press "Hz" button twice to change the display
5. Install the drive belt (Refer to P.11A-17). to the frequency display (Hz).
11A-10 ENGINE MECHANICAL
ON-VEHICLE SERVICE
AC805802AF
<Euro5>
Power steering
10 – 15 mm
oil pump pulley
15˚
Gentry tap
with your finger
15˚
MB992080
(Microphone)
Alternator pulley
AC805654AG
AC805803AE
<Euro5>
Power steering
Belt tension oil pump pulley
gauge
Alternator pulley
AC805655AF
Timing marks
Thickness gauge
Camshaft
sprocket AK500381 AC
<LH drive vehicles> 5. If the idle speed is not within the standard value,
inspect the diesel system (Refer to GROUP 13A −
Troubleshooting − Inspection Chart for Diagnosis
Code P.13A-429).
MB991827
<RH drive vehicles> Diagnosis Crank angle
connector sensor connector
AK500382 AB
MB991827 AK600277AB
Camshaft
sprocket
AK500385 AB
Timing marks
5. Loosen the tensioner pivot side bolt 1 turn and
slot side nut 1 or 2 turns.
Crank shaft NOTE: These works will allow the tensioner
pulley
spring to tension timing belt B automatically.
6. First tighten tensioner slot side nut, and then
tighten pivot side bolt to the specified torque.
AK500379 AB
Tightening torque:
3. Align the timing marks on the sprockets with the Pivot side bolt 23 ± 3 N⋅m
timing mark on the front upper case. Slot side bolt 20 ± 4 N⋅m
CAUTION
When aligning the timing mark, be sure not to
turn the crankshaft in the anti-clockwise direc-
tion as this can cause improper belt tension.
Access cover
AK500386AB
Access cover
7. Install the access cover.
8. Install the timing belt upper cover.
AK500384 AB
ENGINE MECHANICAL
CRANKSHAFT PULLEY
11A-17
CRANKSHAFT PULLEY
REMOVAL AND INSTALLATION
M1112001602814
5
265 N·m to 0 N·m
to 275 N·m
4
3
1
(Engine oil)
AC501821AB
Crankshaft pulley
MB991800
AC505988AB
AC501824 AB
1. Loosen the locking nut of the tensioner pulley.
1. Use the following special tools to hold the
CAUTION crankshaft pulley.
To reuse the drive belt, draw an arrow indicating • Pulley holder (MB991800)
the rotating direction (clockwise) on the back of • Crank pulley holder (MB992100)
the belt using chalk, etc.
2. Loosen the crankshaft pulley bolt and remove the
2. Rotate the adjusting bolt to the anti-clockwise crankshaft pulley washer and crankshaft pulley.
direction (to the left), and remove the drive belt. 3. If the crankshaft pulley cannot be removed from
the crankshaft, follow the procedure below.
<<B>> ALTERNATOR AND POWER STEERING (1) Install the crankshaft pulley bolt and
OIL PUMP DRIVE BELT REMOVAL crankshaft pulley washer to the crankshaft
AC501823
L-shaped
pulley. At this time, the crankshaft pulley bolt
hexagon wrench must be loosened by 3 to 4 turns from the
completely tightened state.
MB992099
Auto tensioner
AC507702 AB
Crankshaft pulley
washer Crankshaft pulley
Crankshaft
Crankshaft pulley MB991800
pulley bolt
Degrease
AC501824 AB
CAUTION
* Remove and assemble the marked parts in each cylinder unit.
Pre-removal and Post-installation Operation
• Inlet Manifold Removal and Installation (Refer to GROUP
15 − Inlet Manifold P.15-15).
11 ± 1 N·m 16 11 ± 1 N·m
Apply engine oil to all
moving parts before 17 N 5
installation. 20 ± 1 N·m
18
6N
15 18
7
20 ± 1 N·m
4
19
21
20
22 21
24 11 13 24 20
23 13
25* 9 22
18 ± 2 N·m 8 14 25* 23
12 18 ± 2 N·m
26*
10 26*
27*
N 28 27*
29* 28 N
2 N 3 29*
88 ± 10 N·m
10 ± 2 N·m AC501908AD
26. Valve spring retainer Loosen the mounting bolts of the front camshaft
27. Valve spring bearing cap and camshaft bearing cap in the order
>>A<< 28. Valve stem seal shown in the figure. Then, remove the front camshaft
29. Valve spring seat bearing cap and camshaft bearing caps.
REMOVAL SERVICE POINTS
<<A>> CAMSHAFT SPROCKET REMOVAL
MD998719
MB990767
AC507554AB
11A-22 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
<<C>> VALVE SPRING RETAINER LOCK >>B<< VALVE SPRING RETAINER LOCK
REMOVAL INSTALLATION
CAUTION
When removing valve spring retainer lock, leave MD998772
the piston of each cylinder in the TDC (Top Dead
Centre) position. The valve may fall into the cylin-
der if the piston is not properly in the TDC posi-
tion.
MD998772
AC501910AB
Valve
Nut
Rocker arm
Valve stem assembly
seal
Valve guide
AC308654AC
5.5 – 6.5 mm
Adjusting screw
2. Use the special tool valve stem seal installer AC501912AB
(MB991999) to fill a new valve stem seal in the
valve guide using the valve stem area as a guide. 1. Screw the adjusting screw into the rocker arm
assembly, and then temporarily assemble using a
nut so that the adjusting screw protrusion
becomes the dimension shown in the figure.
2. Apply the engine oil to the sliding surface of the
parts below.
ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
11A-23
• Roller and valve-side sliding area of the rocker
Engine front
arm assembly
• Concave spherical surface of pivot bolt or spheri-
cal surface of adjusting screw Front right camshaft
bearing cap
Stem end cap Rocker arm assembly Right camshaft bearing cap
3 1 5 7
9
10 4 2 6 8
Pivot
bolt
AC501913 AB
2. Set the timing mark of the exhaust camshaft in the >>G<< INLET CAMSHAFT/DOWEL PIN/C-
position shown in the figure. SPRING/SUB GEAR/WAVE WASHER/SNAP RING
INSTALLATION
>>F<< RIGHT CAMSHAFT BEARING CAP/O-
RING/EXHAUST OIL PIPE ASSEMBLY/FRONT
RIGHT CAMSHAFT BEARING CAP
Inlet camshaft
INSTALLATION
1. Place the right camshaft bearing cap onto the
camshaft journal section.
2. Apply the engine oil to the O-ring section of
exhaust oil pipe assembly, and insert the tip of
exhaust oil pipe assembly into the cylinder head.
Then, place the pipe section onto the right AC501916AB
camshaft bearing cap.
1. Fix the inlet camshaft hexagonal area using a vice
or other devices.
11A-24 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
Inlet camshaft
2.3 – 2.8 mm
Dowel pin
2. Press fit the dowel pin into the inlet camshaft and AC501919 AB
sub gear so that the dimension becomes as
shown in the figure. 1. Fix the hexagonal area of inlet camshaft assembly
using a vice or other devices.
C-spring Dowel pin
CAUTION
Avoid turning the sub gear than necessary.
Hole of sub gear (M8) Thread hole of
camshaft (M6)
Screwdriver
10 4 2 6 8
9
3 1 5 7
AC501922AB
Front left
camshaft
bearing cap AC501923AB
(Engine oil)
3. Apply specified sealant to the matching area of
the cylinder head assembly and the front left
camshaft bearing cap as shown, and install the
left camshaft bearing cap to the cylinder head MD998713 AC102323AC
assembly.
1. Apply engine oil to the entire inner diameter of the
Specified sealant: 3M ATD Part No.8660 oil seal lip.
11A-26 ENGINE MECHANICAL
CAMSHAFT AND VALVE STEM SEAL
2. Use special tool camshaft oil seal installer 1. Use the following special tool as during removal to
(MD998713) to press-fit the oil seal as shown. hold the camshaft sprocket.
• Front hub and flange yoke holder (MB990767)
>>K<< CAMSHAFT SPROCKET INSTALLATION • Pin (MD998719)
2. Tighten the camshaft sprocket mounting bolt to
the specified torque.
Tightening torque: 88 ± 10 N⋅m
MD998719
MB990767
AC507554AB
ENGINE MECHANICAL
OIL PAN AND OIL STRAINER
11A-27
OIL PAN AND OIL STRAINER
REMOVAL AND INSTALLATION <2WD
(EXCEPT HIGH RIDER)>
M1112008301004
CAUTION
At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine
oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with
surrounding parts, causing engine oil leak when the engine oil pan is installed on the vehicle using
the liquid gasket.
Pre-removal Operation Post-installation Operation
• Engine Room Under Cover Removal (Refer to GROUP 51 • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
− Under Cover P.51-32). Service, Engine Oil Replacement P.12-4).
• Engine Oil Draining (Refer to GROUP 12 − On-vehicle • Engine Room Under Cover Installation (Refer to GROUP
Service, Engine Oil Replacement P.12-4). 51 − Under Cover P.51-32).
48 ± 6 N·m
11 2N (Engine oil)
19 ± 3 N·m
N 10
3
39 ± 5 N·m
4 7
9.0 ± 3.0 N·m
AC506493 AC
joint assembly
MD998727 MD998727
connecting bolt
18 ± 2 N·m
Front suspension
upper arm (LH)
AC600311AF
CAUTION
At the time of factory shipment or when the engine is overhauled, liquid gasket is used for the engine
oil pan gasket. Use the replacement engine oil pan gasket since the sealed surface may interfere with
surrounding parts, causing oil leak when the engine oil pan is installed on the vehicle using the liquid
gasket.
Pre-removal Operation Post-installation Operation
• Under Skid Plate and Engine Room Under Cover • Power Steering Gear Box and Linkage Assembly Installa-
Removal (Refer to GROUP 51 − Under Cover P.51-32). tion (Refer to GROUP 37 − Power Steering Gear Box and
• Engine Oil Draining (Refer to GROUP 12 − On-vehicle Linkage P.37-22).
Service, Engine Oil Replacement P.12-4). • Front Differential Carrier Assembly Installation (Refer to
• Differential Gear Oil Draining (Refer to GROUP 26 − On- GROUP 26 − Differential Carrier and Freewheel Clutch
vehicle Service, Gear Oil Replacement P.26-11) <4WD>. P.26-33) <4WD>.
• Front Differential Carrier Assembly Removal (Refer to • Differential Gear Oil Refilling (Refer to GROUP 26 − On-
GROUP 26 − Differential Carrier and Freewheel Clutch vehicle Service, Gear Oil Replacement P.26-11) <4WD>.
P.26-33) <4WD>. • Engine Oil Refilling (Refer to GROUP 12 − On-vehicle
• Power Steering Gear Box and Linkage Assembly Service, Engine Oil Replacement P.12-4).
Removal (Refer to GROUP 37 − Power Steering Gear • Under Skid Plate and Engine Room Under Cover Installa-
Box and Linkage P.37-22). tion (Refer to GROUP 51 − Under Cover P.51-32).
ENGINE MECHANICAL
OIL PAN AND OIL STRAINER
11A-31
48 ± 6 N·m
10 2N (Engine oil)
19 ± 3 N·m
N9 8 3
7N
6
9.0 ± 3.0 N·m
5N
4
39 ± 5 N·m
AC506494AC
MD998727 MD998727
Engine oil pan side
AC102325 AI
6 132 ± 5 N·m
11 ± 1 N·m
10
7
9 8
11 N
3 11
3N
1
Engine oil
AC903691AC
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps <Except high power
• Timing belt, timing belt B (Refer to engine>
P.11A-43) • Transmission assembly (Refer to
>>F<< 1. Crankshaft B sprocket GROUP 22A − Transmission
2. Crankshaft key Assembly P.22A-9) <2WD>
>>E<< 3. Crankshaft front oil seal • Transmission assembly (Refer to
GROUP 22A − Transmission
Assembly P.22A-10) <4WD>
11A-34 ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
Crankshaft rear oil seal removal 1. Use special tool flywheel stopper (MB991883) to
steps <Except high power secure the flywheel assembly.
engine> (Continued)
2. Remove the flywheel bolts.
• Clutch cover and clutch disc (Refer
to GROUP 21B − Clutch P.21B-3)
<<B>> >>D<< 4. Flywheel bolt INSTALLATION SERVICE POINTS
5. Flywheel assembly >>A<< CRANKSHAFT REAR OIL SEAL INSTAL-
>>B<< 10. Oil seal case assembly LATION
>>A<< 11. Crankshaft rear oil seal 1. Apply a small amount of engine oil to the entire
Crankshaft rear oil seal removal
inner diameter of the oil seal lip.
steps <High power engine>
<<A>> • Transmission assembly (Refer to
GROUP 22A − Transmission
Assembly P.22A-10) <4WD>
• Clutch cover and clutch disc (Refer MB992147
to GROUP 21B − Clutch P.21B-3)
8.5 mm
<<B>> >>D<< 6. Flywheel bolt Oil seal
>>C<< 7. Adapter
8. Flywheel assembly
9. Crankshaft adapter
>>B<< 10. Oil seal case assembly Oil seal case
>>A<< 11. Crankshaft rear oil seal AK503243AB
REMOVAL SERVICE POINTS 2. Use special tool oil seal installer (MB992147) to
press-fit the crankshaft rear oil seal.
<<A>> TRANSMISSION ASSEMBLY REMOVAL
3. Press-fit the crankshaft rear oil seal into the oil
CAUTION seal case assembly to have the dimension shown
AC300897 in the illustration.
MB991883 AC503164 AD
: Clean
>>C<< ADAPTER INSTALLATION : Clean and degrease
Install the adapter to the flywheel so that the identifi-
cation mark (φ4 mm) faces the transmission side.
MB991883
Crankshaft
AC802014AB
Front case
1. Use special tool flywheel stopper (MB991883) to
secure the flywheel assembly in the same manner
as removal. Engine front
AC502148AB
2. Tighten the flywheel bolts to the specified torque.
Tightening torque: 1. Clean or degrease the oil pump case, the
<Except high power engine> 133 ± 4 N⋅m crankshaft and the crankshaft B sprocket as
<High power engine> 132 ± 5 N⋅m shown.
NOTE: Also clean the degreased surfaces.
>>E<< CRANKSHAFT FRONT OIL SEAL 2. Install the crankshaft B sprocket in the direction
INSTALLATION shown in the illustration.
Crankshaft MD998382
(Engine oil)
MD998383 Crankshaft
(Oil applied to the front oil seal
circumference) AC102329AI
11A-36 ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
4
6 135 ± 5 N·m
11 ± 1 N·m
5
8
9N
2 3 9
Crankshaft front oil seal removal Crankshaft rear oil seal removal
steps steps (Continued)
• Timing belt, timing belt B (Refer to >>B<< 8. Oil seal case assembly
P.11A-43) >>A<< 9. Crankshaft rear oil seal
>>E<< 1. Crankshaft B sprocket
2. Crankshaft key REMOVAL SERVICE POINT
>>D<< 3. Crankshaft front oil seal <<A>> DRIVE PLATE BOLT REMOVAL
Crankshaft rear oil seal removal
steps
• Transmission assembly (Refer to MB991883
GROUP 23A − Transmission
Assembly P.23A-135) <4A/T>
• Transmission assembly (Refer to
GROUP 23A − Transmission
Assembly P.23A-139) <5A/T>
<<A>> >>C<< 4. Drive plate bolt
5. Adapter plate
6. Drive plate
AC802013AB
7. Inertia ring assembly
ENGINE MECHANICAL
CRANKSHAFT OIL SEAL
11A-37
1. Use special tool flywheel stopper (MB991883) to CAUTION
secure the inertia ring assembly. After the installation, until a sufficient period of
2. Remove the drive plate bolts. time (one hour or more) elapses, do not apply the
oil or water to the sealant application area or
INSTALLATION SERVICE POINTS start the engine.
>>A<< CRANKSHAFT REAR OIL SEAL INSTAL- 3. Applying an appropriate amount of engine oil to
LATION the entire circumference of its crankshaft oil seal
1. Apply a small amount of engine oil to the entire rear lip portion, and then set the crankshaft rear
inner diameter of the oil seal lip. oil seal case assembly to the cylinder block and
tighten the mounting bolts to the specified torque.
Tightening torque: 11 ± 1 N⋅m
MB992147
>>C<< DRIVE PLATE BOLT INSTALLATION
8.5 mm Oil seal
MB991883
(Engine oil)
AC503164 AD
MD998383 Crankshaft
2. Apply a continuous bead of the specified sealant (Oil applied to the front oil seal
circumference)
to the crankshaft rear oil seal case assembly AC102329AI
Crankshaft B sprocket
Crankshaft
Front case
Engine front
AC502148AB
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-39
CYLINDER HEAD GASKET
REMOVAL AND INSTALLATION
M1112004005081
8 10 3
(Engine oil)
24 ± 4 N·m
5
7 11
6
2
10 ± 2 N·m
1
88 ± 10 N·m
AC502177AE
Mating marks
AC502181AB
AC606081AE
Provide one punch mark on the head of the cylin-
Make mating marks on the radiator hose and hose der head bolt each time the bolt is tightened.
clamp as shown to install them in the original posi- Replace the bolt that already has five punch
tion. Then, remove them. marks (the evidence of having been tightened
five times)
<<B>> CAMSHAFT SPROCKET REMOVAL
Engine front
6 14 16 8
2 10 18 12 4
MD998719
1 9 17 11 3
5 13 15 7
MB990767 AC502179 AB
AC507554AB
Loosen the cylinder head bolts in two or three steps
1. Use the following special tools to hold the in the order of the numbers shown in the illustration.
camshaft sprocket.
• Front hub and flange yoke holder (MB990767) INSTALLATION SERVICE POINTS
• Pin (MD998719) >>A<< CYLINDER HEAD GASKET INSTALLA-
2. Loosen the camshaft sprocket mounting bolt and TION
remove the camshaft sprocket. CAUTION
Do not allow any foreign materials get into the
<<C>> POWER STEERING OIL PUMP ASSEMBLY
coolant passages, oil passages and cylinder.
REMOVAL
1. With the hose installed, remove the power 1. Degrease the cylinder head gasket mounting
steering oil pump assembly from the bracket. surface.
2. After removing the power steering oil pump
assembly, secure it with a cord in the location
where the removal and installation of the cylinder
head assembly cannot be hindered.
ENGINE MECHANICAL
CYLINDER HEAD GASKET
11A-41
CAUTION >>B<< CYLINDER HEAD BOLTS INSTALLATION
The thickness of the original cylinder head gas- CAUTION
ket is selected according to protrusion amount of • Before installing the cylinder head bolt, check
the piston. Therefore, If the cylinder block, pis- the number of punch marks on its head. (the
ton, connecting rod or crankshaft is replaced, the bolt is reusable if it is four or less.) The
protrusion amount may be changed. Always number of punch marks corresponds to that
select a correct gasket by measuring the protru- to times the bolt has been tightened to the
sion amount (Refer to GROUP 11B − Cylinder plastic area. If the bolt has five punch marks,
Head and Valves P.11B-46). replace it.
Identification mark 1. Set the cylinder head bolt washer with its shear
Timing belt side
droop toward the bolt head.
Cylinder head gasket 2. Apply a small amount of engine oil to the thread of
the bolts and to the washers.
Engine front
13 5 3 11
17 9 1 7 15
AC502182AB
AC606082 BA
<Except Euro5>
10
3
4 10 ± 2 N·m
48 ± 6 N·m
9
7
42 ± 8 N·m 44 ± 10 N·m
2 10
44 ± 10 N·m
23 ± 3 N·m
6
10 ± 2 N·m
5 AC805880 AB
23 ± 3 N·m
16
15
14
20 ± 4 N·m
13
11 12
AC502913 AE
11
5 10 ± 2 N·m 4
48 ± 6 N·m
42 ± 8 N·m
10
8
44 ± 10 N·m
2
10 ± 2 N·m 11
44 ± 10 N·m
3 23 ± 3 N·m
7
10 ± 2 N·m
10 ± 2 N·m 6
AC805668 AB
23 ± 3 N·m
17
16
15
20 ± 4 N·m
14
12 13
AC502913 AF
Timing mark
Timing
mark Injection pump
sprocket
Crankshaft
sprocket AC502914AB
Flange
bolt
Water
AC502915AB
pump
2. Remove the timing belt.
Hexagon
socket
<<B>> TIMING BELT B REMOVAL head bolt
CAUTION Tensioner B
To reuse the timing belt B, draw an arrow indicat- spacer
Front lower case
ing the rotating direction on the back of the belt
using chalk, etc.
Washer
Tensioner B spring AC502918AB
1. Loosen the timing belt B tensioner assembly >>B<< TIMING BELT B INSTALLATION
mounting bolts.
Balancer
2. Push the timing belt B tensioner assembly to Timing mark shaft
water pump side and tighten the timing belt B sprocket
Timing mark
tensioner assembly mounting bolts.
Timing mark
3. Remove the timing belt B.
Timing belt B
Crankshaft
Balancer sprocket B
shaft sprocket AC502919AB
Flange
Hexagon socket
head bolt
AC502920AB
AC502923 AB
3. Loosen timing belt B tensioner assembly
mounting flange bolt, one to two turns. 2. Assemble the flange by aligning the timing mark
4. Tighten the timing belt B tensioner assembly of the front lower case and the timing mark of the
mounting hexagon socket head bolt. flange.
5. timing belt B tensioner assembly mounting flange
bolt. >>D<< TENSIONER ARM ASSEMBLY/TIMING
BELT/AUTO TENSIONER INSTALLATION
NOTE: If the bolt is tightened first, the timing belt
B tensioner assembly should be turned together, 1. To reuse the auto tensioner, bleed the air
resulting in reduced timing belt B tensioner according to the procedure below, and then set
assembly. the rod to the auto tensioner.
CAUTION
Balancer shaft
sprocket • If a horizontal press such as a vice is used,
the air entrainment may occur. Thus, a verti-
cal press must be used.
• If the compression is too fast, the procedure
Belt may damage the rod. Make sure to compress
deflection slowly and thoroughly.
• To prevent a damage to the auto tensioner, do
Crankshaft
sprocket B not push down the rod exceeding the bottom
AC502921AB end (a position where the rod protrusion is at
0.5 mm from the auto tensioner).
6. Ensure that the deflection is as specified when the
timing belt B is pushed by the index finger at the
position indicated by an arrow. Press Rod
Belt deflection: 4 − 5 mm
Crankshaft
Crankshaft sprocket B
Flange AC502924 AB
sprocket
Crankshaft
(1) Set the auto tensioner to the vertical press,
and then slowly compress the rod to the
bottom end (a position where the rod
protrusion is at 0.5 mm from the auto
tensioner). Perform this operation 2 to 3 times.
(2) With the rod protruding (a position where the
AC502922AB rod protrusion is at 5 mm from the auto
tensioner), check that there is a rigidity when
1. Clean or degrease the crankshaft, the flange and the rod is pushed with a load (100 to 200 N).
crankshaft sprocket as shown.
ENGINE MECHANICAL
TIMING BELT
11A-49
(3) If the rod rigidity is not obtained by repeating
the operations of (1) and (2), replace the auto Camshaft Timing mark
tensioner. sprocket
B
Rod
A Timing mark
Auto tensioner
AC502924 AC
Auto tensioner
4. Align the timing mark of each sprocket.
Crankshaft Crankshaft
sprocket Slide sprocket B
Crankshaft
AC502925AB
(5) Insert a wire or pin in the aligned set hole. Key top end
NOTE: When the auto tensioner is replaced
with a new part, the auto tensioner is set with a
pin.
Notched area AC502926AB
2. Install the auto tensioner in position. Leave the
wire or pin installed until the auto tensioner is 5. In the order below, install the timing belt without
completely installed. slack.
3. Install the tensioner arm assembly. NOTE: When installing the timing belt into the
crankshaft sprocket, slide the crankshaft sprocket
to near the tip of the key, and then install the tim-
ing belt. (When installing the timing belt, be care-
ful not to damage the belt by the cut-out of
crankshaft sprocket.) After that, install the crank-
shaft sprocket to the correct position.
(1) Crankshaft sprocket
(2) Idler pulley
(3) Injection pump sprocket
(4) Idler pulley
(5) Camshaft sprocket
(6) Tensioner pulley
6. Check that the timing marks on sprockets are at
the correct positions.
7. Remove the wire or pin of the auto tensioner.
11A-50 ENGINE MECHANICAL
VACUUM PUMP
8. Turn the crankshaft 2 turns clockwise, and then 9. Check again that the timing marks on sprockets
measure the protrusion of auto tensioner rod. are at the correct positions.
Standard value: 2.3 − 7.6 mm
VACUUM PUMP
REMOVAL AND INSTALLATION
M1112005200458
<Except Euro5>
3.0 ± 0.5 N·m
1
9
7
8
10
24 ± 3 N·m
11 ± 1 N·m
6
2 4
23 ± 3 N·m 5
20 ± 4 N·m
24 ± 4 N·m 3
AC805886 AC
1
8 9 11
10
12
24 ± 3 N·m 11 ± 1 N·m
2 7
5
23 ± 3 N·m
6
20 ± 4 N·m
24 ± 4 N·m
4
50 ± 5 N·m
AC805665 AC
ENGINE ASSEMBLY
REMOVAL AND INSTALLATION
M1112001006784
1 3
11 ± 1 N·m
14 ± 4 N·m
12
23 ± 3 N·m 48 ± 7 N·m
7
13
22 ± 4 N·m
14
AC903710 AC
<<A>> POWER STEERING OIL PUMP ASSEMBLY 2. Lift the special tool sling chain set (MB991683)
REMOVAL and chain block slowly to remove the engine
1. With the hose installed, remove the power assembly upwards from the engine compartment.
steering oil pump assembly from the bracket.
2. After removing the power steering oil pump INSTALLATION SERVICE POINT
assembly, secure it with a cord in the location >>A<< ENGINE ASSEMBLY INSTALLATION
where the removal and installation of the engine
assembly cannot be hindered.
<<C>> TRANSMISSION ASSEMBLY REMOVAL 1. Use special tool sling chain set (MB991683) and
<M/T> chain block to lift the engine assembly in the same
manner as removal.
CAUTION
2. Install the engine assembly, being careful not to
AC300897
pinch the cables, hoses or wiring harness
connectors.
Engine front
Flywheel
assembly
Flywheel
bolt
AC308604 AB
GROUP 11B
ENGINE OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS
M1113000203046
Description Specifications
Total displacement mL 2,477
Bore × Stroke mm 91.1 × 95
Compression ratio 17 <Except Euro5>,
16.5 <Euro5>
Compression chamber Vortex chamber type
Camshaft arrangement DOHC
Number of valve Intake 2
Exhaust 2
Valve timing Intake valve Open 20° BTDC <Except Euro5>,
13° BTDC <Euro5>
Close 40° BTDC <Except Euro5>,
30° BTDC <Euro5>
Exhaust valve Open 38° BBDC
Close 22° ATDC
Rocker arm End pivot type
Lubrication system Pressure feed, full-flow filtration
Oil pump Trochoid type
Fuel system Common rail type injection pump
Turbocharger Water-cooled
Cooling system Water-cooled
Water pump type Centrifugal impeller type
SERVICE SPECIFICATIONS
M1113000303601
REWORK DIMENSIONS
M1113024301728
TORQUE SPECIFICATIONS
M1113023405274
Item N⋅m
Alternator
Cooling fan bolt 11 ± 1
Fan clutch bolt 11 ± 1
Crankshaft bolt 265 → 0 → 275
Idler pulley bolt <Euro5> 50 ± 5
Power steering pump bracket "A" bolt (Bolt, washer assembly) 20 ± 4
Power steering pump bracket "A" bolt (Flange bolt) 24 ± 4
Power steering pump bracket "B" bolt (M8 × 30) 23 ± 2
Power steering pump bracket "B" bolt (M8 × 90) 24 ± 4
Alternator pivot nut 44 ± 10
Oil level gauge bolt 48 ± 6
Inlet manifold
Vacuum pump pipe "B" bolt 24 ± 3
Air temperature sensor 14 ± 1
EGR pipe "B" bolt (EGR valve side) 49 ± 6
EGR pipe "B" bolt (EGR cooler side) 17 ± 2
EGR pipe "A" heat protector bolt 11 ± 1
EGR pipe "A" bolt and nut 17 ± 2
EGR valve bolt 48 ± 6
Throttle body bolt 13 ± 2
Fuel inlet pipe bolt 20 ± 4
Inlet manifold stay bolt 24 ± 3
Inlet manifold bolt 24 ± 3
Inlet manifold nut 20 ± 2
Exhaust manifold
<Except Euro5>
Engine hanger bolt 24 ± 3
Eye bolt (oil pipe) 17 ± 2
Oil pipe bolt 9.0 ± 1.0
ENGINE OVERHAUL
TORQUE SPECIFICATIONS
11B-5
Item N⋅m
Eye bolt (water pipe) 53 ± 7
Water pipe bolt 11 ± 1
Oil return pipe bolt 9.0 ± 1.0
Turbocharger nut 59 ± 10
Exhaust manifold heat protector bolt 14 ± 1
Exhaust manifold nut (M8) 18 ± 2
Exhaust manifold nut (M10) 30 ± 2
<Euro5>
Engine hanger bolt 24 ± 3
Eye bolt 17 ± 2
Oil pipe bolt 24 ± 3
Heat protector bolt 9.0 ± 1.0
Heat protector bracket bolt (M6) 9.0 ± 1.0
Heat protector bracket bolt (M8) 24 ± 3
Turbocharger water pipe bolt (M6) 11 ± 1
Turbocharger water pipe bolt (M8) 24 ± 3
Vacuum pipe and hose bolt 23 ± 6
Connector bracket bolt 9.5 ± 1.5
E-VRV bolt 9.5 ± 2.5
Oil return pipe bolt 9.0 ± 1.0
Turbocharger heat protector bolt 14 ± 1
Turbocharger bolt and nut 59 ± 10
Exhaust manifold heat protector A bolt 14 ± 1
Exhaust manifold heat protector B bolt 14 ± 1
Exhaust manifold nut (M8) 34 ± 3
Exhaust manifold nut (M10) 62 ± 10
Timing belt
Oil pipe bolt 11 ± 1
Vacuum pump bolt 24 ± 3
Vacuum pump pipe "A" bolt 24 ± 3
Cover bolt 11 ± 1
Crank angle sensor bolt 11 ± 1
Timing belt cover bolt 10 ± 2
Glow plug plate nut 1.8 ± 0.2
Glow plug 9.0 ± 1.0 → +30° to 40°
Tensioner arm bolt 48 ± 6
Auto tensioner bolt 23 ± 3
Pump sprocket nut 64 ± 5
Idler pulley bolt 44 ± 10
Hexagon socket head bolt 20 ± 4
11B-6 ENGINE OVERHAUL
TORQUE SPECIFICATIONS
Item N⋅m
Timing belt tensioner "B" bolt 23 ± 3
Balancer shaft sprocket bolt and nut 36 ± 3
Common rail and supply pump
EGR cooler bracket bolt 24 ± 3
EGR cooler bolt 24 ± 3
Supply pump bolt 24 ± 4
EGR cooler nut 28 ± 4
Suction control valve kit bolt 8.9 ± 1.9
Fuel supply pump pipe flare nut 35 ± 5
Fuel supply pump pipe bolt 10 ± 2
Fuel supply pump pipe bracket bolt 10 ± 2
Bracket bolt <Euro5> 20 ± 4
Fuel injection pipe flare nut 35 ± 5
Fuel injection pipe bolt 10 ± 2
Common rail bolt 24 ± 4
Fuel return pipe bolt 10 ± 2
Eyebolt (Cylinder head side) <Except Euro5> 17 ± 2
Eyebolt (Cylinder head side) <Euro5> 20 ± 2
Eyebolt (Common rail side) 20 ± 2
Rocker cover and injector
Rocker cover bolt 3.0 ± 1.0 → 10 ± 2
Injector holder bolt 10 ± 1 → +120° to 125°
Eye bolt 15 ± 2
Camshaft sprocket bolt 88 ± 10
Timing belt rear cover bolt 10 ± 2
Water hose and pipe
Water pipe "A" bolt <Except Euro5> 24 ± 3
Water pipe bolt (M6) 11 ± 1
Water pipe bolt (M8) 24 ± 3
Water pipe "D" flare nut 54 ± 4
Water pipe "D" bolt 24 ± 3
Joint 39 ± 5
Front upper case stiffener bolt 50 ± 5
Engine coolant temperature gauge unit 11 ± 1
Engine coolant temperature sensor 29 ± 10
Water outlet fitting bolt and nut 24 ± 3
Water inlet fitting bolt 24 ± 3
Plate bolt 10 ± 2
Water pump bolt 24 ± 3
Rocker arm and camshaft
ENGINE OVERHAUL
TORQUE SPECIFICATIONS
11B-7
Item N⋅m
Cam position sensor bolt 11 ± 1
Camshaft bearing cap bolt (M6) 11 ± 1
Camshaft bearing cap bolt (M8) 20 ± 1
Pivot bolt 18 ± 2
Cylinder head and valves
Cylinder head bolt 78 ± 2 → 0 → 29 ± 2 → +90° → +90°
Oil pan and oil pump
Oil filter 22 ± 2
Oil pressure switch 10 ± 2
Oil cooler bolt 39 ± 5
Heat protector bolt <Except Euro5> 10 ± 2
Oil filter bracket bolt 24 ± 4
Harness bracket bolt 9.5 ± 2.5
Oil drain plug 39 ± 5
Oil pan bolt 9.0 ± 3.0
Oil screen bolt 19 ± 3
Stiffener bolt 19 ± 3
Front upper case bolt 24 ± 4
Plug cap 23 ± 3
Balancer shaft driven gear bolt 37 ± 3
Front lower case bolt 24 ± 4
Plug 37 ± 7
Oil pump cover screw 12 ± 2
Balancer shaft gear cover bolt 23 ± 4
Piston and connecting rod
Connecting rod cap nut 27 ± 2 → +90° to 94°
Crankshaft and cylinder block
Drive plate bolt (A/T) 135 ± 5
Flywheel bolt (M/T) 132 ± 5
Rear plate bolt 9.0 ± 1.0
Bell housing cover bolt 9.0 ± 1.0
Oil seal case bolt 11 ± 1
Bearing cap bolt 40 ± 2 → +35° to 39°
Check valve 32 ± 2
Engine support bracket bolt 54 ± 5
11B-8 ENGINE OVERHAUL
SEALANTS
SEALANTS
M1113000503531
D998781
B992100
B992048
B992098
MB990784
D998713
MB992046
D998775
D998727
D998380
D998251
ENGINE OVERHAUL
SPECIAL TOOLS
11B-11
Tool Number Name Use
MD998250 Balancer shaft bearing Installation of silent shaft rear bearing
installer
D998250
MD998385 Balancer shaft drive Installation of silent shaft drive oil seal
gear oil seal guide
D998385
D998383
D998382
MB991614
MB992147 Oil seal installer Removal and installation of rear oil seal
11B-12 ENGINE OVERHAUL
ALTERNATOR
ALTERNATOR
REMOVAL AND INSTALLATION
M1113027600684
<Except Euro5>
20 ± 4 N·m
10
7 9
44 ± 10 N·m
8 11
24 ± 4 N·m
23 ± 2 N·m 3
24 ± 4 N·m 48 ± 6 N·m
2
1
12
13
5 6
11 ± 1 N·m 4
265 N·m
11 ± 1 N·m 0 N·m
275 N·m
AK502994AC
7
50 ± 5 N·m
20 ± 4 N·m
44 ± 10 N·m
10
11
9
12
24 ± 4 N·m
23 ± 2 N·m
24 ± 4 N·m
3
48 ± 6 N·m
2
1
13
14
5 6
11 ± 1 N·m 4
265 N·m
11 ± 1 N·m 0 N·m
275 N·m
AKB00328AB
MB992099
Crankshaft pulley
Crankshaft sprocket
Crankshaft bolt
Crankshaft bolt
MB992100 AK502851AB
<Except Euro5>
1
14 ± 1 N·m
3 24 ± 3 N·m
20 ± 2 N·m 4
2
24 ± 3 N·m
12
13
18 48 ± 6 N·m
15 24 ± 3 N·m
14 19
16
17
13 ± 2 N·m 20 20 ± 4 N·m
17 ± 2 N·m
17 ± 2 N·m
9
11 11 ± 1 N·m
10 5
8
49 ± 6 N·m
7 17 ± 2 N·m
AK801103AB
<Euro5>
1
14 ± 1 N·m
24 ± 3 N·m
3
20 ± 2 N·m 2
24 ± 3 N·m
12
13
18
48 ± 6 N·m
15 24 ± 3 N·m 5
17 ± 2 N·m
14 19
6 4
7
16
17
13 ± 2 N·m 20 20 ± 4 N·m
49 ± 6 N·m
8 17 ± 2 N·m
17 ± 2 N·m
11
9
17 ± 2 N·m
10
AKB00325 AB
B side
A side
AK500701AB
Projection
AK500703AB
1. As shown in the illustration, temporarily tighten to
Position the projection as shown in the illustration.
6.0 ± 1.0 N⋅m the bolts located at side "A."
2. As shown in the illustration, tighten to the >>D<< EGR PIPE GASKET INSTALLATION
specified torque of 24 ± 3 N⋅m the bolts located at
side "B" Tighten nuts to the specified torque of 20
± 2 N⋅m.
3. As shown in the illustration, tighten to the
specified torque of 24 ± 3 N⋅m the bolts located at
side "A."
AK500704AB
AK500702AB
11B-18 ENGINE OVERHAUL
EXHAUST MANIFOLD
EXHAUST MANIFOLD
REMOVAL AND INSTALLATION
M1113011901195
<Except Euro5>
17 ± 2 N·m 17 ± 2 N·m
53 ± 7 N·m
11 ± 1 N·m 2 4
7 9.0 ± 1.0 N·m
5
59 ± 10 N·m 3
8 6
14 ± 1 N·m
9 11 ± 1 N·m
18
12
16
14
17
11 10
53 ± 7 N·m
20
9.0 ± 1.0 N·m
19 21
13
15
18 ± 2 N·m
24 ± 3 N·m
30 ± 2 N·m
AK801104AB
19 8
24 ± 3 N·m
18 14 ± 1 N·m
21
17 23
9.0 ± 1.0 N·m 16
59 ± 10 N·m
22 24
11 ± 1 N·m
25
26
12 11
14 ± 1 N·m
9 23 ± 6 N·m
34 ± 3 N·m
24 ± 3 N·m
24 ± 3 N·m
62 ± 10 N·m
10
13
AKB00327AB
<Euro5>
>>D<< TURBOCHARGER WATER PIPE GASKET
INSTALLATION
Projection
Projection
Projection
AK801164AE
>>B<< OIL RETURN PIPE GASKET Position the projection as shown in the illustration.
INSTALLATION
Projection
AK500740AB
ENGINE OVERHAUL
TIMING BELT
11B-21
TIMING BELT
REMOVAL AND INSTALLATION
M1113001902164
9 24 ± 3 N·m
10 ± 2 N·m
4
24 ± 3 N·m 5
10
11 ± 1 N·m
20 ± 4 N·m
29
20 21 AK801106AB
REMOVAL SERVICE POINTS 3. Use the special tool remove the pump sprocket.
<<A>> TIMING BELT REMOVAL • Injection pump sprocket puller (MB992098)
• Crank pulley puller (MB992099)
AK500721
AK404168
MB992048
Using chalk, etc., mark an arrow on the back of the
timing belt to indicate the direction of rotation. This is
AK502995 AC
to ensure correct installation of the belt in case it is
1. Use the special tool Injection pump sprocket reused.
holder (MB992048), hold the pump sprocket. NOTE: Water or oil on the belt shortens its life drasti-
CAUTION cally, so the removed timing belt, sprocket, and ten-
Never strike the shaft or sprocket to remove the sioner must be free from oil and water. Do not
sprocket. This may cause malfunction in the immerse parts in cleaning solvent.
injection pump. Be sure to use a puller to remove NOTE: If there is oil or water on any part, check front
the sprocket. case oil seals, camshaft oil seal and water pump for
2. Remove the pump sprocket nut. leaks.
MB992098
MB992099
AK503162AB
ENGINE OVERHAUL
TIMING BELT
11B-23
<<F>> BALANCER SHAFT, RIGHT REMOVAL INSTALLATION SERVICE POINTS
Right side >>A<< CRANKSHAFT SPROCKET "B" INSTAL-
LATION
Remove this
plug and insert
a screwdriver Crankshaft sprocket "B"
Crankshaft
AK500724AB
2. Insert a Phillips screwdriver [shank diameter 8 Clean and then degrease the front face of the oil
mm] through the plug hole and lock the balancer pump gear drive shaft, crankshaft sprocket "B" and
shaft. crankshaft surface on which sprocket "B" is attached.
3. Loosen the balancer shaft sprocket nut. NOTE: Degreasing is necessary to prevent decrease
in the friction between contacting surfaces.
<<G>> BALANCER SHAFT, LEFT REMOVAL
>>B<< SPACER INSTALLATION
Left side
Oil seal
Insert bar Spacer
Balancer
shaft
AK500725AB Chamfered
Sharp edge
AK402871 AB
1. Insert a wrench extension bar or similar rod and
lock the balancer shaft. Install the spacer with its chamfered end toward the
2. Loosen the balancer shaft sprocket bolt. oil seal.
<<H>> CRANKSHAFT SPROCKET "B" REMOVAL >>C<< BALANCER SHAFT SPROCKET, LEFT
INSTALLATION
Left side
Insert bar
MD998778 AK404167AB
AK500725AB
Use the special tool Crankshaft sprocket puller
(MD998778), if the sprocket is stuck and hard to 1. Lock the balancer shaft in the same way as used
remove. in the removal procedure.
2. Install the balancer shaft sprocket and tighten the
bolt to the specified torque of 36 ± 3 N⋅m.
11B-24 ENGINE OVERHAUL
TIMING BELT
>>D<< BALANCER SHAFT SPROCKET, RIGHT >>F<< TIMING BELT "B" INSTALLATION
INSTALLATION
Timing mark
Right side
Remove this Timing mark
plug and insert
a screwdriver
Tensioner "B"
Hexagon socket
head bolt
AK500729AB
Crankshaft Crankshaft
sprocket Flange sprocket "B"
Crankshaft
MB992048
AK502995 AC
AK500731 AB
1. Use the special tool Injection pump sprocket
1. Clean and then degrease the following surfaces holder (MB992048) to prevent the pump sprocket
and parts: Sprocket mounting surface of from rotating.
crankshaft, flange, and crankshaft sprocket. 2. Tighten the pump sprocket nut to the specified
NOTE: Degreasing is necessary to prevent torque of 64 ± 5 N⋅m.
decrease in the friction between contacting sur-
faces. >>I<< AUTO TENSIONER INSTALLATION
2. Clean the crankshaft contacting surface of the CAUTION
crankshaft sprocket. Always bleed the auto-tensioner of air before
3. Install the flange, aligning a timing mark on a front installing the auto-tensioner. (Refer to auto ten-
lower case with that on the flange. sioner inspection P.11B-27 .)
Timing mark
(on timing belt rear cover)
Timing mark
(on camshaft procket)
Timing mark
(on front
upper case)
Timing belt
Timing mark
(on crankshaft
sprocket "B")
AK500734AB
1. Align the timing marks on each sprocket. crankshaft sprocket → idler pulley → pump
2. In accordance with the following procedure, install sprocket → idler pulley → camshaft sprocket →
a timing belt not to be slack. tensioner pulley
11B-26 ENGINE OVERHAUL
TIMING BELT
Oil pump
INSPECTION
M1113002001428
30 to 40˚
TIMING BELTS
AK501273AC
The timing belts must be checked closely. Should the
6. Using the special tool Angle gauge (MB991614), following defects be evident, replace the belt with a
tighten the glow plug to a further 30° to 40°. new one.
7. Install a glow plug plate to the glow plug, and then
tighten them to the specified torque of 1.8 ± 0.2
N⋅m.
8. Pull out the set pin of an auto tensioner.
9. Turn the crankshaft twice in a clockwise direction
and measure the protrusion height of the auto
tensioner.
Standard value: 2.3 − 7.6 mm
10.Confirm the timing marks on each sprocket are in AK202794
position.
1. Hardened back surface rubber.
ENGINE OVERHAUL
TIMING BELT
11B-27
Glossy, non-elastic, and so hard that no mark is Canvas on load side tooth flank worn (Fluffy canvas
produced even when scratched by fingernails. fibers, rubber gone and color changed to white, and
unclear canvas texture)
Cracks Cracks Last stage:
Canvas on load side tooth flank worn down and rub-
ber exposed (tooth width reduced)
8. Missing tooth.
Peeling of canvas
Cracks in sides
AUTO-TENSIONER
1. Check the auto-tensioner for leaks from the
sealed sections.
Cracks in tooth roots AK202793 AB Replace it if leaky.
2. Cracked back surface rubber. 2. Check the rod end for wear and other damage.
3. Cracked or separated canvas. Replace the auto-tensioner if the rod is badly
4. Cracked tooth bottom. worn or damaged.
5. Cracked side.
AK500737AB
Abnormal wear
(Fluffy strand)
AK202795 AB
3. Measure the extension length of the rod.
6. Abnormal wear on side. If it is not within the standard value range, replace
NOTE: Normal belt should have clear-cut sides as the auto-tensioner.
if cut by a sharp knife. Standard value: 14.5 mm
4. Measure the amount of the retraction when the
Canvas lost and rod is pressed with the force of 100 − 200 N. If it
rubber exposed deviates from the standard value, replace the auto
tensioner.
Missing Standard value: within 1.0 mm
Tooth
AK801061AB
ENGINE OVERHAUL
COMMON RAIL AND SUPPLY PUMP
11B-29
COMMON RAIL AND SUPPLY PUMP
REMOVAL AND INSTALLATION
M1113029200239
<Except Euro5>
5
2
6
24 ± 4 N·m
17 ± 2 N·m
15
14
12
18 10 ± 2 N·m
11
16 10
9
10 ± 2 N·m
17
1
20 ± 2 N·m
8
35 ± 5 N·m
10 ± 2 N·m
24 ± 3 N·m 7
13
3 35 ± 5 N·m
4 24 ± 4 N·m
24 ± 3 N·m
AKB00337AB
CAUTION
*1: Unless replaced, do not remove the sensor.
<Euro5>
6
2
7
24 ± 4 N·m
10
20 ± 4 N·m
20 ± 2 N·m
17
16
14
20 13 10 ± 2 N·m
18
12
11
10 ± 2 N·m
19
1
20 ± 2 N·m
24 ± 3 N·m 9
35 ± 5 N·m
5
10 ± 2 N·m
8
15
35 ± 5 N·m
24 ± 3 N·m 24 ± 4 N·m
4
3
24 ± 3 N·m
AKB00324 AB
Bracket
AK801189AC
<Euro5>
Fuel supply pump pipe
AK801190AB
AKB00339AB
11B-34 ENGINE OVERHAUL
ROCKER COVER AND INJECTOR
2 7
3.0 ± 1.0 N·m 10 ± 2 N·m
1
8
3 4
9 6
15 ± 2 N·m 5
13 10 ± 1 N·m
15 ± 2 N·m 10 +120˚ to 125˚
12 14
13 11
15
16
14
17
10 ± 2 N·m 20
19
88 ± 10 N·m
18
AK801108AB
Fuel injector
AK500708
Injection part of the nozzle AC900270 AB
Remove the camshaft sprocket holding the hexago-
nal area of the camshaft with a wrench. (1) Using a resin spatula, scrape off the carbon
deposit on the fuel injector nozzle side face
INSTALLATION SERVICE POINTS ("A" shown in the figure).
>>A<< CAMSHAFT SPROCKET INSTALLATION
Fuel injector
AC900203 AB
MB990784
AC900204AB
CAUTION CAUTION
In order to prevent carbon from adhering to the • When the tightening angle is smaller than the
inner surface of the cylinder, blow air with the specified tightening angle, the appropriate
piston in the TDC position. tightening capacity cannot be secured.
(5) Remove the special tool MB990784, and blow • When the tightening angle is larger than the
off the carbon deposit on the cylinder head specified tightening angle, remove the bolt to
(fuel injector insertion hole) by air. start from the beginning again according to
(6) Check that there is no carbon deposit the procedure.
remaining on the contact surface of the fuel
injector nozzle gasket.
NOTE: Repeat step 4 to step 6 several times
until the carbon deposit is completely removed. MB991614
Fuel injector
Injector supporter
AK500711AB
Pivot boss
8. Using the special tool Angle gauge (MB991614),
tighten the injector holder bolt in the illustrated
Nozzle sequence by a further 120 to 125°.
gasket
AC502872 AB
Oil seal
AK500713AB
ENGINE OVERHAUL
ROCKER COVER AND INJECTOR
11B-37
Using a proper socket wrench, the oil seal is pressed Specified sealant:
and fit into the rocker cover. Three bond 1217G or equivalent
Rocker cover
Oil seal Connector
Injector
AK603148AB
AK500712AB
10 mm
AK603149AB
CAUTION
Pay attention that the connector does not dam-
10 mm
age the seal lip when inserting the rocker cover.
Semicircular 2. Slightly press the oil seal lip to the place in the
packing Cylinder head opposite direction of the connector, shown in the
AK304411AB
illustration.
Rocker cover 3. Leave enough clearance for the connector to
avoid touching the seal lip.
Gasket "A"
10 mm
AK603150AB
10 mm 10 mm AK800029AB 4. Slowly get the seal lip through not making contact
with the connector.
1. Apply specified sealant to portions indicated in
illustration. 5. Put the rocker cover down to the installation
location.
11B-38 ENGINE OVERHAUL
WATER HOSE AND PIPE
2
6 9 3
4 10 1 5
AK603151AB AK500741AB
6. Check that the injector-sealing surface has the 7. In accordance with the tightening order shown in
seal lip. the illustration, tighten bolts to 3.0 ± 1.0 N⋅m.
8. Again, in accordance with the tightening order
shown in the illustration, tighten bolts to the
specified torque of 10 ± 2 N⋅m.
<Except Euro5>
39 ± 5 N·m
54 ± 4 N·m 24 ± 3 N·m
9
2
8 5 1
24 ± 3 N·m
3
7 24 ± 3 N·m
11 ± 1 N·m
6
4 10
24 ± 3 N·m 50 ± 5 N·m
18 19
20
21
11
15
17
12
10 ± 2 N·m
22
16
24 ± 3 N·m 24 ± 3 N·m
14 13
29 ± 10 N·m 11 ± 1 N·m
AK403582 AB
ENGINE OVERHAUL
WATER HOSE AND PIPE
11B-39
Removal steps Removal steps (Continued)
1. Water hose 12. Water hose
2. Water pipe "A" >>C<< 13. Coolant temperature gauge unit
3. Water hose >>B<< 14. Coolant temperature sensor
4. Water hose 15. Water outlet fitting
>>E<< 5. Water pipe 16. Water outlet fitting gasket
>>E<< 6. O-ring 17. Water inlet fitting
7. Water hose >>A<< 18. Thermostat
8. Water pipe "D" 19. Plate
9. Joint 20. Gasket
>>D<< 10. Front upper case stiffener 21. Water pump
11. Water hose 22. Water pump gasket
<Euro5>
39 ± 5 N·m
54 ± 4 N·m
6
5 2
24 ± 3 N·m
4 24 ± 3 N·m
11 ± 1 N·m
3
1 7
24 ± 3 N·m 50 ± 5 N·m
15 16
17
18 8
12
14
9
10 ± 2 N·m
19
13
24 ± 3 N·m 24 ± 3 N·m
11 10
29 ± 10 N·m 11 ± 1 N·m
AK801109 AB
"B"
"B"
Manufacturing "A"
Valve opening year and month
tenperature Manufacturer
mark AK801125AB
AK500675AB
AK400587AD
AK400588AD
ENGINE OVERHAUL
ROCKER ARMS AND CAMSHAFT
11B-41
ROCKER ARMS AND CAMSHAFT
REMOVAL AND INSTALLATION
M1113005402042
11 ± 1 N·m
11 ± 1 N·m 3 7
4
8
20 ± 1 N·m
20 ± 1 N·m 10
6 10
6 10
5 6 10
6 9
11 17 12
16
15
14 19
13
21 18
19 21 20
18
20 22
23
23 18 ± 2 N·m
18 ± 2 N·m 22 1
11 ± 1 N·m
2
AK503039AB
Adjusting screw
Nut
Rocker arm
Camshaft AK500652AB
Camshaft AK500652AC
4 2 6 8
10
9 3 1 5 7
10 4 2 6 8
AK500656 AB
AK500659AB
screwdriver
Thickness gauge
MB992046
AK500660
Adjusting
Measure the cam height. screw
Standard value: Nut
Intake:
35.47 mm <Except Euro5>
35.42 mm <Euro5> AK500662AB
exhaust: 35.41 mm
2. While holding the adjusting screw with a
Limit:
screwdriver to prevent it from turning, tighten the
Intake:
lock nut to the specified torque using a special
34.97 mm <Except Euro5>
tool Valve adjusting socket (MB992046).
34.92 mm <Euro5>
exhaust: 34.91 mm Tightening torque: 15 ± 3 N⋅m
3. Turn the crankshaft 360° clockwise to bring No. 4
cylinder to the top dead centre position.
VALVE CLEARANCE ADJUSTMENT
Turn the crankshaft clockwise to bring No. 1 cylinder
to the top dead centre position.
78 ± 2 N·m 0 N·m
29 ± 2 N·m +90˚ +90˚
1
2
9
21 10
5 11
6 15
7 16
13 18
14
20
17
12
19
8
3
AK600424AB
REMOVAL SERVICE POINTS 2. Relieve the spring tension and remove the valve,
<<A>> CYLINDER HEAD BOLTS REMOVAL retainer, spring, etc. Store removed valves,
springs, and other parts, tagged to indicate their
cylinder no. and location for assembly.
MD998775
AK404126
Punch mark
AK404135AB
MD998772
AK404133AB
CAUTION
The valve spring, if excessively compressed,
causes the bottom end of the retainer to be in
contact with, and damage, the stem seal.
Compress the valve spring using the special tool
Valve spring compressor (MD998772), them install
AK404133AB
the retainer lock.
1. Set special tool Valve spring compressor
(MD998772) as illustrated to compress the valve
spring. Remove the retainer lock.
>>C<< CYLINDER HEAD GASKET
INSTALLATION
ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
11B-47
1 2 3 4 5 6 7 8
AK402940 AB
<Except Euro5>
Rank Average value of Protrusion tolerance Thickness of selected Identification tab
piston protrusions for each rank mm gasket (when
mm tightened) mm
A 0.06 − 0.12 0.17 0.95 ± 0.04 Non-equipped
B 0.12 − 0.18 0.23 1.00 ± 0.04
C 0.18 − 0.24 − 1.05 ± 0.04
<Euro5>
Rank Average value of Protrusion tolerance Thickness of selected Identification tab
piston protrusions for each rank mm gasket (when
mm tightened) mm
A 0.16 − 0.22 0.17 1.07 ± 0.04 Equipped
B 0.22 − 0.28 0.23 1.12 ± 0.04
C 0.28 − 0.34 − 1.17 ± 0.04
NOTE: If the piston projection exceeds the tolerance,
replace the piston, connecting rod, crankshaft or cyl-
inder block and check again.
11B-48 ENGINE OVERHAUL
CYLINDER HEAD AND VALVES
>>D<< CYLINDER HEAD BOLT INSTALLATION 6. Make paint marks on each bolt’s head and on the
CAUTION cylinder head.
Before installing the cylinder head bolt, check CAUTION
the number of punch marks on its head. (the bolt • When the tightening angle is smaller than the
is reusable if it is four or less.) the number of specified tightening angle, the appropriate
punch marks corresponds to that to times the tightening capacity cannot be secured.
bolt has been tightened to the plastic area. if the • When the tightening angle is larger than the
bolt has five punch marks, replace it. specified tightening angle, remove the bolt to
1. Set the cylinder head bolt washer with its shear start from the beginning again according to
droop toward the bolt head. the procedure.
2. Apply engine oil to the bolt threads and washers. 7. Turn the bolts 90° in the tightening direction and in
the indicated sequence.
8. Give another 90° turn in the tightening direction to
each bolt, making sure that the paint mark on the
bolt head and that on the cylinder head are on the
same line.
INSPECTION
M1113007002987
CYLINDER HEAD
AK404127
13 5 3 11
17 9 1 7 15
AK404142
18 10 2 8 16
14 6 4 12 Check the cylinder head gasket surface for flatness
by using a straightedge in the directions of illustra-
AK500584AB tion.
Standard value: 0.03 mm
3. Tighten the bolts to 78 ± 2 N⋅m in the indicated
Limit: 0.2 mm
sequence.
4. Loosen all the bolts completely.
VALVE
5. Tighten the bolts again to a torque of 29 ± 2 N⋅m
in the indicated sequence. After that, confirm all
bolts are reached to the specified torque, and then
go to the next process. Contact
(Should be at
centre of face)
Margin
90˚ 90˚
AK300593AB
Stem diameter
Guide inside diameter AK300168 AE
VALVE SPRING
AK600918AB
Out of square
Assemble the valve, then measure the contact width.
If the measurement exceeds the specified limit,
replace the valve seat.
Free height Standard value: 1.1 − 1.5 mm
75˚
1.
1. Before correcting the valve seat, check for 4. Using valve seat cutter, correct the valve seat to
clearance between the valve guide and valve and, the specified width and angle.
if necessary, replace the valve guide. See "VALVE SEAT RECONDITIONING
2. Using the seat grinder, correct to obtain the PROCEDURE."
specified seat width and angle.
3. After correction, valve and valve seat should be VALVE GUIDE REPLACEMENT PROCEDURE
lapped with a lapping compound. 1. Force out the valve guide toward the cylinder
block using a press.
VALVE SEAT REPLACEMENT PROCEDURE CAUTION
Do not use a replacement valve guide of the
0.5 - 1 mm
same size as the removed one.
2. Machine the valve guide hole in the cylinder head
to the size matched to the selected oversize valve
guide.
Cut away
Valve guide hole diameter:
0.5 - 1 mm
0.05 O.S.: 11.050 − 11.068 mm
NOTE: Do not install a valve guide of the same
size again.
AK400379 AC
Valve seat
height
AK500586AB
10 ± 2 N·m
10 ± 2 N·m
22 ± 2 N·m 1
2 10 ± 2 N·m
3 38
7 37
8
9.5 ± 2.5 N·m 9
Apply engine oil to
all moving parts
24 ± 4 N·m
before installation.
5 6 36
4
39 ± 5 N·m
23 ± 4 N·m
33 17
34 18
23 35
24 ± 4 N·m 24
37 ± 3 N·m 24 ± 4 N·m
12 ± 2 N·m
22 30 19 9.5 ± 2.5 N·m
21 32 16
31
13
20 26
23 ± 3 N·m 29 19 ± 3 N·m
25 28
27 37 ± 7 N·m
15
14 12
19 ± 3 N·m
AK404158AB
AK404136AB
<<B>> OIL PAN REMOVAL
Put alignment marks on the outer and inner rotors for
reference in reassembly.
MD998727
MD998380
AK404130AB
MD998380
(Right side only)
AK402949AB
Oil seal
Apply
engine Balancer shaft
MD998380 drive gear
(Right side only) oil
AK402958AB
Alignment
mark
MD998383
MD998382
(Apply oil to outer surface) AK500589AB
AK404137AB
11B-54 ENGINE OVERHAUL
OIL PAN AND OIL PUMP
Bolt
>>F<< FLANGE BOLT INSTALLATION Groove hole
portion portion
AK503041AB
Socket wrench
Oil seal
Oil pan
AK404160AB
AK600888AB
CAUTION
Use care not to allow the sealant to plug the oil
passage.
Apply sealant to the threads of the switch.
Specified sealant: MD998012 AK404159AB
Three bond 1207F or equivalent
2. Using special tool Oil pressure switch socket
>>L<< OIL PRESSURE SWITCH INSTALLATION wrench (MD998012), tighten the oil pressure
switch to the specified torque.
Tightening torque: 10 ± 2 N⋅m
Bracket
side
AK503746 AB
AK400405AC
Standard value
Front:
General service tool
Right 0.02 − 0.05 mm
Left 0.02 − 0.06 mm
Rear: 0.06 − 0.10 mm
OIL PUMP
AK404129AB
AK404141AB
2. Check journal for size, damage, and contact with 4. Check the body clearance using a thickness
bearing. If defects are evident, replace the gauge.
balancer shaft, bearing, or front case assembly.
Standard value: 0.10 − 0.18 mm
3. Check the balancer shaft oil clearance. If wear is Limit: 0.35 mm
excessive, replace the balancer shaft bearing,
balancer shaft or front case assembly.
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-57
PISTON AND CONNECTING ROD
REMOVAL AND INSTALLATION
M1113008403840
6
Apply engine oil to
7
all moving parts 8 12
before installation.
4
10 11
13
9
14
3
2
27 ± 2 N·m +90˚ to 94˚
1
AK403589 AC
D5
<Euro 5>
MB992010 Front mark
AK801093AD
AK500593AB AK500591AB
1. When replacing the piston pin, read off the Install the expander coil and oil ring in the piston ring
cylinder bore size mark on the cylinder block as groove.
illustrated, and select a piston according to the
following table.
ENGINE OVERHAUL
PISTON AND CONNECTING ROD
11B-59
>>C<< PISTON RING NO. 1 / PISTON RING NO. 2
INSTALLATION Bolt
MB992010
Connecting rod
AK402300AC
No. 1
No. 2
AK202807 AB
1. Verifying the mark made during disassembly, 7. Make sure that connecting rod big end side
install the bearing cap to the connecting rod. If the clearance meets the specification.
connecting rod is new with no index mark, make Standard value: 0.10 − 0.25 mm
sure that the bearing locking notches come on the Limit: 0.40 mm
same side as shown.
2. The connecting rod cap bolts and nuts are INSPECTION
M1113008502651
tightened using the torque-to-yield method. For
this reason, each bolt to be reused must be PISTON RING
checked for elongation before installation. Piston Thickness gauge
Whether or not the bolt has been elongated can
be determined by running a nut with fingers
through all the threads of the bolt. If the nut does
not turn smoothly over all the threads, the bolt has
been elongated and must be replaced.
3. Apply engine oil to the threads and bearing
surface of each nut before installation.
4. Finger-tighten the nuts on the bolts, then tighten
the nuts alternately and repeatedly to install the AK402966AB
cap properly.
5. Tighten the nuts to a torque of 27 ± 2 N⋅m. No.1 oil ring groove
MB991614
Ring carrier
AK402967AB
AK500742 AB
1. Check for side clearance. If the limit is exceeded,
replace the ring or piston, or both.
6. Using the special tool Angle gauge (MB991614), NOTE: In cases of keystone type, measure the
tighten the connecting rod cap nut in the ring to groove clearance as shown.
illustrated sequence by a further 90° to 94°. Standard value:
CAUTION No. 1: 0.07 − 0.10 mm
• When the tightening angle is smaller than the No. 2: 0.05 − 0.06 mm
specified tightening angle, the appropriate Oil: 0.02 − 0.06 mm
tightening capacity cannot be secured.
Limit:
• When the tightening angle is larger than the
No. 1: 0.15 mm
specified tightening angle, remove the bolt to
No. 2: 0.15 mm
start from the beginning again according to
Oil: 0.10 mm
the procedure.
AK404154AB
11B-62 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
CAUTION
On the flexible flywheel equipped engines, do not remove any of the bolts "A" of the flywheel shown
in the illustration. The balance of the flexible flywheel is adjusted in an assembled condition. Remov-
ing the bolt, therefore, can cause the flexible flywheel to be out of balance giving and resulting in
damage.
2
Apply engine oil to
all moving parts 13
before installation.
1
133 ± 4 N·m
11 ± 1 N·m 14 4
9.0 ± 1.0 N·m 6
28
26 5
24
54 ± 5 N·m
25 23
10
18
18
11
17 40 ± 2 N·m +35˚ to 39˚
20
19 AKB00336AB
No.1, 3 No.2, 4
Cylinder Cylinder
No.4
No.1 No.5
AK503244 AB
No.1
No.2
Check valve Oil jet
No.3
No.4
AK402957AB
No.5
There are two types of oil jets installed.
one for No.1 and 3 and the other for N0.2 and 4. AK402986AB
Make sure that the correct one is installed with cor-
rect direction as shown. (2) The cylinder block bore diameter identification
marks are stamped at the position shown in
the illustration from front to rear beginning at
>>B<< CRANKSHAFT BEARING INSTALLATION
No.1.
1. When the bearing needs replacing, select a
proper bearing by the following procedure. Identification For upper
NOTE: If the crankshaft is machined to an under- color
sized, bearings for undersized crankshaft should
be used and therefore the following selection pro- Identification mark
cedure is unnecessary.
Identification mark
Identification
For lower color
AK503245AB
11B-64 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
(3) Select proper bearings from the below table b. Next, check the cylinder block bearing bore iden-
on the basis of the identification data tification mark stamped on the cylinder block. If it
confirmed under Items (1) and (2). is "A" read the "Bearing identification mark" col-
umn to find the identification mark of the bearing
Example
to be used. In this case, it is "1" or "Green"
a. If the measured value of a crankshaft journal
outer diameter is 65.997 mm, the journal is clas-
sified as "1" or "Yellow" in the table. In case the
crankshaft is also replaced by a spare part, check
the identification colors of the journals painted on
the new crankshaft.
Combination of crankshaft journal diameter and cylinder block bearing bore Bearing
diameter identification mark
Crankshaft journal Classification Cylinder block bearing
Identification color or mark O.D. mm bore diameter
Using both ID (mark and color) or identification mark
either one
1 Yellow 65.994 − 66.000 A 1 or Green
B 2 or Yellow
C 3 or None
2 None 65.988 − 65.994 A 2 or Yellow
B 3 or None
C 4 or Blue
3 White 65.982 − 65.988 A 3 or None
B 4 or Blue
C 5 or Red
For upper
Groove
Groove
For lower
AK503246AB AK301467AD
Press
AK404143AB
AK500598AB
CAUTION
• When the tightening angle is smaller than the
specified tightening angle, the appropriate
tightening capacity cannot be secured.
• When the tightening angle is larger than the
specified tightening angle, remove the bolt to
start from the beginning again according to
the procedure. AK500580AB
4. Using the special tool Angle gauge (MB991614), 2. Apply a bead of FIPG to the surface of the rear oil
tighten the bearing cap bolts in the illustrated seal case as shown in the drawing.
sequence by a further 35° to 39°.
Specified sealant:
Three bond 1217G or equivalent
NOTE: Be sure to install the case quickly while
the sealant is wet (within 15 minutes).
3. Install the oil seal into the cylinder block after
applying an appropriate amount of engine oil to
the entire circumference of its lip portion.
4. Install the rear oil seal case by tightening its bolts
to 11 ± 1 N⋅m.
AK404157 NOTE: After installation, keep the sealed area away
from the oil for approximately one hour.
5. After installing the bearing caps, make sure that
the crankshaft turns smoothly and the end play is
correct. If the end play exceeds the limit, replace
crankshaft bearings.
11B-66 ENGINE OVERHAUL
CRANKSHAFT AND CYLINDER BLOCK
INSPECTION
M1113008802759
OIL JET / CHECK VALVE
Engine oil
AK404145
12 mm
AK404146 AB
GROUP 12
ENGINE
LUBRICATION
CONTENTS
GENERAL INFORMATION
M1121000101242
The lubrication method is a fully force-fed, full-flow fil- • Avoid contaminating clothes, particularly under-
tration type. Water-cooled oil cooler built into the oil pants, with oil.
filter bracket have been adopted. • Do not put oily rags in pockets, the use of overalls
without pockets will avoid this.
ENGINE OILS • Do not wear heavily soiled clothing and oil-
HEALTH WARNING impregnated foot-wear. Overalls must be cleaned
Prolonged and repeated contact with mineral oil will regularly and kept separate from personal cloth-
result in the removal of natural fats from the skin, ing.
leading to dryness, irritation and dermatitis. In addi- • Where there is a risk of eye contact, eye protec-
tion, used engine oil contains potentially harmful con- tion should be worn, for example, chemical gog-
taminants which may cause skin cancer. Adequate gles or face shields; in addition an eye wash
means of skin protection and washing facilities must facility should be provided.
be provided. • Obtain first aid treatment immediately for open
cuts and wounds.
RECOMMENDED PRECAUTIONS • Wash regularly with soap and water to ensure all
The most effective precaution is to adapt working oil is removed, especially before meals (skin
practices which prevent, as far as practicable, the cleansers and nail brushes will help). After clean-
risk of skin contact with mineral oils, for example by ing, the application of preparations containing
using enclosed systems for handling used engine oil lanolin to replace the natural skin oils is advised.
and by degreasing components, where practicable, • Do not use petrol, kerosine, diesel fuel, gas oil,
before handling them. Other precautions: thinners or solvents for cleaning skin.
• Avoid prolonged and repeated contact with oils, • Use barrier creams, applying them before each
particularly used engine oils. work period, to help the removal of oil from the
• Wear protective clothing, including impervious skin after work.
gloves where practicable. • If skin disorders develop, obtain medical advice
without delay.
SERVICE SPECIFICATION
M1121000300414
SEALANT
M1121000501262
SPECIAL TOOLS
M1121000602433
MH061590
MB992118
12-4 ENGINE LUBRICATION
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
ENGINE OIL CHECK 4. Install a new drain plug gasket so that it faces in
M1121000901475 the direction shown in the illustration, and then
CAUTION tighten the drain plug to the specified torque.
Tightening torque: 39 ± 5 N⋅m
NOTE: Install the drain plug gasket so it faces in
the direction shown in the illustration.
"X" mark 5. Refill with specified quantity of oil.
Specified Engine Oil
• ACEA classification: "For service A1/B1,
A3/B3, A3/B4 or A5/B5"
• API classification: "For service CF-4"
Maximum Minimum
Total quantity (Includes volume inside oil fil-
ACB00687 AB
ter and oil cooler):
When burning away and removing soot accumu- <2WD with 15 inch tyres> 7.4L
lated in the DPF, fuel can mix with the engine oil <2WD with 16 inch tyres, 4WD> 6.4L
and an increase in the engine oil level may occur. NOTE:
This does not indicate an abnormality. However,
if the engine oil level is at or over the "X" mark on
the engine oil level gauge, change the engine oil
<Vehicles with diesel particulate filter (DPF)>.
1. Pull out the engine oil level gauge slowly and
check that the engine oil level is in the illustrated
range.
2. Check that the engine oil is not excessively dirty,
that there is no engine coolant or fuel mixed in,
and that it has sufficient viscosity. AC903479
Engine oil
pan side
AC502277AC
ENGINE LUBRICATION
ON-VEHICLE SERVICE
12-5
2. Remove the engine oil filler cap.
Engine oil pan WARNING
drain plug
Use care as oil could be hot.
3. Remove the drain plug to drain oil.
4. Remove the under cover.
Engine oil
pan side
AC502277AC
MH061590
4. Install a new drain plug gasket so that it faces in
the direction shown in the illustration, and then
tighten the drain plug to the specified torque.
Tightening torque: 39 ± 5 N⋅m
AC000093AN
NOTE: Install the drain plug gasket so it faces in
the direction shown in the illustration.
5. Use the special tool oil filter wrench (MH061590)
5. Refill with specified quantity of oil.
to remove the engine oil filter.
Specified Engine Oil 6. Clean the filter bracket side mounting surface.
• ACEA classification: "For service C1, C2,
C3 or C4"
• JASO classification: "For service DL-1"
Total quantity (Includes volume inside oil fil-
ter and oil cooler):
<2WD with 15 inch tyres> 7.4L
<2WD with 16 inch tyres, 4WD> 6.4L
NOTE:
O-ring
AC103250AD
AK802450AG
AK403473
Engine oil filter
3
10 ± 2 N·m
2
1
3.5 ± 0.4 N·m
AC804274AC
MD998012
AC503935 AG
>>A<< ENGINE OIL PRESSURE SWITCH INSTAL- 2. In the same manner as removal, use special tool
LATION oil pressure switch wrench (MD998012) to tighten
CAUTION the engine oil pressure switch to the specified
torque.
Tightening torque: 10 ± 2 N⋅m
AC804286AB
AC611856AL
12-8 ENGINE LUBRICATION
ENGINE OIL PRESSURE SWITCH
2
1
AC903779
AC903864 AB
AK402699AC
MB992118
AK502606 AD
12-10 ENGINE LUBRICATION
ENGINE OIL COOLER
1
N6
5
4N
3
2
39 ± 5 N·m
AC806119AB
GROUP 13
FUEL
CONTENTS
GROUP 13A
DIESEL FUEL
CONTENTS
CODE NO. P0653 ANALOG SENSOR REFERENCE SENSOR (MAIN) CIRCUIT HIGH INPUT . . 13A-341
VOLTAGE NO.2 TOO HIGH . . . . . . . . . . . . 13A-291 CODE NO. P2124 ACCELERATOR PEDAL POSITION
CODE NO. P0683 GLOW CONTROL UNIT SENSOR (MAIN) CIRCUIT HIGH INPUT
COMMUNICATION ABNORMALITY <Euro5> INTERMITTENT . . . . . . . . . . . . . . . . . . . . . 13A-345
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-292 CODE NO. P2127 ACCELERATOR PEDAL POSITION
CODE NO. P1203 CAPACITOR INSUFFICIENT SENSOR (SUB) CIRCUIT LOW INPUT . . . 13A-349
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2128 ACCELERATOR PEDAL POSITION
CODE NO. P1204 CAPACITOR EXCESSIVE SENSOR (SUB) CIRCUIT HIGH INPUT . . . 13A-357
CHARGING. . . . . . . . . . . . . . . . . . . . . . . . . 13A-296 CODE NO. P2138 ACCELERATOR PEDAL POSITION
CODE NO. P1272 PRESSURE LIMITER SENSOR (MAIN AND SUB) RANGE/PERFORMANCE
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . 13A-297 PROBLEM . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-360
CODE NO. P1273 SUPPLY PUMP INSUFFICIENT CODE NO. P2146 INJECTOR COMMON 1
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-300 (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
CODE NO. P1274 SUPPLY PUMP PROTECTION <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-368
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-301 CODE NO. P2146 INJECTOR COMMON 1
CODE NO. P1275 SUPPLY PUMP EXCHANGE (CYLINDER NO.1 AND NO.4) CIRCUIT OPEN
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-302 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-371
CODE NO. P1276 FUEL FILTER EXCHANGE CODE NO. P2147 INJECTOR COMMON 1
<Vehicles with fuel filter pressure switch> . 13A-304 (CYLINDER NO. 1 AND NO. 4) CIRCUIT EARTH
SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-374
CODE NO. P1277 FUEL FILTER FREEZE <Vehicles
with fuel filter pressure switch> . . . . . . . . . . 13A-307 CODE NO. P2147 INJECTOR COMMON CIRCUIT
GND SHORT <Except Euro5> . . . . . . . . . . 13A-378
CODE NO. P1298 VARIABLE GEOMETRY
TURBOCHARGER CONTROL SYSTEM CODE NO. P2148 INJECTOR COMMON 1
MALFUNCTION (HIGH PRESSURE) <Euro5> (CYLINDER NO. 1 AND NO. 4) CIRCUIT BATTERY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 SHORT <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-383
CODE NO. P1299 VARIABLE GEOMETRY CODE NO. P2148 INJECTOR COMMON CIRCUIT
TURBOCHARGER CONTROL SYSTEM BATTERY SHORT <Except Euro5> . . . . . . 13A-387
MALFUNCTION (LOW PRESSURE) <Euro5> CODE NO. P2149 INJECTOR COMMON 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-308 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1427 NO. 3 EXHAUST GAS <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-392
TEMPERATURE SENSOR CIRCUIT LOW INPUT CODE NO. P2149 INJECTOR COMMON 2
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-310 (CYLINDER NO.2 AND NO.3) CIRCUIT OPEN
CODE NO. P1428 NO. 3 EXHAUST GAS <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-396
TEMPERATURE SENSOR CIRCUIT HIGH INPUT CODE NO. P2150 INJECTOR COMMON 2(CYLINDER
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-313 NO. 2 AND NO. 3) CIRCUIT EARTH SHORT <Euro5>
CODE NO. P1497 DPF SYSTEM MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-399
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-319 CODE NO. P2151 INJECTOR COMMON 2(CYLINDER
CODE NO. P1498 EXCESSIVE PM ACCUMULATED NO. 2 AND NO. 3) CIRCUIT BATTERY SHORT
IN DPF <Euro5> . . . . . . . . . . . . . . . . . . . . . 13A-320 <Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-403
CODE NO. P1499 ABNORMALLY HIGH DPF CODE NO. P2228 BAROMETRIC PRESSURE
TEMPERATURE <Euro5> . . . . . . . . . . . . . 13A-320 SENSOR CIRCUIT LOW INPUT . . . . . . . . . 13A-406
CODE NO. P1608 BATTERY CURRENT SENSOR CODE NO. P2229 BAROMETRIC PRESSURE
SYSTEM <Euro5>. . . . . . . . . . . . . . . . . . . . 13A-322 SENSOR CIRCUIT HIGH INPUT . . . . . . . . 13A-407
CODE NO. P1625 INJECTION QUANTITY CODE NO. P2413 EGR SYSTEM PERFORMANCE
COMPENSATION VALUE ERROR . . . . . . 13A-327 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-408
CODE NO. P1626 INJECTION QUANTITY CODE NO. P2454 EXHAUST DIFFERENTIAL
COMPENSATION VALUE ERROR NOT CODING PRESSURE SENSOR CIRCUIT LOW INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-328 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-411
CODE NO. P2118 THROTTLE VALVE CONTROL DC CODE NO. P2455 EXHAUST DIFFERENTIAL
MOTOR CURRENT MALFUNCTION . . . . . 13A-329 PRESSURE SENSOR CIRCUIT HIGH INPUT <Euro5>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-417
CODE NO. P2122 ACCELERATOR PEDAL POSITION
SENSOR (MAIN) CIRCUIT LOW INPUT . . 13A-333 CODE NO. P252F ENGINE OIL LEVEL
MALFUNCTION <Euro5> . . . . . . . . . . . . . . 13A-419
CODE NO. P2123 ACCELERATOR PEDAL POSITION
13A-4
CODE NO. U1073 BUS OFF . . . . . . . . . . . 13A-420 4LLC SWITCH SYSTEM <M/T-High power engine
CODE NO. U1101 A/T-ECU TIME-OUT <A/T> vehicle> . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-505
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-421 CONDENSER FAN RELAY SYSTEM <Vehicles with A/
CODE NO. U1102 ASTC-ECU TIME-OUT <Except C condenser fan> . . . . . . . . . . . . . . . . . . . . 13A-507
vehicles for Morocco> . . . . . . . . . . . . . . . . . 13A-422 A/C SWITCH SYSTEM . . . . . . . . . . . . . . . . 13A-509
CODE NO. U1109 ETACS TIME-OUT . . . . 13A-424 A/C COMPRESSOR RELAY SYSTEM . . . . 13A-512
CODE NO. U1110 A/C-ECU TIME-OUT <Euro5> POWER STEERING FLUID PRESSURE SWITCH
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-425 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-514
CODE NO. U1117 ETACS-ECU (IMMOBILIZER-ECU) GLOW SYSTEM <Except Euro5> . . . . . . . . 13A-520
TIME-OUT. . . . . . . . . . . . . . . . . . . . . . . . . . 13A-427 PTC HEATER RELAY SYSTEM . . . . . . . . . 13A-525
CODE NO. U1190 THE NETWORK SYSTEM BLOWER SWITCH SYSTEM <Euro5> . . . . 13A-528
DIAGNOSIS CODE OUTPUT PERMITTED SIGNAL
REAR WINDOW DEFOGGER SYSTEM <Euro5>
CANNOT BE RECEIVED . . . . . . . . . . . . . . 13A-428
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-533
SYMPTOM CHART. . . . . . . . . . . . . . . . . . . 13A-429
DPF LAMP SYSTEM <Euro5> . . . . . . . . . . 13A-537
CHECK CHART CLASSIFIED BY PROBLEM
DATA LIST REFERENCE TABLE . . . . . . . . 13A-542
SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . 13A-432
ACTUATOR TEST REFERENCE TABLE . . 13A-574
SYMPTOM PROCEDURES . . . . . . . . . . . . 13A-433
CHECK AT THE ENGINE-ECU TERMINALS
COMMUNICATION WITH ENGINE-ECU IS NOT
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-576
POSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . 13A-433
INSPECTION PROCEDURE USING AN
THE ENGINE WARNING LAMP DOES NOT
OSCILLOSCOPE . . . . . . . . . . . . . . . . . . . . 13A-586
ILLUMINATE RIGHT AFTER THE IGNITION SWITCH
IS TURNED TO THE "ON" POSITION . . . . 13A-438
THE ENGINE WARNING LAMP REMAINS ON-VEHICLE SERVICE . . . . . . . . . . . 13A-589
ILLUMINATING AND NEVER GOES OUT OR IS EVACUATION OF WATER FROM FUEL FILTER
BLINKING . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
STARTING IMPOSSIBLE (NO INITIAL FUEL LINE AIR-BLEEDING . . . . . . . . . . . . 13A-589
COMBUSTION) <M/T> . . . . . . . . . . . . . . . . 13A-445 FUEL FILTER CARTRIDGE REPLACEMENT
STARTING IMPOSSIBLE (NO INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-589
COMBUSTION) <A/T> . . . . . . . . . . . . . . . . 13A-453 FUEL LINE LEAK CHECK. . . . . . . . . . . . . . 13A-590
STARTING IMPOSSIBLE (STARTER OPERATIVE COMPONENT LOCATION . . . . . . . . . . . . . 13A-591
BUT NO INITIAL COMBUSTION). . . . . . . . 13A-462
ENGINE CONTROL RELAY CONTINUITY CHECK
IMPROPER STARTING (LONG TIME TO START) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-464
ENGINE COOLANT TEMPERATURE SENSOR
IMPROPER IDLING . . . . . . . . . . . . . . . . . . 13A-466 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-594
THE ENGINE STALLS WHEN DECELERATING INJECTOR CHECK . . . . . . . . . . . . . . . . . . . 13A-595
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-468
INTAKE AIR TEMPERATURE SENSOR NO.1 CHECK
POOR ACCELERATION. . . . . . . . . . . . . . . 13A-471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-595
A LARGE AMOUNT OF FUEL CONSUMPTION INTAKE AIR TEMPERATURE SENSOR NO.2 CHECK
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-473 <Except Euro5> . . . . . . . . . . . . . . . . . . . . . . 13A-595
KNOCKING, ABNORMAL NOISE. . . . . . . . 13A-475 SUCTION CONTROL VALVE CHECK . . . . 13A-596
WHITE SMOKE. . . . . . . . . . . . . . . . . . . . . . 13A-477 FUEL TEMPERATURE SENSOR CHECK . 13A-596
BLACK SMOKE . . . . . . . . . . . . . . . . . . . . . 13A-479 COMMON RAIL CHECK . . . . . . . . . . . . . . . 13A-596
BATTERY RUNDOWN <Euro5>. . . . . . . . . 13A-481 THROTTLE VALVE CONTROL SERVO CHECK
BATTERY RUNDOWN <Except Euro5>. . . 13A-486 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-596
OVERHEATING . . . . . . . . . . . . . . . . . . . . . 13A-487
ENGINE-ECU POWER SUPPLY SYSTEM 13A-488 FUEL INJECTOR . . . . . . . . . . . . . . . . 13A-598
ENGINE-ECU BATTERY BACK-UP SYSTEM FUEL INJECTOR REMOVAL AND INSTALLATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-493 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-598
1ST AND 2ND RAIL SWITCH SYSTEM <M/T>
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13A-497 COMMON RAIL AND SUPPLY PUMP13A-604
BACK-UP LAMP SWITCH SYSTEM <M/T> 13A-501 COMMON RAIL AND SUPPLY PUMP REMOVAL AND
13A-5
GENERAL INFORMATION
M1133000101089
The common rail fuel injection system consists of ECU. The engine-ECU carries out activities such as
sensors which detect the condition of the diesel fuel injection control and idle speed control. In addi-
engine, an engine electronic control unit (engine- tion, the engine-ECU is equipped with several self-
ECU) which controls the system based on signals diagnosis functions which make troubleshooting eas-
from these sensors, and actuators which operate ier in the event that a problem develops.
according to control commands from the engine-
FUEL INJECTION CONTROL
The injector drive time, the injection timing and the
fuel pressure are controlled so that the appropriate
quantities of fuel are supplied to the engine in
response to engine conditions which can change fre-
quently. A single injector is mounted at each cylinder.
The supply pump increases the fuel pressure to the
pressure which is required for high-pressure injec-
tion, and then send the fuel each injector.
SELF-DIAGNOSIS FUNCTION
• When an abnormality is detected in any of the • The RAM data relating to the sensors and actua-
sensors or actuators, the engine warning lamp tors which is stored in the engine-ECU can be
illuminates to warn the driver. read using the M.U.T.-III. In addition, the actuator
• When an abnormality is detected in any of the can be force-driven under certain conditions.
sensors or actuators, a diagnosis code number
corresponding to the problem which occurred is
output.
To fuel tank
5 Variable geometry 3 Camshaft
control solenoid valve position Supply
sensor pump
3 Injector
Variable geometry
actuator 9 Fuel
temperature
sensor
4 Engine coolant
temperature sensor 1 Suction control
valve
Catalytic 2 Crank angle sensor
converter
12
No. 1 exhaust
gas temperature Catalytic From fuel
sensor DPF
converter 15 Exhaust differential pressure sensor Fuel filter tank
13
No. 2 exhaust gas 14 No. 3 exhaust gas temperature sensor
temperature sensor (catalyst temperature) (DPF temperature) AKB00240 AB
DIESEL FUEL
GENERAL INFORMATION
13A-9
<Except Euro5>
1 Air flow sensor Accelerator pedal Engine- 1 Suction control Engine control relay
position sensor ECU valve
2 Crank angle sensor (main) A/C relay
3 Camshaft position Barometric 2 Throttle valve Glow plug relay
Accelerator pedal pressure control servo
sensor position sensor PTC heater relay
sensor (DC motor)
4 Engine coolant (sub) <Vehicles with PTC
temperature sensor Power steering fluid 3 Injector heater>
5 Rail pressure sensor pressure switch 4 EGR valve Glow indicator lamp
6 Intake air temperature Vehicle speed (DC motor) Engine warning lamp
sensor No. 1 sensor Tachometer
7 Intake air temperature Power supply CAN communication
sensor No. 2 Ignition switch-IG (output signal)
8 Manifold absolute Ignition switch-ST
pressure sensor A/C switch
9 Fuel temperature A/C load signal
sensor Back-up switch
10 Throttle postion <M/T>
sensor 1st and 2nd rail
11 EGR valve position switch <M/T>
sensor PTC heater control
12 Fuel filter pressure signal <Vehicles
switch with PTC heater>
<Vehicles for Russia CAN
and Morocco> communication
(input signal)
To fuel tank
3 Camshaft
position
sensor Supply
pump
Turbocharger 3 Injector
9 Fuel
temperature
4 Engine coolant sensor
temperature sensor 1 Suction control
2 Crank angle sensor valve
Catalytic
Waste gate converter
actuator
12 Fuel filter pressure switch From fuel
<Vehicles for Russia and Morocco> Fuel filter tank
AKB00239AB
13A-10 DIESEL FUEL
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1133000300488
Items Specifications
Engine coolant temperature Engine coolant temperature at − 14 − 17
sensor resistance kΩ 20°C
Engine coolant temperature at 5.1 − 6.5
0°C
Engine coolant temperature at 2.1 − 2.7
20°C
Engine coolant temperature at 0.9 − 1.3
40°C
Engine coolant temperature at 0.48 − 0.68
60°C
Engine coolant temperature at 0.26 − 0.36
80°C
Intake air temperature sensor Intake air temperature at −20°C 13 − 17
No.1 resistance kΩ Intake air temperature at 0°C 5.4 − 6.6
Intake air temperature at 20°C 2.3 − 3.0
Intake air temperature at 40°C 1.0 − 1.5
Intake air temperature at 60°C 0.56 − 0.76
Intake air temperature at 80°C 0.31 − 0.43
Intake air temperature sensor Intake air temperature at −20°C 13 − 18
No.2 resistance kΩ <Except Intake air temperature at 0°C 5.1 − 6.9
Euro5>
Intake air temperature at 20°C 2.0 − 3.0
Intake air temperature at 40°C 0.9 − 1.5
Intake air temperature at 60°C 0.40 − 0.78
Intake air temperature at 80°C 0.23 − 0.42
Injector coil resistance Ω (at 20°C) Approximately 0.45
Suction control valve resistance Ω (at 20°C) Approximately 2.1
Fuel temperature resistance kΩ (at 20°C) 2.0 − 3.0
Throttle valve control servo resistance (at 20°C) Ω 0.3 − 100
SEALANTS
M1133000500385
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
MB992042
MB990784
MB991614
B992048
B992098
B992099
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1133003700430
Refer to , GROUP 00 − How to Use Troubleshooting/ shooting.
Inspection Service Points − Contents of Trouble-
DIESEL FUEL
TROUBLESHOOTING
13A-13
WARNING DIAGNOSIS FUNCTION
M1133003800954
A high-tension voltage is flowing between
the engine-ECU and the injectors while the ENGINE WARNING LAMP (CHECK
engine is running. Handle them carefully to ENGINE LAMP)
avoid receiving electric shocks from the volt-
age.
CAUTION
After replacing the engine-ECU, register the Engine warning lamp
injector identification code and learn fuel injec-
20engine lamp)
(Check
METHOD OF READING AND ERASING 2. After repairing, re-check using the M.U.T.-III and
DIAGNOSIS CODES check that the abnormal input and output have
Refer to , GROUP 00 − How to Use Troubleshooting/ returned to normal as a result of the repairs.
Inspection Service Points − How to Cope with Inter- 3. Erase the diagnosis code memory.
mittent Malfunctions. 4. Remove the M.U.T.-III, and then start the engine
again and carry out a road test to confirm that the
INSPECTION USING M.U.T.-III DATA LIST problem has disappeared.
AND ACTUATOR TESTING
1. Carry out inspection by means of the data list and
the actuator test function, if there is an
abnormality, check and repair the chassis harness
and components.
DIESEL FUEL
TROUBLESHOOTING
13A-17
PROVISIONAL DIAGNOSIS CODE CON- 2. Turn the ignition switch to the "ON" position.
FIRMED 3. Select "MPI/GDI/DIESEL" from System select
If detecting the malfunction during the first drive Screen of the M.U.T.-III.
cycle, the engine-ECU temporarily stores the diagno- 4. Select "Special Function" from MPI/GDI/DIESEL
sis code as the provisional diagnosis code. If detect- Screen.
ing the same malfunction during the next drive cycle, 5. Select "Provisional DTCs" from Special Function
the engine-ECU determines that the malfunction Screen.
exists. The engine-ECU outputs the diagnosis code.
On the M.U.T.-III it is possible to display the stored FREEZE FRAME DATA
provisional diagnosis code which the engine-ECU When the engine-ECU detects a malfunction and
had detected during the first drive cycle. This makes stores a diagnosis code, it also stores a current sta-
it possible to confirm in one drive cycle whether the tus of the engine. This function is called "Freeze
malfunction could happen again after the repair. frame data". By analyzing this "Freeze frame" data
CONFIRMATION METHOD with the M.U.T.-III, an effective troubleshooting can
1. After the ignition switch is in "LOCK" (OFF) be performed.
position, connect the M.U.T.-III to the diagnosis The display items of freeze frame data are shown
connector. below.
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
AK503644 AB
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 Harness side connector AKA00090 AB
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-47 (GR)
AK503644 AB
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
OPERATION ECU.
• The voltage is applied from the engine-ECU (ter- • The voltage is earthed to the engine-ECU (termi-
minal No. 131) to the suction control valve (termi- nal No. 146) from the suction control valve (termi-
nal No. 1) via the power transistor in the engine- nal No. 2).
DIESEL FUEL
TROUBLESHOOTING
13A-29
FUNCTION YES : Go to Step 2.
• The engine-ECU performs duty control over the NO : Repair or replace the connector.
suction control valve.
• The engine-ECU checks whether the amount of STEP 2. Check suction control valve itself.
current for driving duty is adequate. • Check suction control valve itself (Refer to P.13A-
596).
TROUBLE JUDGMENT
Q: Is the check result normal?
Check Conditions YES : Go to Step 3.
• Battery positive voltage is 8 − 16 V NO : Replace the suction control valve.
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up
• The supply pump and injector are being normally STEP 3. Connector check: C-103 engine-ECU
controlled. connector
• The fuel injection rate is 4 mm3/st or more. Connector: C-103
<L.H. drive vehicles>
Judgment Criterion
• When the driving duty ratio of the suction control
valve is lower than the specified value, the driving
current is higher than the specified value.
PROBABLE CAUSES
• Failed suction control valve C-103 (B)
• Short circuit in suction control valve circuit or
loose connector contact <R.H. drive vehicles>
• Failed engine-ECU
DIAGNOSIS PROCEDURE
117 116
Harness side 143 142 141 140 139138 137 136 135 134 133 132 131
connector 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5. YES : Go to Step 6.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P0016: Crank Angle Sensor/Camshaft Position Sensor Phase Problem
Code No. P0047: Variable Geometry Control Solenoid Valve Circuit Low Input <Euro5>
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00128 AD
2 1
STEP 2. Connector check: A-56 variable
Harness side
geometry control solenoid valve connector connector AK900982AC
Connector: A-56
• Disconnect connector, and measure at harness
side.
A-56 (BR)
• Ignition switch: ON
• Voltage between terminal No. 2 and earth.
OK: System voltage
Q: Is the check result normal?
2 1 YES : Go to Step 6 .
Harness side NO : Go to Step 5 .
connector AK900982AC
A-20X
2 1
3
4 C-105 (B)
Relay box's side
connector AK501321 AC
<R.H. drive vehicles>
Connector: A-56
A-56 (BR)
C-105 (B)
2 1
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Harness side
connector AK900982AC 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
<R.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-56
C-105 (B)
A-56 (BR)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-56 (BR)
2 1
Harness side
connector AK900982AC
2 1
Connector: C-105
<L.H. drive vehicles> Harness side
connector AK900982AC
Connector: A-20X
A-20X
C-105 (B)
2 1
3
<R.H. drive vehicles> 4
Relay box's side
connector AK501321 AC
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
STEP 11. M.U.T.-III actuator test
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 • Item 36: Variable geometry control solenoid valve
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
OK: The variable geometry actuator is oper-
Harness side connector AKA00089 AB ated
• Check output line for damage. Q: Is the check result normal?
Q: Is the check result normal?
13A-38 DIESEL FUEL
TROUBLESHOOTING
Code No. P0048: Variable Geometry Control Solenoid Valve Circuit High Input <Euro5>
Fusible link 23
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B
A-20X 4 1
1 2
3 Engine control relay
4 OFF ON
3 2
To engine-ECU
R
2
A-56
Variable geometry
1 2 control solenoid valve
W-R
C-105 17
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00128 AD
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0072: Intake Air Temperature Sensor No. 1 Circuit Low Input <Euro5>
1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00356 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
C-105 (B) Diesel Particulate Filter (DPF) System −
Forcible DPF Regeneration ).
<R.H. drive vehicles>
STEP 8. Perform resistance measurement at A-
135 air flow sensor connector.
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit. • Disconnect connector, and measure at harness
Q: Is the check result normal? side.
YES : Go to Step 7 . • Resistance between terminal No. 1 and earth.
NO : Repair the damaged harness wire. OK: Continuity (2 Ω or less)
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-45
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-135 (terminal
connector No. 1) air flow sensor connector and C-105
Connector: C-105
(terminal No. 86) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line for damage.
Connector: A-135
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 11. Connector check: C-105 engine-ECU STEP 12. Check harness between A-135 (terminal
connector No. 2) air flow sensor connector and C-105
Connector: C-105
(terminal No. 62) engine-ECU connector.
<L.H. drive vehicles> Connector: A-135
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0072: Intake Air Temperature Sensor No. 2 Circuit Low Input <Except Euro5>
A-136
(MU802409)
Intake air temperature
sensor No. 2
1 2
2 1
B-P L-R
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00091 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-136 (B)
2 1
C-105 (B) Harness side
connector AK501317 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 2 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-136 (terminal
connector No. 2) intake air temperature sensor No. 2
Connector: C-105
connector and C-105 (terminal No. 32) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-136
A-136 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AK501317 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-136 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AK501317 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0073: Intake Air Temperature Sensor No. 1 Circuit High Input <Euro5>
1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00356 AB
C-105 (B)
STEP 3. Check intake air temperature sensor No.
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
(Refer to P.13A-595).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace the air flow sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
C-105 (B) Diesel Particulate Filter (DPF) System −
Forcible DPF Regeneration ).
<R.H. drive vehicles>
STEP 8. Perform resistance measurement at A-
135 air flow sensor connector.
Connector: A-135
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for open circuit. • Disconnect connector, and measure at harness
Q: Is the check result normal? side.
YES : Go to Step 7 . • Resistance between terminal No. 1 and earth.
NO : Repair the damaged harness wire. OK: Continuity (2 Ω or less)
Q: Is the check result normal?
YES : Go to Step 7 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-55
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-135 (terminal
connector No. 1) air flow sensor connector and C-105
Connector: C-105
(terminal No. 86) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line open circuit and damage.
Connector: A-135
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0073: Intake Air Temperature Sensor No. 2 Circuit High Input <Except Euro5>
A-136
(MU802409)
Intake air temperature
sensor No. 2
1 2
2 1
B-P L-R
C-105 32 38
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00091 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-136 (terminal STEP 7. M.U.T.-III data list
No. 1) intake air temperature sensor No. 2 • Item 8: Intake air temperature sensor No. 2
connector and C-105 (terminal No. 38) engine- OK: At ambient temperature (atmospheric
ECU connector. temperature) or equivalent.
Connector: A-136 Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
A-136 (B) Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
2 1 (Refer to GROUP 00 − Precautions Before
Harness side Service − How to Perform Chassis Number
connector AK501317 AB Writing ). After replacing the engine-ECU,
register the injector identification code and
Connector: C-105
<L.H. drive vehicles> learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
A-136 (B)
2 1
C-105 (B) Harness side
connector AK501317 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 2 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-136 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AK501317 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Based on The input signals, the engine-ECU STEP 3. Connector check: C-105 engine-ECU
checks whether the fuel pressure in the common connector and A-47 suction control valve
rail exceeds the maximum withstand pressure of connector.
the system.
Connector: C-105
TROUBLE JUDGMENT <L.H. drive vehicles>
Check Conditions
• Rail pressure sensor is normal
• Battery positive voltage is 8 − 16 V
Judgment Criterion
• The rail pressure exceeds the threshold value of C-105 (B)
an abnormal high pressure for 3 seconds (contin-
uous or accumulated).
<R.H. drive vehicles>
PROBABLE CAUSES
• Failed suction control valve
• Failed rail pressure sensor
• Failed engine-ECU
DIAGNOSIS PROCEDURE
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK503644 AB AK503644 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-62 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Perform output wave pattern STEP 7. Replace the common rail assembly and
measurement at A-47 suction control valve fuel injection tubes.
(Using an oscilloscope). • After replacing the common rail assembly and
fuel injection tubes, re-check the trouble symp-
Connector: A-47
2 1
toms
Harness side
Q: Does trouble symptom persist?
connector YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
A-47 (GR) (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
AK503644 AB learn fuel injection (Refer to GROUP 00 −
• Engine: Idling Precautions Before Service − What The
• Connect the oscilloscope special patterns pickup Common Rail Engine Learns ). After
to engine-ECU terminal No. 146 and earth. registering the injector identification code,
the vehicle equipped with the DPF carries
OK: The waveform should show a pattern out the forcible DPF regeneration. (Refer to
similar to the illustration of inspection proce- GROUP 17 − Emission Control − Diesel
dure using an oscilloscope (Refer to P.13A- Particulate Filter (DPF) System − Forcible
586). DPF Regeneration ).
Q: Is the check result normal? NO : The check is end.
YES : Go to Step 7 .
NO : Replace the suction control valve. After
replacing the suction control valve, learn the
supply pump (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
• Failed rail pressure sensor. STEP 4. Connector check: A-44 rail pressure
• Harness damage in rail pressure sensor circuit or sensor connector and C-105 engine-ECU
loose connector contact. connector.
• Failed engine-ECU
Connector: A-44
DIAGNOSTIC PROCEDURE
C-105 (B)
STEP 3. Release the air from the fuel line.
• After releasing the air from the fuel line, continue
idle operation for about five minutes and recheck <R.H. drive vehicles>
for trouble symptoms.
Q: Does the trouble symptom persist?
YES : Go to Step 4 .
NO : The check is end.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1 3 2 1
A-44 (B) A-44 (B)
Harness side Harness side
connector AK501327 AB connector AK501327 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-131, and repair if necessary. connector A-131, and repair if necessary.
• Check power supply line for damage. • Check output line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-66 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 8 .
STEP 7. Check harness between A-44 (terminal
NO : Repair the damaged harness wire.
No. 3) rail pressure sensor connector and C-105
(terminal No. 88) engine-ECU connector.
STEP 8. Detection of fuel leakage from injector
Connector: A-44
body
• Remove the injector. Check whether there is the
evidence of the fuel leakage from the injector
body.
Q: Is the check result normal?
YES : Go to Step 9 .
3 2 1 NO : Replace the abnormal injector. After
A-44 (B) replacing the injector, register the injector
Harness side
connector AK501327 AB identification code and learn fuel injection.
(Refer to GROUP 00 − Precautions Before
Connector: C-105 Service − What The Common Rail Engine
<L.H. drive vehicles>
Learns ).
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
AKA00355 AB
TROUBLE JUDGMENT
Check Conditions
• Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
Harness side A-135 (B)
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 0.50 V or
• Disconnect connector, and measure at harness
less.
side.
PROBABLE CAUSES • Ignition switch: ON
• Failed air flow sensor • Voltage between terminal No. 5 and earth.
• Open/short circuit or harness damage in air flow OK: System voltage
sensor circuit or loose connector contact Q: Is the check result normal?
• Failed engine-ECU YES : Go to Step 5 .
NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 4. Connector check: A-20X engine control
STEP 1. M.U.T.-III data list relay connector
• Refer to Data List Reference Table P.13A-542.
Connector: A-20X
a. Item 114: Air flow sensor
Q: Is the check result normal? A-20X
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope 2 1
with Intermittent Malfunctions ). 3
NO : Go to Step 2 . 4
Relay box's side
connector
STEP 2. Connector check: A-135 air flow sensor AK501321 AC
• Disconnect connector, and measure at harness 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
side. 117 116
• Resistance between terminal No. 4 and earth. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 7. Check harness between A-135 (terminal STEP 8. M.U.T.-III data list
No. 4) air flow sensor connector and C-103 Connector: A-135
(terminal No. 155) engine-ECU connector.
Connector: A-135
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 Harness side connector AKA00090 AB
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 11. Check harness between A-135 (terminal STEP 12. Perform voltage measurement at C-103
No. 3) air flow sensor connector and C-103 engine-ECU connector.
(terminal No. 140) engine-ECU connector. Connector: C-103
Connector: A-135 <L.H. drive vehicles>
C-103 (B)
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
<R.H. drive vehicles>
Harness side connector AKA00090 AB
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Harness side A-135 (B)
connector AKA00399AB
Harness side connector AKA00090 AB • Measure engine-ECU terminal voltage.
• Check output line for short circuit. • Disconnect A-135 air flow sensor connector.
Q: Is the check result normal?
• Ignition switch: ON
YES : Replace the air flow sensor. • Voltage between terminal No. 140 and earth.
NO : Repair the damaged harness wire. OK: 4.9 − 5.1 V
Q: Is the check result normal?
YES : Go to Step 14 .
NO : Go to Step 13 .
DIESEL FUEL
TROUBLESHOOTING
13A-73
YES : Check and repair harness between A-135
STEP 13. Connector check: C-103 engine-ECU
(terminal No. 3) air-flow sensor connector
connector
and C-103 (terminal No. 140) engine-ECU
Connector: C-103 connector.
<L.H. drive vehicles> • Check output line for open circuit.
NO : Repair or replace the connector.
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: A-135
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Fusible link 23
W-R
10 Relay
box
20A
W-B A-115
3
W-B W-B
4 1
A-20X
1 2 Engine
3 OFF control
ON relay
4
3 2
R To engine-ECU
A-135
1 2 3 4 5 Heat
sensitizing Air flow sensor
resistance
3 4
W-R BR-B
C-103 140 155
AKA00355 AB
TROUBLE JUDGMENT
Check Conditions
• Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been
in "ON" position or the engine has started up.
Harness side A-135 (B)
Judgment Criterion connector AKA00399AB
• The air flow sensor output voltage is 4.72 V or
• Disconnect connector, and measure at harness
more.
side.
PROBABLE CAUSES • Resistance between terminal No. 4 and earth.
• Failed air flow sensor OK: Continuity (2 Ω or less)
• Open circuit in air flow sensor circuit or loose Q: Is the check result normal?
connector contact YES : Go to Step 7 .
• Failed engine-ECU NO : Go to Step 4 .
DIAGNOSIS PROCEDURE
STEP 4. Connector check: C-103 engine-ECU
connector
STEP 1. M.U.T.-III data list Connector: C-103
• Refer to Data List Reference Table P.13A-542. <L.H. drive vehicles>
a. Item 114: Air flow sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ). C-103 (B)
NO : Go to Step 2 .
<R.H. drive vehicles>
STEP 2. Connector check: A-135 air flow sensor
connector
Connector: A-135
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side A-135 (B)
connector AKA00399AB Harness side connector AKA00090 AB
YES : Go to Step 6 .
STEP 5. Check harness between A-135 (terminal
NO : Repair the damaged harness wire.
No. 4) air flow sensor connector and C-103
(terminal No. 155) engine-ECU connector.
STEP 6. M.U.T.-III data list
Connector: A-135
• Refer to Data List Reference Table P.13A-542.
a. Item 114: Air flow sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
Harness side NO : Replace the engine-ECU. When the engine-
A-135 (B)
connector AKA00399AB ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Connector: C-103 Service − How to Perform Chassis Number
<L.H. drive vehicles>
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
C-103 (B) the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
<R.H. drive vehicles> GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
117 116
00 − How to Use Troubleshooting/
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
Harness side connector AKA00090 AB NO : Replace the air flow sensor.
• Check earthing line for open circuit.
Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-77
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AK900797 AB
AK900797 AB
Q: Is the check result normal?
• Use special tool test harness (MB991709) to con- YES : Check and repair harness between A-105
nect connector, and measure at pick-up harness. (terminal No. 1) manifold absolute pressure
• Ignition switch: ON sensor connector and C-105 (terminal No.
• Voltage between terminal No. 1 and earth. 72) engine-ECU connector.
OK: 4.9 − 5.1 V • Check power supply line for damage.
Q: Is the check result normal? NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-79
STEP 5. Perform voltage measurement at A-105 STEP 6. Connector check: C-105 engine-ECU
manifold absolute pressure sensor connector. connector
Connector: A-105 Connector: C-105
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
<R.H. drive vehicles>
• Use special tool harness (MB991709) to connect
connector, and measure at pick-up harness.
• Ignition switch: ON
• Voltage between terminal No. 3 and earth.
OK: 0.5 V or less
Q: Is the check result normal? C-105 (B)
YES : Go to Step 7.
NO : Go to Step 6. 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
STEP 7. Perform voltage measurement at A-105 STEP 8. Perform voltage measurement at C-105
manifold absolute pressure sensor connector. engine-ECU connector.
Connector: A-105 Connector: C-105
3 2 1 <L.H. drive vehicles>
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
<R.H. drive vehicles>
• Use special tool harness (MB991709) to connect
connector, and measure at pick-up harness.
• Ignition switch: ON
• Voltage between terminal No. 2 and earth.
OK: The voltage should be 0.7 − 1.2 V. When
the accelerator pedal is quickly depressed
from the idling state, the voltage temporarily C-105 (B)
rises.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
YES : Go to Step 8. 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
Code No. P0107: Manifold Absolute Pressure Sensor Circuit Low Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AK900797 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector. <R.H. drive vehicles>
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-105 (terminal
connector No. 1) manifold absolute pressure sensor
Connector: C-105
connector and C-105 (terminal No. 72) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
C-105 (B)
AK900797 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 11 .
STEP 9. Perform resistance measurement at A-
NO : Repair or replace the connector.
105 manifold absolute pressure sensor
connector.
STEP 11. Check harness between A-105 (terminal
Connector: A-105
3 2 1 No. 3) manifold absolute pressure sensor
Harness side connector and C-105 (terminal No. 31) engine-
A-105 (L) connector ECU connector.
Connector: A-105
3 2 1
Harness side
A-105 (L) connector
AK900797 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK900797 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 15. Perform voltage measurement at C-105 STEP 16. Connector check: C-105 engine-ECU
engine-ECU connector. connector
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK900797 AB
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0108: Manifold Absolute Pressure Sensor Circuit High Input
A-105 Manifold
absolute
1 2 3 pressure
sensor
3 2 1
LG-B G-L GR
C-105 31 37 72
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AK900797 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector. <R.H. drive vehicles>
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 6 .
STEP 5. Check harness between A-105 (terminal
NO : Repair the damaged harness wire.
No. 3) manifold absolute pressure sensor
connector and C-105 (terminal No. 31) engine-
ECU connector. STEP 6. M.U.T.-III data list
• Refer to Data List Reference Table P.13A-542.
Connector: A-105
3 2 1 a. Item 6: Manifold absolute pressure sensor
Harness side Q: Is the check result normal?
A-105 (L) connector
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
AK900797 AB (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Connector: C-105 Writing ). After replacing the engine-ECU,
<L.H. drive vehicles>
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
C-105 (B) out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
<R.H. drive vehicles>
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
Code No. P0112: EGR Gas Temperature Sensor Circuit Low Input <Euro5>
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKB00262 AB
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
• Ignition switch: ON
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-157 (terminal
connector No. 1) EGR gas temperature sensor connector
Connector: C-105
and C-105 (terminal No. 30) engine-ECU
<L.H. drive vehicles> connector.
Connector: A-157
A-157 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AKB00263 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-157 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AKB00263 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0112: Intake Air Temperature Sensor No. 1 Circuit Low Input <Except Euro5>
1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00356 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 1 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 11. Connector check: C-105 engine-ECU STEP 12. Check harness between A-135 (terminal
connector No. 2) air flow sensor connector and C-105
Connector: C-105
(terminal No. 62) engine-ECU connector.
<L.H. drive vehicles> Connector: A-135
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0113: EGR Gas Temperature Sensor Circuit High Input <Euro5>
A-157
EGR gas temperature
sensor
1 2
1 2
B-P L-R
C-105 30 36
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKB00262 AB
STEP 2. Connector check: A-157 EGR gas • Disconnect connector, and measure at harness
temperature sensor connector side.
• Ignition switch: ON
Connector: A-157 • Voltage between terminal No. 2 and earth.
A-157 (B) OK: 4.5 − 4.9 V
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-157 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
Harness side
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector AKB00263 AB
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-157 (terminal
connector No. 1) EGR gas temperature sensor connector
Connector: C-105
and C-105 (terminal No. 30) engine-ECU
<L.H. drive vehicles> connector.
Connector: A-157
A-157 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AKB00263 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-157 (B)
C-105 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AKB00263 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0113: Intake Air Temperature Sensor No. 1 Circuit High Input <Except Euro5>
1 2
B-L Y-L
86 62
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00356 AB
C-105 (B)
STEP 3. Check intake air temperature sensor No.
1 itself.
• Check intake air temperature sensor No. 1 itself <R.H. drive vehicles>
(Refer to P.13A-595).
Q: Is the check result normal?
YES : Go to Step 4 .
NO : Replace the air flow sensor.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-135 (terminal STEP 7. M.U.T.-III data list
No. 2) air flow sensor connector and C-105 • Item 43: Intake air temperature sensor No. 1
(terminal No. 62) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-135 temperature) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
Harness side A-135 (B) (Refer to GROUP 00 − Precautions Before
connector AKA00399AB Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 • Disconnect connector, and measure at harness
side.
• Resistance between terminal No. 1 and earth.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0117: Engine Coolant Temperature Sensor Circuit Low Input
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00095 AB
PROBABLE CAUSES
• Failed engine coolant temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-113
• Short circuit or harness damage in engine cool- STEP 3. Perform resistance measurement at A-
ant temperature sensor circuit or loose connector 107 engine coolant temperature sensor
contact connector.
• Failed engine-ECU
Connector: A-107
DIAGNOSIS PROCEDURE
STEP 4. Perform voltage measurement at A-107 • Voltage between terminal No. 1 and earth.
engine coolant temperature sensor connector. OK: 4.5 − 4.9 V
Connector: A-107 Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
A-107 (B)
2 1
Harness side
connector AK501323 AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-107 (terminal
connector No. 1) engine coolant temperature sensor
Q: Is the check result normal?
connector and C-105 (terminal No. 63) engine-
ECU connector.
Connector: C-105
<L.H. drive vehicles> Connector: A-107
A-107 (B)
C-105 (B)
2 1
Harness side
<R.H. drive vehicles> connector AK501323 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
<R.H. drive vehicles>
Harness side connector AKA00089 AB
YES : Go to Step 6 .
NO : Repair or replace the connector.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 7 .
STEP 10. Check harness between A-107 (terminal
NO : Repair the damaged harness wire.
No. 2) engine coolant temperature sensor
connector and C-105 (terminal No. 87) engine-
ECU connector. STEP 11. Connector check: C-105 engine-ECU
connector
Connector: A-107
Connector: C-105
<L.H. drive vehicles>
A-107 (B)
2 1
Harness side C-105 (B)
connector AK501323 AB
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-107 (B)
2 1
Harness side
connector AK501323 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0118: Engine Coolant Temperature Sensor Circuit High Input
A-107
(MU802406) Engine coolant
temperature sensor
1 2
2 1
LG V
C-105 87 63
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00095 AB
PROBABLE CAUSES
• Failed engine coolant temperature sensor
• Open circuit in engine coolant temperature sen- sor circuit or loose connector contact
DIESEL FUEL
TROUBLESHOOTING
13A-119
• Failed engine-ECU STEP 3. Perform resistance measurement at A-
107 engine coolant temperature sensor
DIAGNOSIS PROCEDURE connector.
Connector: A-107
STEP 1. M.U.T.-III data list
• Item 7: Engine coolant temperature sensor
OK:
Engine cold state: At ambient temperature A-107 (B)
(atmospheric temperature) or equivalent.
Engine hot state: At 80 − 120°C
Q: Is the check result normal? 2 1
YES : Intermittent malfunction (Refer to GROUP Harness side
connector
00 − How to Use Troubleshooting/ AK501323 AB
Inspection Service Points − How to Cope • Disconnect connector, and measure at sensor
with Intermittent Malfunctions ). side.
NO : Go to Step 2 . • Resistance between terminal No. 1 and No. 2.
OK:
STEP 2. Connector check: A-107 engine coolant Engine coolant temperature at −20°C: 14 − 17
temperature sensor connector kΩ
Engine coolant temperature at 0°C: 5.1 − 6.5
Connector: A-107
kΩ
Engine coolant temperature at 20°C: 2.1 − 2.7
kΩ
Engine coolant temperature at 40°C: 0.9 − 1.3
A-107 (B)
kΩ
Engine coolant temperature at 60°C: 0.48 −
0.68 kΩ
2 1
Engine coolant temperature at 80°C: 0.26 −
Harness side 0.36 kΩ
connector AK501323 AB
Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 4 .
YES : Go to Step 3 . NO : Replace the engine coolant temperature
NO : Repair or replace the connector. sensor.
A-107 (B)
2 1
Harness side
connector AK501323 AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-107 (terminal
connector No. 1) engine coolant temperature sensor
Q: Is the check result normal?
connector and C-105 (terminal No. 63) engine-
ECU connector.
Connector: C-105
<L.H. drive vehicles> Connector: A-107
A-107 (B)
C-105 (B)
2 1
Harness side
<R.H. drive vehicles> connector AK501323 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
<R.H. drive vehicles>
Harness side connector AKA00089 AB
YES : Go to Step 6 .
NO : Repair or replace the connector.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-107 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 7 .
STEP 10. Check harness between A-107 (terminal
NO : Repair the damaged harness wire.
No. 2) engine coolant temperature sensor
connector and C-105 (terminal No. 87) engine-
ECU connector.
Connector: A-107
A-107 (B)
2 1
Harness side
connector AK501323 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-132
(MU805200) Hall IC
Electronic-controlled
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
13A-124 DIESEL FUEL
TROUBLESHOOTING
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
Connector: A-132 Connector: C-105
<L.H. drive vehicles>
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
connector AK604705 AB
<R.H. drive vehicles>
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-132 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 6 5 4 3 2 1
Harness side
Harness side connector AKA00089 AB connector AK604705 AB
• Check power supply line for open/short circuit. • Disconnect connector, and measure at harness
Q: Is the check result normal? side.
YES : Go to Step 6 . • Resistance between terminal No. 4 and earth.
NO : Repair the damaged harness wire. OK: Continuity (2 Ω or less)
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Go to Step 8 .
13A-126 DIESEL FUEL
TROUBLESHOOTING
STEP 8. Connector check: C-105 engine-ECU STEP 9. Check harness between A-132 (terminal
connector No. 4) electronic-controlled throttle valve
Connector: C-105
connector and C-105 (terminal No. 34) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-132
C-105 (B)
A-132 (B)
<R.H. drive vehicles> 6 5 4 3 2 1
Harness side
connector AK604705 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Harness side connector AKA00089 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
A-132 (B)
6 5 4 3 2 1
Harness side
connector AK604705 AB
STEP 13. Check harness between A-132 (terminal STEP 14. Check harness between A-132 (terminal
No. 1) electronic-controlled throttle valve No. 2) electronic-controlled throttle valve
connector and C-105 (terminal No. 40) engine- connector and C-105 (terminal No. 93) engine-
ECU connector. ECU connector.
Connector: A-132 Connector: A-132
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Check output line for short circuit. • Check power supply line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 14 . YES : Replace the electronic-controlled throttle
NO : Repair the damaged harness wire. valve.
NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-129
YES : Go to Step 6 .
STEP 15. Check harness between A-132 (terminal
NO : Repair the damaged harness wire.
No. 1) electronic-controlled throttle valve
connector and C-105 (terminal No. 40) engine-
ECU connector.
Connector: A-132
A-132 (B)
6 5 4 3 2 1
Harness side
connector AK604705 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-132
(MU805200) Hall IC
Electronic-controlled
throttle valve
1 2 3 4 5 6
2 1 4
W R B
B
93 40 34
Engine-ECU
5V
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00096 AB
OPERATION FUNCTION
• A power voltage of 5 V is applied to the elec- • The throttle position sensor converts the throttle
tronic-controlled throttle valve (terminal No. 2) valve position into voltage and inputs it into the
from the engine-ECU (terminal No. 93). engine-ECU.
• The power voltage is earthed to the engine-ECU • The engine-ECU control the throttle valve posi-
(terminal No. 34) from the electronic-controlled tion.
throttle valve (terminal No. 4).
• The sensor signal is inputted to the engine-ECU TROUBLE JUDGMENT
(terminal No. 40) from the electronic-controlled Check Conditions
throttle valve output terminal (terminal No. 1). • Battery positive voltage is 8 − 16 V
• 2 seconds later after the ignition switch has been in "ON" position or the engine has started up
DIESEL FUEL
TROUBLESHOOTING
13A-131
Judgment Criterion STEP 3. Perform resistance measurement at A-
• The throttle position sensor output voltage is 4.85 132 electronic-controlled throttle valve
V or more for 0.5 second. connector.
PROBABLE CAUSES Connector: A-132
• Failed throttle position sensor
• Open circuit or harness damage in throttle posi-
tion sensor circuit or loose connector contact
• Failed engine-ECU
STEP 2. Connector check: A-132 electronic- STEP 4. Connector check: C-105 engine-ECU
controlled throttle valve connector connector
Connector: A-132 Connector: C-105
<L.H. drive vehicles>
A-132 (B)
6 5 4 3 2 1 C-105 (B)
Harness side
connector AK604705 AB
<R.H. drive vehicles>
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector.
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 5. Check harness between A-132 (terminal STEP 6. M.U.T.-III data list
No. 4) electronic-controlled throttle valve • Refer to Data List Reference Table P.13A-542.
connector and C-105 (terminal No. 34) engine- a. Item 45: Throttle position sensor
ECU connector.
Q: Is the check result normal?
Connector: A-132 YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
A-132 (B)
(Refer to GROUP 00 − Precautions Before
6 5 4 3 2 1 Service − How to Perform Chassis Number
Harness side Writing ). After replacing the engine-ECU,
connector AK604705 AB register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Connector: C-105
<L.H. drive vehicles>
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
C-105 (B) DPF Regeneration ).
A-46
(MU802406)
Fuel temperature sensor
1 2
2 1
BR Y-B
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00097AB
A-46 (B)
STEP 5. Connector check: C-105 engine-ECU
2 1 connector
Harness side Connector: C-105
connector AK501326 AB <L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side connector AKA00089 AB
Harness side
• Check output line for short circuit. connector AK501326 AB
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-46 (terminal
connector No. 2) fuel temperature sensor connector and C-
Connector: C-105
105 (terminal No. 79) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line for damage.
Connector: A-46
C-105 (B)
A-46 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AK501326 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-46 (B)
C-105 (B)
2 1
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-46
(MU802406)
Fuel temperature sensor
1 2
2 1
BR Y-B
79 55
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 5V
AKA00097AB
A-46 (B)
STEP 5. Connector check: C-105 engine-ECU
2 1 connector
Harness side Connector: C-105
connector AK501326 AB <L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-46 (terminal STEP 7. M.U.T.-III data list
No. 1) fuel temperature sensor connector and C- • Item 21: Fuel temperature sensor
105 (terminal No. 55) engine-ECU connector. OK: At ambient temperature (fuel tempera-
Connector: A-46 ture) or equivalent.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
A-46 (B)
NO : Replace the engine-ECU. When the engine-
2 1 ECU is replaced, write the chassis number
Harness side (Refer to GROUP 00 − Precautions Before
connector AK501326 AB Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
Connector: C-105
<L.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
C-105 (B) GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
<R.H. drive vehicles> DPF Regeneration ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 A-46 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1
Harness side connector AKA00089 AB
Harness side
• Check output line for open circuit. connector AK501326 AB
C-105 (B)
A-46 (B)
2 1
<R.H. drive vehicles>
Harness side
connector AK501326 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
3 2 1
A-44 (B) Connector: C-105
Harness side <L.H. drive vehicles>
connector AK501327 AB
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
<R.H. drive vehicles>
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 5. Check harness between A-44 (terminal STEP 6. Check harness between A-44 (terminal
No. 1) rail pressure sensor connector and C-105 No. 2) rail pressure sensor connector and C-105
(terminal No. 70) engine-ECU connector. (terminal No. 64) engine-ECU connector.
Connector: A-44 Connector: A-44
3 2 1 3 2 1
A-44 (B) A-44 (B)
Harness side Harness side
connector AK501327 AB connector AK501327 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-131, and repair if necessary. connector A-131, and repair if necessary.
• Check power supply line for damage. • Check output line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6. YES : Go to Step 7.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-145
YES : Replace the engine-ECU. When the engine-
STEP 7. Perform voltage measurement at A-44
ECU is replaced, write the chassis number
rail pressure sensor connector.
(Refer to GROUP 00 − Precautions Before
Connector: A-44 Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
3 2 1 the vehicle equipped with the DPF carries
A-44 (B)
Harness side out the forcible DPF regeneration. (Refer to
connector AK501327 AB GROUP 17 − Emission Control − Diesel
• Use special tool test harness (MB991658) to con- Particulate Filter (DPF) System − Forcible
nect connector, and measure at pick-up harness. DPF Regeneration ).
• Engine: Idling (after warning up) NO : Replace the common rail assembly and fuel
• Voltage between terminal No. 2 and earth. injection tubes.
OK: 1.15 − 1.75 V
Q: Is the check result normal?
13A-146 DIESEL FUEL
TROUBLESHOOTING
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
C-105 (B)
STEP 2. Connector check: A-44 rail pressure
sensor connector
<R.H. drive vehicles>
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501327 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
• Measure engine-ECU terminal voltage.
• Ignition switch: ON
STEP 3. Perform voltage measurement at A-44 • Voltage between terminal No. 70 and earth.
rail pressure sensor connector. OK: 4.9 − 5.1 V
Connector: A-44 Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-44 (terminal
connector No. 1) rail pressure sensor connector and C-105
Connector: C-105
(terminal No. 70) engine-ECU connector.
<L.H. drive vehicles>
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
<R.H. drive vehicles> Harness side
connector AK501327 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
YES : Go to Step 11 .
STEP 9. Perform resistance measurement at A-44
NO : Repair or replace the connector.
rail pressure sensor connector.
Connector: A-44
STEP 11. Check harness between A-44 (terminal
No. 3) rail pressure sensor connector and C-105
(terminal No. 88) engine-ECU connector.
Connector: C-105
<L.H. drive vehicles>
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
Connector: C-105
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
<L.H. drive vehicles> 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
STEP 15. Perform voltage measurement at C-105 STEP 16. Connector check: C-105 engine-ECU
engine-ECU connector. connector
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-44
(MU802408)
Rail pressure
3 2 1 sensor
2 1 3
W R B
A-131
5 6 4
W R B B
C-105 64 70 88
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
C-105 (B)
STEP 2. Connector check: A-44 rail pressure
sensor connector
<R.H. drive vehicles>
Connector: A-44
C-105 (B)
3 2 1
A-44 (B)
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501327 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 5 .
STEP 3. Perform resistance measurement at A-44 NO : Repair or replace the connector.
rail pressure sensor connector.
Connector: A-44
3 2 1
A-44 (B)
Harness side
connector AK501327 AB
YES : Go to Step 6 .
STEP 5. Check harness between A-44 (terminal
NO : Repair the damaged harness wire.
No. 3) rail pressure sensor connector and C-105
(terminal No. 88) engine-ECU connector.
STEP 6. M.U.T.-III data list
Connector: A-44
• Refer to Data List Reference Table P.13A-542.
a. Item 63: Rail pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
3 2 1 with Intermittent Malfunctions ).
Harness side
A-44 (B) NO : Replace the engine-ECU. When the engine-
connector AK501327 AB ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Connector: C-105 Service − How to Perform Chassis Number
<L.H. drive vehicles>
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
C-105 (B) the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
<R.H. drive vehicles>
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
A-42
No. 1
1 2 injector G
1 2
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AJ
Check Conditions
• Ignition switch is in ON position
13A-158 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
A-42 (GR) <L.H. drive vehicles>
1 2
Harness side
connector AKA00186 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
A-42 (GR)
C-105 (B)
1 2
Harness side
connector AKA00186 AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41
No. 2
1 2 injector R-L
P-B
73 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AN
Check Conditions
• Ignition switch is in ON position
DIESEL FUEL
TROUBLESHOOTING
13A-161
DIAGNOSIS PROCEDURE STEP 3. Check harness between No. 2 injector
CAUTION connector and engine-ECU connector.
A high-tension voltage is flowing between the Connector: A-41
engine-ECU and the injectors while the engine is
running. Handle them carefully to avoid receiving
electric shocks from the voltage.
A-41 (GR)
STEP 1. Connector check: A-41 No. 2 injector
connector
1 2
Connector: A-41
Harness side
connector AKA00187AB
Connector: C-105
<L.H. drive vehicles>
A-41 (GR)
1 2
Harness side
connector AKA00187AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
STEP 4. Check harness between A-41 (terminal STEP 5. Connector check: C-105 engine-ECU
No. 2) No. 2 injector connector and C-105 connector
(terminal No. 73) engine-ECU connector. Connector: C-105
Connector: A-41 <L.H. drive vehicles>
A-41 (GR)
C-105 (B)
1 2
Harness side
connector AKA00187AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41
No. 2
1 2 injector R-L
W-L
25 75
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AK
Check Conditions
• Ignition switch is in ON position
13A-164 DIESEL FUEL
TROUBLESHOOTING
A-41 (GR)
STEP 1. Connector check: A-41 No. 2 injector
connector
1 2
Connector: A-41
Harness side
connector AKA00187AB
Connector: C-105
<L.H. drive vehicles>
A-41 (GR)
1 2
Harness side
connector AKA00187AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
A-41 (GR)
C-105 (B)
1 2
Harness side
connector AKA00187AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-130
No. 3
1 2 injector L-O
W-L
49 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AP
Check Conditions
• Ignition switch is in ON position
DIESEL FUEL
TROUBLESHOOTING
13A-167
DIAGNOSIS PROCEDURE STEP 3. Check harness between No. 3 injector
CAUTION connector and engine-ECU connector.
A high-tension voltage is flowing between the Connector: A-130
engine-ECU and the injectors while the engine is
running. Handle them carefully to avoid receiving
electric shocks from the voltage.
Connector: C-105
<L.H. drive vehicles>
A-130 (GR)
1 2
Harness side
connector AKA00188 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
STEP 4. Check harness between A-130 (terminal STEP 5. Connector check: C-105 engine-ECU
No. 2) No. 3 injector connector and C-105 connector
(terminal No. 49) engine-ECU connector. Connector: C-105
Connector: A-130 <L.H. drive vehicles>
A-130 (GR)
C-105 (B)
1 2
Harness side
connector AKA00188 AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-130
No. 3
1 2 injector L-O
W-L
25 50
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AL
Check Conditions
• Ignition switch is in ON position
13A-170 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
<L.H. drive vehicles>
A-130 (GR)
1 2
Harness side
connector AKA00188 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
A-130 (GR)
C-105 (B)
1 2
Harness side
connector AKA00188 AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129
No. 4
1 2 injector Y-G
R-Y
25 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AO
Check Conditions
• Ignition switch is in ON position
DIESEL FUEL
TROUBLESHOOTING
13A-173
DIAGNOSIS PROCEDURE STEP 3. Check harness between No. 4 injector
CAUTION connector and engine-ECU connector.
A high-tension voltage is flowing between the Connector: A-129
engine-ECU and the injectors while the engine is
running. Handle them carefully to avoid receiving
electric shocks from the voltage.
A-129 (GR)
STEP 1. Connector check: A-129 No. 4 injector
connector
1 2
Connector: A-129
Harness side
connector AKA00189AB
Connector: C-105
A-129 (GR) <L.H. drive vehicles>
1 2
Harness side
connector AKA00189AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
STEP 4. Check harness between A-129 (terminal STEP 5. Connector check: C-105 engine-ECU
No. 2) No. 4 injector connector and C-105 connector
(terminal No. 25) engine-ECU connector. Connector: C-105
Connector: A-129 <L.H. drive vehicles>
A-129 (GR)
C-105 (B)
1 2
Harness side
connector AKA00189AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-129
No. 4
1 2 injector Y-G
1 27
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
AKA00099 AM
Check Conditions
• Ignition switch is in ON position
13A-176 DIESEL FUEL
TROUBLESHOOTING
Connector: C-105
A-129 (GR) <L.H. drive vehicles>
1 2
Harness side
connector AKA00189AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 2 .
NO : Repair or replace the connector. <R.H. drive vehicles>
A-129 (GR)
C-105 (B)
1 2
Harness side
connector AKA00189AB
<R.H. drive vehicles>
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
OPERATION
• Refer to Code No. P0335: Crank Angle Sensor
System P.13A-184.
13A-178 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 2 .
FUNCTION NO : Replace the waste gate actuator.
• The engine-ECU checks whether the boost pres-
sure is not higher than the specified value. STEP 2. M.U.T.-III diagnosis code
• Reconfirmation of diagnosis code.
TROUBLE JUDGMENT
Q: Is the diagnosis code set?
Check Condition YES : Replace the engine-ECU. When the engine-
• Engine is running ECU is replaced, write the chassis number
Judgement Criterion (Refer to GROUP 00 − Precautions Before
• The boost pressure exceeds the abnormality Service − How to Perform Chassis Number
determination value for 3 seconds. Writing ). After replacing the engine-ECU,
register the injector identification code and
PROBABLE CAUSES learn fuel injection (Refer to GROUP 00 −
• Failed the waste gate actuator Precautions Before Service − What The
• Failed the engine-ECU Common Rail Engine Learns ). After
registering the injector identification code,
DIAGNOSIS carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
STEP 1. Check waste gate actuator itself. Forcible DPF Regeneration ).
• Check waste gate actuator itself (Refer to NO : Intermittent malfunction (Refer to GROUP
GROUP 15 − On-vehicle Service − Waste Gate 00 − How to Use Troubleshooting/
Actuator Check ). Inspection Service Points − How to Cope
Q: Is the check result normal? with Intermittent Malfunctions ).
DIESEL FUEL
TROUBLESHOOTING
13A-179
PROBABLE CAUSES
STEP 4. M.U.T.-III diagnosis code
• Intercooler air hose disconnected or damaged
• Reconfirmation of diagnosis code.
• Vacuum hose of manifold absolute pressure sen-
sor disconnected or damaged Q: Is the check result normal?
• Failed manifold absolute pressure sensor YES : Replace the engine-ECU. When the engine-
• Failed engine-ECU ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
DIAGNOSIS Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
STEP 1. Check on intercooler air hose. learn fuel injection (Refer to GROUP 00 −
• Check whether the intercooler air hose is discon- Precautions Before Service − What The
nected or damaged. Common Rail Engine Learns ). After
Q: Is the check result normal? registering the injector identification code,
YES : Go to Step 2 . the vehicle equipped with the DPF carries
NO : Repair. out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
STEP 2. Check on vacuum hose of manifold DPF Regeneration ).
absolute pressure sensor. NO : Intermittent malfunction (Refer to GROUP
• Check whether the vacuum hose of manifold 00 − How to Use Troubleshooting/
absolute pressure sensor is disconnected or Inspection Service Points − How to Cope
damaged. with Intermittent Malfunctions ).
Q: Is the check result normal?
YES : Clean or replace the No. 3 fuel injection YES : Replace the engine-ECU. When the engine-
pipe. ECU is replaced, write the chassis number
NO : Replace the No. 3 injector. After replacing (Refer to GROUP 00 − Precautions Before
the injector, register the injector Service − How to Perform Chassis Number
identification code and learn fuel injection. Writing ). After replacing the engine-ECU,
(Refer to GROUP 00 − Precautions Before register the injector identification code and
Service − What The Common Rail Engine learn fuel injection (Refer to GROUP 00 −
Learns ). Then go to Step 3 . Precautions Before Service − What The
Common Rail Engine Learns ). After
STEP 3. M.U.T.-III diagnosis code registering the injector identification code,
• After erasing the diagnosis code through M.U.T.- the vehicle equipped with the DPF carries
III, operate the engine in the warm-up state and out the forcible DPF regeneration. (Refer to
confirm and confirm whether the diagnosis code GROUP 17 − Emission Control − Diesel
is output. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
Q: Is the diagnosis code set? NO : The check is end.
A-07
MU802337
Crank
angle
sensor
1 2 3
3 2 1
R G-R B-W
3 2 1
A-133
P G-R B-Y
C-105 68 67 91
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
FUNCTION 3 2 1
• The crank angle sensor detects the crank angle Harness side
(position) and inputs a pulse signal to the engine- connector AK501329 AB
ECU.
• In response to the signal, the engine ECU detects Q: Is the check result normal?
the engine speed, controls the fuel injection tim- YES : Go to Step 3 .
ing and fuel injection quantity, etc. NO : Repair or replace the connector.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1 3 2 1
Harness side Harness side
connector AK501329 AB connector AK501329 AB
STEP 6. Connector check: C-105 engine-ECU STEP 7. Check harness between A-07 (terminal
connector No. 2) crank angle sensor connector and C-105
Connector: C-105
(terminal No. 67) engine-ECU connector.
<L.H. drive vehicles>
Connector: A-07
A-07 (B)
C-105 (B)
3 2 1
Harness side
<R.H. drive vehicles> connector AK501329 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-07 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-07
A-07 (B)
3 2 1
Harness side A-07 (B)
connector AK501329 AB
YES : Go to Step 13 .
STEP 11. Perform resistance measurement at A-
NO : Repair or replace the connector.
07 crank angle sensor connector.
Connector: A-07
STEP 13. Check harness between A-07 (terminal
No. 1) crank angle sensor connector and C-105
(terminal No. 91) engine-ECU connector.
Connector: A-07
A-07 (B)
3 2 1
Harness side A-07 (B)
connector AK501329 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-07 (B)
STEP 16. M.U.T-III data list
• Refer to Data List Reference Table
3 2 1
a. Item 2: Engine revolution
Harness side
connector AK501329 AB Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
• Use special tool test harness (MB991709) to con- 00 − How to Use Troubleshooting/
nect connector, and measure at pick-up harness. Inspection Service Points − How to Cope
• Engine: Idling with Intermittent Malfunctions ).
• Transmission: Neutral <M/T> or P range <A/T> NO : Replace the crank angle sensor
• Voltage between terminal No. 2 and earth.
OK: Waveforms should be displayed on
Inspection procedure using an oscilloscope
(Refer to P.13A-586), its maximum value
should be 4.8 V or more, and its minimum
valve should be 0.6 V or less with no noise in
waveform.
Q: Is the check result normal?
A-43
MU802337 Camshaft
position
sensor
1 2 3
3 2 1
1 2 3
A-131
C-105 69 66 90
1 2 3 4 5 6 7 8 9 10 10 11
111213141516171819
12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V 5V
Connector: A-43
C-105 (B)
A-43 (B)
3 2 1
<R.H. drive vehicles>
Harness side
connector AK501330 AB
Connector: A-43 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-43
A-43 (B)
3 2 1
Harness side
connector AK501330 AB
C-105 (B)
STEP 5. Connector check: C-105 engine-ECU
connector
<R.H. drive vehicles> Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connector: A-43
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-43 (B) 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 6. Check harness between A-43 (terminal STEP 7. M.U.T.-III diagnosis code
No. 2) camshaft position sensor connector and • Reconfirmation of diagnosis code.
C-105 (terminal No. 66) engine-ECU connector. Q: Is the diagnosis code set?
Connector: A-43 YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
A-43 (B)
learn fuel injection (Refer to GROUP 00 −
3 2 1 Precautions Before Service − What The
Harness side Common Rail Engine Learns ). After
connector AK501330 AB registering the injector identification code,
the vehicle equipped with the DPF carries
Connector: C-105 out the forcible DPF regeneration. (Refer to
<L.H. drive vehicles>
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
C-105 (B) with Intermittent Malfunctions ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-43 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
3 2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side
connector AK501330 AB
Harness side connector AKA00089 AB
• Use special tool harness (MB991709) to connect
NOTE: Before checking harness, check intermediate connector, and measure at pick-up harness.
connector A-131, and repair if necessary. • Ignition switch: ON
• Check output line for short circuit. • Voltage between terminal No. 3 and earth.
Q: Is the check result normal? OK: 4.9 − 5.1 V
YES : Go to Step 7 . Q: Is the check result normal?
NO : Repair the damaged harness wire. YES : Go to Step 11 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-195
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-43 (terminal
connector No. 3) camshaft position sensor connector and
Connector: C-105
C-105 (terminal No. 69) engine-ECU connector.
<L.H. drive vehicles> Connector: A-43
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 13 .
STEP 11. Perform resistance measurement at A-
NO : Repair or replace the connector.
43 camshaft position sensor connector.
Connector: A-43
STEP 13. Check harness between A-43 (terminal
No. 1) camshaft position sensor connector and
C-105 (terminal No. 90) engine-ECU connector.
Connector: A-43
A-43 (B)
3 2 1
Harness side
connector AK501330 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-43 (B)
3 2 1
Harness side
connector AK501330 AB
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
3 OFF Engine control relay
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
Glow plug Glow plug Glow plug Glow plug
C-103
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
Harness side Harness side
connector AKB00264 AB connector AKB00264 AB
A-154 (B)
1 1
Harness side A-153 (B) Harness side
connector AKB00266 AB connector AKB00267 AB
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-150, and repair if necessary. connector A-150, and repair if necessary.
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4 . YES : Go to Step 5 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-202 DIESEL FUEL
TROUBLESHOOTING
STEP 5. Check harness between A-151 (terminal STEP 6. Check harness between A-151 (terminal
No. 3) glow control unit connector and A-155 No. 4) glow control unit connector and A-156
(terminal No. 1) No.3 glow plug connector. (terminal No. 1) No.4 glow plug connector.
Connector: A-151 Connector: A-151
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
Harness side Harness side
connector AKB00264 AB connector AKB00264 AB
A-156 (B)
A-155 (B)
1 1
Harness side Harness side
connector AKB00268 AB connector AKB00269 AB
NOTE: Before checking harness, check intermediate NOTE: Before checking harness, check intermediate
connector A-150, and repair if necessary. connector A-150, and repair if necessary.
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
FUNCTION
• The engine-ECU monitors the EGR flow rate. 3 2 1
6 5 4
TROUBLE JUDGMENT
Harness side
Check Conditions connector AK501331 AB
• Engine is running.
Q: Is the check result normal?
• Battery positive voltage is 8 − 16 V.
YES : Go to Step 3 .
• Normal running (vehicle speed: 65 − 75 km/h,
NO : Repair or replace the connector.
transmission: 5th <M/T>, D range <A/T>).
• The intake air temperature is from 20 to 40 °C.
STEP 3. Connector check: C-103 and C-105
Judgment Criterion engine-ECU connectors
• The EGR flow rate is larger than target EGR flow
rate by the rate that is more than the specified Connectors: C-103, C-105
<L.H. drive vehicles>
value.
PROBABLE CAUSES
• Failed EGR passage (leakage and clogged EGR
passage)
• Harness damage in EGR valve circuit or loose
connector contact C-103 (B) C-105 (B)
• Failed EGR valve operation
• Harness damage in air flow sensor circuit or
<R.H. drive vehicles>
loose connector contact
• Failed air flow sensor (abnormal output charac-
teristics)
• Failed engine-ECU
DIAGNOSTIC PROCEDURE
C-103 (B) C-105 (B)
to P.13A-21).
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 115) engine-ECU connector and A-45 No. 130) engine-ECU connector and A-45
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve assembly connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
3 2 1 3 2 1
6 5 4 6 5 4
Harness side Harness side
connector AK501331 AB connector AK501331 AB
• Check output line for damage. • Check output line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-45 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1
A-45 (GR)
6 5 4
Harness side
connector AK501331 AB
3 2 1
• Check earthing line for damage. 6 5 4
Q: Is the check result normal? Harness side
connector
YES : Go to Step 7 . AK501331 AB
NO : Repair the damaged harness wire. • Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair the damaged harness wire.
13A-206 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 9 .
STEP 8. Check harness between C-105 (terminal
NO : Repair the damaged harness wire.
No. 57) engine-ECU connector and A-45 (terminal
No. 1) EGR valve assembly connector.
STEP 9. Check EGR valve itself.
Connector: C-105
<L.H. drive vehicles> • Check EGR valve itself [Refer to GROUP 17 −
Emission Control − Exhaust Gas Recirculation
(EGR) System − EGR Valve (DC motor) Check ].
Q: Is the check result normal?
YES : Go to Step 10 .
NO : Replace the EGR valve assembly.
C-105 (B)
STEP 10. Check EGR passage for deposits.
<R.H. drive vehicles>
• Check the EGR valve, the EGR pipe and the
inside of the EGR cooler for deposits. (Refer to
GROUP 17 − Emission Control − EGR Valve And
EGR Cooler − Removal And Installation ).
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Cleaning or replace the EGR valve, EGR
C-105 (B) pipe and EGR cooler.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
STEP 11. Connector check: A-135 air flow sensor
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 connector.
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-135
Harness side connector AKA00089 AB
Connector: A-45
A-45 (GR)
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
• Check earthing line for damage. • Check output line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 13 . YES : Go to Step 14 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
STEP 5. Check harness between C-103 (terminal STEP 6. Check harness between C-105 (terminal
No. 130) engine-ECU connector and A-45 No. 81) engine-ECU connector and A-45 (terminal
(terminal No. 4) EGR valve assembly connector. No. 2) EGR valve assembly connector.
Connector: C-103 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1 3 2 1
6 5 4 6 5 4
Harness side Harness side
connector AK501331 AB connector AK501331 AB
• Check output line for damage. • Check earthing line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-211
STEP 7. Check harness between C-105 (terminal STEP 8. Check harness between C-105 (terminal
No. 71) engine-ECU connector and A-45 (terminal No. 57) engine-ECU connector and A-45 (terminal
No. 3) EGR valve assembly connector. No. 1) EGR valve assembly connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1 3 2 1
6 5 4 6 5 4
Harness side Harness side
connector AK501331 AB connector AK501331 AB
• Check power supply line for damage. • Check output line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 8 . YES : Go to Step 9 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
STEP 10. Check EGR passage for air suction. STEP 12. Check harness between A-135 (terminal
• Check the EGR valve, the EGR pipe and the No. 4) air flow sensor connector and C-103
EGR cooler for the air suction. (terminal No. 155) engine-ECU connector.
Q: Is the check result normal? Connector: A-135
YES : Go to Step 11 .
NO : Cleaning or replace the EGR valve, EGR
pipe and EGR cooler.
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
Q: Is the check result normal?
YES : Go to Step 12 .
NO : Repair or replace the connector. <R.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-45
(MU802056)
M
EGR valve assembly
1 2 3
4 5 6
6 4
V Y-B
AKA00102 AB
Connector: A-45
A-45 (GR)
C-103 (B)
3 2 1
6 5 4 <R.H. drive vehicles>
Harness side
connector AK501331 AB
valve (DC motor) check ]. 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 115) engine-ECU connector and A-45 No. 130) engine-ECU connector and A-45
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
3 2 1 3 2 1
6 5 4 6 5 4
Harness side Harness side
connector AK501331 AB connector AK501331 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P0405: EGR Valve Position Sensor Circuit Low Input <Except Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKA00103 AB
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
<R.H. drive vehicles>
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501331 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
• Measure engine-ECU terminal voltage.
• Ignition switch: ON
STEP 3. Perform voltage measurement at A-45 • Voltage between terminal No. 71 and earth.
EGR valve assembly connector. OK: 4.9 − 5.1 V
Connector: A-45 Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-45 (terminal
connector No. 3) EGR valve assembly connector and C-105
Connector: C-105
(terminal No. 71) engine-ECU connector.
<L.H. drive vehicles> Connector: A-45
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
<R.H. drive vehicles> connector AK501331 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
STEP 10. Connector check: C-105 engine-ECU STEP 11. Check harness between A-45 (terminal
connector No. 2) EGR valve assembly connector and C-105
Connector: C-105
(terminal No. 81) engine-ECU connector.
<L.H. drive vehicles> Connector: A-45
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
<R.H. drive vehicles> connector AK501331 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1
6 5 4 A-45 (GR)
Harness side
connector AK501331 AB
C-105 (B)
C-105 (B)
<R.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 15. Perform voltage measurement at C-105 STEP 16. Connector check: C-105 engine-ECU
engine-ECU connector. connector
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0406: EGR Valve Position Sensor Circuit High Input <Except Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKA00103 AB
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
<R.H. drive vehicles>
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501331 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 5 .
STEP 3. Perform resistance measurement at A-45 NO : Repair or replace the connector.
EGR valve assembly connector.
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
YES : Go to Step 6 .
STEP 5. Check harness between A-45 (terminal
NO : Repair the damaged harness wire.
No. 2) EGR valve assembly connector and C-105
(terminal No. 81) engine-ECU connector.
STEP 6. M.U.T.-III data list
Connector: A-45
• Refer to Data List Reference Table P.13A-542.
a. Item 16: EGR valve position sensor
C-105 (B)
STEP 7. M.U.T.-III data list
• Refer to Data List Reference Table P.13A-542.
<R.H. drive vehicles> a. Item 16: EGR valve position sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
C-105 (B)
NO : Replace the EGR valve assembly.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0427: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit Low Input
<Euro5>
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00271 AB
C-105 (B)
2 1 A-159 (B)
Harness side
connector
C-105 (B)
AKB00272 AB
Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 5 .
YES : Go to Step 3 . NO : Repair or replace the connector.
NO : Repair or replace the connector.
13A-232 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 6 .
STEP 5. Check harness between A-159 (terminal
NO : Repair the damaged harness wire.
No. 1) No. 2 exhaust gas temperature sensor
(catalyst temperature) connector and C-105
(terminal No. 59) engine-ECU connector. STEP 6. M.U.T.-III data list
• Refer to Data List Reference Table P.13A-542
Connector: A-159
a. Item 118: No. 2 exhaust gas temperature sensor
(catalyst temperature)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
A-159 (B) with Intermittent Malfunctions ).
2 1
NO : Replace the engine-ECU. When the engine-
Harness side
connector ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
No. 2 exhaust gas learn fuel injection (Refer to GROUP 00 −
temperature sensor
(catalyst temperature) Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
AKB00272 AB (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
Connector: C-105 Forcible DPF Regeneration ).
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0428: No. 2 Exhaust Gas Temperature Sensor (catalyst temperature) Circuit High Input
<Euro5>
A-159
MU802601
No. 2 exhaust gas
temperature sensor
1 2 (catalyst temperature)
2 1
BR-G R-B
A-28
2 8
O-B GR-R
C-105 83 59
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00271 AB
2 1 A-159 (B)
Harness side
connector
2 1 A-159 (B)
Harness side
connector
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Harness side connector AKA00089 AB
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 6 .
NO : Repair or replace the connector.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 7 .
STEP 8. Perform resistance measurement at A-
NO : Repair the damaged harness wire.
159 No. 2 exhaust gas temperature sensor
(catalyst temperature) connector.
STEP 7. M.U.T.-III data list
Connector: A-159
• Refer to Data List Reference Table P.13A-542
a. Item 118: No. 2 exhaust gas temperature sensor
(catalyst temperature)
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope A-159 (B)
2 1
with Intermittent Malfunctions ).
Harness side
NO : Replace the engine-ECU. When the engine- connector
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and No. 2 exhaust gas
temperature sensor
learn fuel injection (Refer to GROUP 00 − (catalyst temperature)
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration. AKB00272 AB
(Refer to GROUP 17 − Emission Control − • Disconnect connector, and measure at harness
Diesel Particulate Filter (DPF) System − side.
Forcible DPF Regeneration ). • Resistance between terminal No. 2 and earth.
OK: Continuity (2 Ω or less)
Q: Is the check result normal?
YES : Go to Step 11 .
NO : Go to Step 9 .
DIESEL FUEL
TROUBLESHOOTING
13A-237
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-159 (terminal
connector No. 2) No. 2 exhaust gas temperature sensor
Connector: C-105
(catalyst temperature) connector and C-105
<L.H. drive vehicles> (terminal No. 83) engine-ECU connector.
Connector: A-159
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00272 AB
Harness side connector AKA00089 AB
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 10 .
NO : Repair or replace the connector.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 7 .
STEP 12. Check harness between A-159 (terminal
NO : Repair the damaged harness wire.
No. 1) No. 2 exhaust gas temperature sensor
(catalyst temperature) connector and C-105
STEP 11. Connector check: C-105 engine-ECU (terminal No. 59) engine-ECU connector.
connector.
Connector: A-159
Connector: C-105
<L.H. drive vehicles>
2 1 A-159 (B)
C-105 (B)
Harness side
connector
<R.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00272 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>
Harness side connector AKA00089 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0489: EGR Valve Position Sensor Circuit Low Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKA00103 AB
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
<R.H. drive vehicles>
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501331 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
• Measure engine-ECU terminal voltage.
• Ignition switch: ON
STEP 3. Perform voltage measurement at A-45 • Voltage between terminal No. 71 and earth.
EGR valve assembly connector. OK: 4.9 − 5.1 V
Connector: A-45 Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
A-45 (GR)
C-105 (B) 3 2 1
6 5 4
Harness side
<R.H. drive vehicles> connector AK501331 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
3 2 1
6 5 4 A-45 (GR)
Harness side
connector AK501331 AB
C-105 (B)
C-105 (B)
<R.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 14 .
STEP 12. Perform voltage measurement at A-45
NO : Repair or replace the connector.
EGR valve assembly connector.
Connector: A-45
STEP 14. Check harness between A-45 (terminal
No. 1) EGR valve assembly connector and C-105
(terminal No. 57) engine-ECU connector.
A-45 (GR)
Connector: A-45
3 2 1
6 5 4 A-45 (GR)
Harness side
connector AK501331 AB
C-105 (B)
C-105 (B)
<R.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
YES : Go to Step 7 .
STEP 17. Connector check: C-105 engine-ECU
NO : Repair or replace the connector.
connector
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0490: EGR Valve Position Sensor Circuit High Input <Euro5>
A-45
(MU802056)
EGR valve assembly
1 2 3
4 5 6
3 1 2
SB G-B BR-B
C-105 71 57 81
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKA00103 AB
C-105 (B)
STEP 2. Connector check: A-45 EGR valve
assembly connector
<R.H. drive vehicles>
Connector: A-45
A-45 (GR)
3 2 1 C-105 (B)
6 5 4
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AK501331 AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 5 .
STEP 3. Perform resistance measurement at A-45 NO : Repair or replace the connector.
EGR valve assembly connector.
Connector: A-45
A-45 (GR)
3 2 1
6 5 4
Harness side
connector AK501331 AB
Code No. P0502: Vehicle Speed Sensor Low Input <2WD-M/T and 4WD vehicles>
Fusible link 23
W-R
Relay 10
box 20A Engine-ECU
C-103
5V
W-B 103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
A-115
3 116 117
131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
W-B
W-B
141
W-L
1 4 C-53*¹
A-20X
or
1 2 Engine C-35*²
11
3 control
ON relay W-L
4 OFF
22
2 3
J/C (2)
R C-127
A-28
10 21
W-L
To engine-ECU
R C-30
C-29
2 4
R W-L
1 3
B-01
(MU802723)
Vehicle speed sensor
1 2 3
B
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKA00104 AB
DIESEL FUEL
TROUBLESHOOTING
13A-251
OPERATION STEP 2. M.U.T.-III data list
• A power voltage of 5 V is applied to the vehicle • Refer to Data list reference table P.13A-542.
speed sensor (terminal No. 3) from the engine-
a. Item 4: Vehicle speed sensor
ECU (terminal No. 114).
Q: Is the check result normal?
FUNCTION YES : Intermittent malfunction (Refer to GROUP
• The vehicle speed sensor converts the vehicle 00 − How to Use Troubleshooting/
speed to the voltage, and then input it into the Inspection Service Points − How to Cope
engine-ECU with Intermittent Malfunctions ).
NO : Go to Step 3 .
TROUBLE JUDGMENT
Check Conditions STEP 3. Connector check: C-103 engine-ECU
• Engine is running connector
• Engine coolant temperature is 80°C or higher
Connector: C-103
• The last fuel injection rate exceeds the specified <L.H. drive vehicles>
value.
• Engine speed is 2,900 r/min or more.
Judgment Criterion
• Vehicle speed is 5 km/h or lower for 2 seconds.
PROBABLE CAUSES
• Failed vehicle speed sensor C-103 (B)
• Open/short circuit or harness damage in vehicle
speed sensor circuit or loose connector contact <R.H. drive vehicles>
• Failed engine-ECU
DIAGNOSIS PROCEDURE
YES : Go to Step 5 .
STEP 4. Check harness between C-103 (terminal
NO : Repair the damaged harness wire.
No. 114) engine-ECU connector and B-01
(terminal No. 3) Vehicle speed sensor connector.
STEP 5. M.U.T.-III diagnosis code
Connector: C-103
<L.H. drive vehicles> • Reconfirmation of diagnosis code.
Q: Is the diagnosis code set?
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
C-103 (B)
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
<R.H. drive vehicles>
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
C-103 (B) Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Connector: B-01
<2WD>
B-01 (B)
<4WD>
B-01 (B)
3 2 1
Harness side
connector AK503653 AB
A-152
Battery temperature
1 2 sensor (integrated in
battery current sensor)
3 4
3 2
BR-B GR-L
155 39
Engine-ECU
5V
C-103 C-105
DIAGNOSIS PROCEDURE
A-152 (GR)
AKB00274 AB
STEP 1. M.U.T.-III data list
• Item No. 402: Battery temperature sensor • Disconnect connector and measure at harness
side.
OK: At ambient temperature (atmospheric
• Ignition switch: ON
temperature) of battery temperature sensor,
• Voltage between terminal No. 2 and earth.
or equivalent
OK: 4.5 − 4.9 V
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP Q: Is the check result normal?
00 − How to Use Troubleshooting/ YES : Go to Step 8 .
Inspection Service Points − How to Cope NO : Go to Step 5 .
with Intermittent Malfunctions ).
NO : Go to Step 2 . STEP 5. Connector check: C-105 engine-ECU
connector
STEP 2. Connector check: A-152 battery current Connector: C-105
sensor connector <L.H. drive vehicles>
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)
STEP 6. Check harness between A-152 (terminal STEP 7. M.U.T.-III data list
No. 2) battery current sensor connector and C- • Item No. 402: Battery temperature sensor
105 (terminal No. 39) engine-ECU connector. OK: At ambient temperature (atmospheric
Connector: A-152 temperature) of battery temperature sensor,
2 1 or equivalent
4 3
Q: Is the check result normal?
Harness side YES : Intermittent malfunction (Refer to GROUP
connector
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
A-152 (GR) ECU is replaced, write the chassis number
AKB00274 AB (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Connector: C-105
<L.H. drive vehicles> Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
C-105 (B) (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
<R.H. drive vehicles> Forcible DPF Regeneration ).
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-103 (B)
A-152 (GR)
<R.H. drive vehicles>
AKB00274 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
<R.H. drive vehicles>
Harness side connector AKA00090 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 11. Connector check: C-105 engine-ECU STEP 12. Check harness between A-152 (terminal
connector No. 2) battery current sensor connector and C-
Connector: C-105
105 (terminal No. 39) engine-ECU connector.
<L.H. drive vehicles>
Connector: A-152
2 1
4 3
Harness side
connector
C-105 (B)
A-152 (GR)
<R.H. drive vehicles>
AKB00274 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0545: No.1 Exhaust Gas Temperature Sensor Circuit Low Input <Euro5>
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00275 AB
PROBABLE CAUSES
• Failed No.1 exhaust gas temperature sensor
• Short circuit in No.1 exhaust gas temperature sensor circuit or connector damage
13A-260 DIESEL FUEL
TROUBLESHOOTING
A-149 (B)
2 1
Harness side
connector AKB00276 AB
C-105 (B)
Q: Is the check result normal?
YES : Go to Step 3 .
NO : Repair or replace the connector.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Check No.1 exhaust gas temperature
Harness side connector
sensor itself. AKA00089 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P0546: No. 1 exhaust gas temperature sensor Circuit High Input <Euro5>
A-149
MU802601
No. 1 exhaust gas
temperature sensor
1 2
2 1
BR-L O-G
C-105 82 58
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00275 AB
PROBABLE CAUSES
• Failed No. 1 exhaust gas temperature sensor
DIESEL FUEL
TROUBLESHOOTING
13A-263
• Open circuit or harness damage in No. 1 exhaust STEP 4. Perform voltage measurement at A-149
gas temperature sensor circuit or loose connector No. 1 exhaust gas temperature sensor connector.
contact
• Failed engine-ECU Connector: A-149
DIAGNOSTIC PROCEDURE
STEP 6. Check harness between A-149 (terminal STEP 7. M.U.T.-III data list
No. 1) No. 1 exhaust gas temperature sensor • Refer to Data List Reference Table P.13A-542
connector and C-105 (terminal No. 58) engine- a. Item 117: No. 1 exhaust gas temperature sensor
ECU connector.
Q: Is the check result normal?
Connector: A-149 YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
A-149 (B) (Refer to GROUP 00 − Precautions Before
2 1 Service − How to Perform Chassis Number
Harness side Writing ). After replacing the engine-ECU,
connector AKB00276 AB register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Connector: C-105
<L.H. drive vehicles>
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
(Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
Forcible DPF Regeneration ).
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 A-149 (B)
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
2 1
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 Harness side
connector AKB00276 AB
Harness side connector
• Disconnect connector, and measure at harness
AKA00089 AB
C-105 (B)
A-149 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 11. Connector check: C-105 engine-ECU STEP 12. Check harness between A-149 (terminal
connector. No. 1) No. 1 exhaust gas temperature sensor
Connector: C-105
connector and C-105 (terminal No. 58) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-149
C-105 (B)
A-149 (B)
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-103
127
B-R
A-115
5
B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
AKA00105 AB
DIAGNOSIS PROCEDURE
13A-268 DIESEL FUEL
TROUBLESHOOTING
STEP 1. M.U.T.-III data list. STEP 4. Check at A-134 power steering fluid
• Refer to Data List Reference Table P.13A-542. pressure switch connector.
a. Item 75: Power steering fluid pressure switch Connector: A-134
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
A-134 (B)
Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
NO : Go to Step 2
1
STEP 2. Connector check: A-134 power steering Harness side
connector AK501383 AB
pressure switch connector
• Disconnect connector, and measure at harness
Connector: A-134
side.
• Ignition switch: ON
• Voltage between terminal No.1 and earth.
A-134 (B) OK: System voltage
Q: Is the check result normal?
YES : Go to Step 7 .
1 NO : Go to Step 5 .
Harness side
connector AK501383 AB
STEP 5. Connector check: C-103 engine-ECU
Q: Is the check result normal? connector
YES : Go to Step 3 . Connector: C-103
NO : Repair or replace the connector. <L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
with Intermittent Malfunctions ).
NO : Replace the engine-ECU. When the engine-
158 157156 155 154 153 152 151 150 149 148 147 146
Harness side connector AKA00090 AB ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Connector: A-134 Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
A-134 (B) learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
1 the vehicle equipped with the DPF carries
Harness side out the forcible DPF regeneration. (Refer to
connector AK501383 AB GROUP 17 − Emission Control − Diesel
NOTE: Before checking harness, check intermediate Particulate Filter (DPF) System − Forcible
connectors A-27 and A-115, and repair if necessary. DPF Regeneration ).
• Check output line for short circuit.
Q: Is the check result normal?
TROUBLE JUDGMENT
FUNCTION Check Conditions
• To check whether the information such as the idle • Ignition switch is in ON position
learned value and so on is stored in the memory
of engine-ECU.
13A-270 DIESEL FUEL
TROUBLESHOOTING
FUNCTION
• The main microcomputer detects errors in the
sub microcomputer used for monitoring.
13A-272 DIESEL FUEL
TROUBLESHOOTING
OPERATION or
• When the ignition switch is turned ON, the current • For 30 seconds, the battery backup voltage sub-
should be supplied from the combination meter tracted from the final target generation voltage
(terminal No. 52) to the alternator (terminal No. equals 1.9 V or more.
3). When the engine starts under those condi-
tions, the alternator should generate currents. PROBABLE CAUSES
• The engine-ECU checks the voltage of the bat- • Failed battery
tery backup terminal (terminal No. 103) to moni- • Failed drive belt
tor the electricity generation voltage of the • Loose connector contact
alternator. • Open/short circuit or harness damage in alterna-
tor G-terminal circuit
FUNCTION • Harness damage in battery backup circuit
• The engine-ECU compares the battery voltage • Failed alternator
with the voltage generated from the alternator to • Failed engine-ECU
check whether the electrical generation is normal.
DIAGNOSIS PROCEDURE
TROUBLE JUDGMENT
Check Conditions STEP 1. Checking engine start conditions
• Ignition switch is "ON" position. • Check whether the user uses the booster cable to
• The engine speed is 1 500 r/min or more. start the engine.
• The battery backup voltage is 13.5 V or more.
NOTE: This diagnosis code can be output due to the
• The G-terminal duty ratio is 10.2 % or more and
battery voltage drop.
89.8 % or less.
Q: Have you ever used the booster cable to start the
Judgement Criterion
engine?
• For 30 seconds, the final target generation volt- YES : Delete the diagnosis code and check end.
age subtracted from the battery backup voltage NO : Go to Step 2 .
equals 0.8 V or more.
DIESEL FUEL
TROUBLESHOOTING
13A-273
STEP 2. Battery check STEP 5. Perform voltage measurement at C-103
• Check the battery (Refer to GROUP 54A − Bat- engine-ECU connector.
tery − On-vehicle Service − Battery Test ). Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 3 .
NO : Replace the battery.
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
STEP 6. Connector check: A-122 alternator
115 114 113 112 111 110 109 108 107 106 105 104 103
connector
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
STEP 7. Check harness between C-103 (terminal STEP 8. Check harness between battery and C-
No. 121) engine-ECU connector and A-122 103 (terminal No. 103) engine-ECU connector.
(terminal No. 1) alternator connector. Connector: C-103
Connector: C-103 <L.H. drive vehicles>
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
<R.H. drive vehicles>
<R.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
115 114 113 112 111 110 109 108 107 106 105 104 103 117 116
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
117 116 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB
Harness side connector AKA00090 AB
NOTE: Before checking harness, check intermediate
Connector: A-122 connector A-115, and repair if necessary.
• Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair the damaged harness wire.
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
TROUBLE JUDGMENT
STEP 2. Check suction control valve itself.
Check Conditions • Check suction control valve itself (Refer to P.13A-
• Battery positive voltage is 8 − 16 V 596).
• 2 seconds later after the ignition switch has been
Q: Is the check result normal?
in "ON" position or the engine has started up. YES : Go to Step 3 .
• The supply pump and injector are being normally NO : Replace the suction control valve.
controlled.
• The fuel injection rate is 4 mm3/st or more.
STEP 3. Connector check: C-103 engine-ECU
Judgment Criterion connector
• When the driving duty ratio of the suction control
Connector: C-103
valve is higher than the specified value, the driv- <L.H. drive vehicles>
ing current is lower than the specified value.
PROBABLE CAUSES
• Failed suction control valve
• Open/short circuit or harness damage in suction
control valve circuit or loose connector contact
• Failed engine-ECU C-103 (B)
AK503644 AB
Q: Is the check result normal?
YES : Go to Step 4 .
Q: Is the check result normal?
NO : Repair or replace the connector.
DIESEL FUEL
TROUBLESHOOTING
13A-277
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
• Check power supply line for open/short circuit Connector: C-103
and damage. <L.H. drive vehicles>
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
C-103 (B) 115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
115 114 113 112 111 110 109 108 107 106 105 104 103 145 144
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 158 157156 155 154 153 152 151 150 149 148 147 146
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 Harness side connector AKA00090 AB
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-47 (GR)
AK503644 AB
Code No. P0629: Suction Control Valve Battery Short <Except Euro5>
1
A-47
(MU802768) Suction
control
1 2 valve
P
2
SB
C-103
146 131
103104105106107108109110 111112113 114115
101 102 118119120121122123124125126127128 129130
OPERATION FUNCTION
• The voltage is applied from the engine-ECU (ter- • The engine-ECU performs duty control over the
minal No. 131) to the suction control valve (termi- suction control valve.
nal No. 1) via the power transistor in the engine- • The engine-ECU checks whether the amount of
ECU. current for driving duty is adequate.
• The voltage is earthed to the engine-ECU (termi-
nal No. 146) from the suction control valve (termi- TROUBLE JUDGMENT
nal No. 2). Check Conditions
• Battery positive voltage is 8 − 16 V
DIESEL FUEL
TROUBLESHOOTING
13A-279
• 2 seconds later after the ignition switch has been STEP 2. Check suction control valve itself.
in "ON" position or the engine has started up • Check suction control valve itself (Refer to P.13A-
• The supply pump and injector are being normally 596).
controlled.
Q: Is the check result normal?
• The fuel injection rate is 4 mm3/st or more.
YES : Go to Step 3.
Judgment Criterion NO : Replace the suction control valve.
• When the driving duty ratio of the suction control
valve is lower than the specified value, the driving STEP 3. Connector check: C-103 engine-ECU
current is higher than the specified value. connector
PROBABLE CAUSES Connector: C-103
• Failed suction control valve <L.H. drive vehicles>
• Short circuit in suction control valve circuit or
loose connector contact
• Failed engine-ECU
DIAGNOSIS PROCEDURE
C-103 (B)
STEP 1. Connector check: A-47 suction control
valve connector <R.H. drive vehicles>
Connector: A-47
2 1
Harness side
connector
A-47 (GR)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
AK503644 AB 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
AK503644 AB AK503644 AB
• Check power supply line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5. YES : Go to Step 6.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
A-132
(MU805200)
Electronic-controlled
1 2 3 4 5 6 throttle valve
5 6
G-B G
AKA00107 AB
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side
connector AK604705 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P0642: Analog Sensor Reference Voltage No. 1 Too Low
Code No. P0643: Analog Sensor Reference Voltage No. 1 Too High
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
3 OFF Engine control relay
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
Glow plug Glow plug Glow plug Glow plug
C-103
Code No. P0652: Analog Sensor Reference Voltage No. 2 Too Low
Judgment Criterion
• The detected voltage of analog sensor reference
voltage No. 2 is 4.86 V or less for 0.5 second.
[Power supply for other than accelerator pedal
position sensor (main)]
13A-290 DIESEL FUEL
TROUBLESHOOTING
Code No. P0653: Analog Sensor Reference Voltage No. 2 Too High
W-R
10 Relay
20A box
W-B A-115
3
W-B W-B W
A-20X 1 4
1 2
3 OFF Engine control relay
4 ON
2 3
A-151
To engine-ECU
R
GND
1 9 7 1 2 3 4
Y BR-Y G-R L-B
LG-R GR-R B A-150
2 1 4 3
Y L G R
120 126 1 1 1 1
A-153 A-154 A-155 A-156
1 1 1 1
Engine-
ECU
No.1 No.2 No.3 No.4
Glow plug Glow plug Glow plug Glow plug
C-103
Connector: A-151
4 3 2 1
8 7 6 5
11 10 9 A-151 (B)
4 3 2 1
Harness side
8 7 6 5 connector AKB00264 AB
11 10 9 A-151 (B)
Harness side Connector: C-103
connector AKB00264 AB <L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
4 3 2 1 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
8 7 6 5
11 10 9 A-151 (B) Harness side connector AKA00090 AB
Harness side
connector AKB00264 AB
• Check signal line for open/short circuit and dam-
age.
• Disconnect connector, and measure at harness
Q: Is the check result normal?
side.
YES : Go to Step 6 .
• Resistance between terminal No.7 and earth.
NO : Repair the damaged harness wire.
Q: Is the check result normal?
13A-294 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between A-151 (terminal STEP 7. Check harness between A-151 (terminal
No. 9) glow control unit connector and C-103 No. 6) glow control unit connector and A-20X
(terminal No. 126) engine-ECU connector. (terminal No. 3) engine control relay connector.
Connector: A-151 Connector: A-151
4 3 2 1 4 3 2 1
8 7 6 5 8 7 6 5
11 10 9 A-151 (B) 11 10 9 A-151 (B)
Harness side Harness side
connector AKB00264 AB connector AKB00264 AB
2 1
3
C-103 (B) 4
Relay box's side
connector AK501321 AC
<R.H. drive vehicles>
• Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair the damaged harness wire.
TROUBLE JUDGMENT
OPERATION Check Conditions
• Refer to Code No. P0003: Suction Control Valve • Battery positive voltage is 8 − 16 V
Open P.13A-26. <Euro 5> • Engine speed is 600 r/min or more
• Refer to Code No. P0004: Suction Control Valve • 2 seconds later after the ignition switch has been
Battery Short P.13A-29. <Euro 5> in "ON" position or the engine has started up
• Refer to Code No. P0191: Rail Pressure Sensor • Rail pressure is normal
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Judgment Criterion
Circuit Low Input P.13A-147. • After a pressure higher than the pressure of the
• Refer to Code No. P0193: Rail Pressure Sensor pressure limiter opening valve is detected, fuel
Circuit High Input P.13A-155. leakage diagnosis (supply pump discharge rate
• Refer to Code No. P0628: Suction Control Valve excessive) is detected within the predetermined
Open P.13A-276. <Except Euro 5> time.
• Refer to Code No. P0629: Suction Control Valve
PROBABLE CAUSES
Battery Short P.13A-279. <Except Euro 5>
• Failed suction control valve
FUNCTION • Failed fuel system
• The engine-ECU controls the fuel discharge rate • Failed common rail assembly
using the suction control valve. • Open/short circuit or harness damage in suction
• The engine-ECU monitors the signals input from control valve circuit or loose connector contact
the rail pressure sensor. • Failed engine-ECU
• The engine-ECU checks whether the pressure
limiter valve is open, based on changes in the DIAGNOSIS PROCEDURE
signals input from the rail pressure sensor (rapid NOTE: This diagnosis code is outputted for an air
drop of pressure after it goes extremely high). penetration in the fuel line of the supply pump due to
lack of fuel. Therefore, bleed air from the fuel line
after the fuel supply, and delete the diagnosis code
through M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-297
STEP 1. M.U.T.-III diagnosis code STEP 5. Connector check: C-103 engine-ECU
Q: Is any other diagnosis code than P1272 output?
connector and A-47 suction control valve
YES : Inspection chart for diagnosis codes (Refer connector
to P.13A-21). Connector: C-103
NO : Go to Step 2 . <L.H. drive vehicles>
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
STEP 4. Check suction control valve itself 158 157156 155 154 153 152 151 150 149 148 147 146
• Check suction control valve itself (Refer to P.13A- Harness side connector AKA00090 AB
596).
Connector: A-47
Q: Is the check result normal?
2 1
YES : Go to Step 5 .
NO : Replace the suction control valve. After Harness side
replacing the suction control valve, learn the connector
supply pump (Refer to GROUP 00 − A-47 (GR)
Precautions Before Service − What The
Common Rail Engine Learns ).
AK503644 AB
STEP 6. Check harness between C-103 (terminal STEP 7. Check harness between C-103 (terminal
No. 131) engine-ECU connector and A-47 No. 146) engine-ECU connector and A-47
(terminal No. 1) suction control valve connector. (terminal No. 2) suction control valve connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
AK503644 AB AK503644 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 7 . YES : Go to Step 8 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-299
YES : Go to Step 9 .
STEP 8. Perform output wave pattern
NO : Replace the engine-ECU then replace the
measurement at A-47 suction control valve
common rail assembly and fuel injection
(Using an oscilloscope).
tubes. When the engine-ECU is replaced,
Connector: A-47 write the chassis number (Refer to GROUP
2 1 00 − Precautions Before Service − How to
Harness side Perform Chassis Number Writing ). After
connector replacing the engine-ECU, register the
injector identification code and learn fuel
A-47 (GR)
injection (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail
Engine Learns ). After registering the
injector identification code, the vehicle
AK503644 AB equipped with the DPF carries out the
• Engine: Idling forcible DPF regeneration. (Refer to
• Connect the oscilloscope special patterns pickup GROUP 17 − Emission Control − Diesel
to engine-ECU terminal No. 131 and earth. Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
OK: The waveform should show a pattern
similar to the illustration of Inspection proce-
dure using an oscilloscope (Refer to P.13A- STEP 9. Replace the common rail assembly and
586). fuel injection tubes.
• After replacing the common rail assembly and
Q: Is the check result normal?
common tubes, re-check the trouble symptoms
Q: Does trouble symptom persist?
YES : Replace the suction control valve. After
replacing the suction control valve, learn the
supply pump (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
NO : The check is end.
PROBABLE CAUSES
OPERATION • Failed supply pump
• Refer to Code No. P0191: Rail Pressure Sensor • Failed common rail assembly
Range/Performance Problem P.13A-143. • Failed engine-ECU
• Refer to Code No. P0192: Rail Pressure Sensor
Circuit Low Input P.13A-147. DIAGNOSIS PROCEDURE
• Refer to Code No. P0193: Rail Pressure Sensor
Circuit High Input P.13A-155.
STEP 1. M.U.T.-III diagnosis code
FUNCTION Q: Is any other diagnosis code than P1274 output?
• The engine-ECU monitors the signals input from YES : Inspection chart for diagnosis codes (Refer
the rail pressure sensor. to P.13A-21).
• Based on these input signals, the engine-ECU NO : Go to Step 2 .
checks whether the fuel pressure in the common
rail is abnormal.
STEP 2. Check suction control valve itself
TROUBLE JUDGMENT • Check suction control valve itself (Refer to P.13A-
596).
Check Conditions
• Engine is running Q: Is the check result normal?
• Rail pressure sensor is normal YES : Go to Step 3 .
NO : Replace the suction control valve. After
Judgment Criterion replacing the supply pump, learn the supply
• For 1 seconds, the rail pressure stays in the criti- pump (Refer to GROUP 00 − Precautions
cal pressure range in which the supply pump is Before Service − What The Common Rail
burned out. Engine Learns ).
DIESEL FUEL
TROUBLESHOOTING
13A-301
YES : Replace the engine-ECU. When the engine-
STEP 3. Replace the supply pump assembly.
ECU is replaced, write the chassis number
• After the supply pump assembly, learn the sup-
(Refer to GROUP 00 − Precautions Before
ply pump (Refer to GROUP 00 − Precautions
Service − How to Perform Chassis Number
Before Service − What The Common Rail Engine
Writing ). After replacing the engine-ECU,
Learns ).
register the injector identification code and
• After learning the supply pump assembly, re-
learn fuel injection (Refer to GROUP 00 −
check the trouble symptoms.
Precautions Before Service − What The
Q: Does trouble symptom persist? Common Rail Engine Learns ). After
YES : Go to Step 4 . registering the injector identification code,
NO : The check is end. the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
STEP 4. Replace the common rail assembly and GROUP 17 − Emission Control − Diesel
fuel injection tubes. Particulate Filter (DPF) System − Forcible
• After replacing the common rail assembly and DPF Regeneration ).
fuel injection tubes, re-check the trouble symp- NO : The check is end.
toms
Q: Does trouble symptom persist?
DIAGNOSIS PROCEDURE
OPERATION
• Refer to Code No. P0191: Rail Pressure Sensor
STEP 1. M.U.T.-III diagnosis code
Range/Performance Problem P.13A-143.
• Refer to Code No. P0192: Rail Pressure Sensor Q: Is any other diagnosis code than P1275 output?
Circuit Low Input P.13A-147. YES : Inspection chart for diagnosis codes (Refer
• Refer to Code No. P0193: Rail Pressure Sensor to P.13A-21).
Circuit High Input P.13A-155. NO : Go to Step 2 .
Code No. P1276: Fuel Filter Exchange <Vehicles with fuel filter pressure switch>
C-103
110
AKB00283 AB
2 1
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
2 1
Harness side
connector AK700919AC
A-143 (B)
<R.H. drive vehicles>
2 1
Harness side
C-103 (B) connector AK700919AC
STEP 8. Connector check: C-103 engine-ECU STEP 9. Check harness between A-143 (terminal
connector No. 1) fuel filter pressure switch connector and
Connector: C-103
C-103 (terminal No. 110) engine-ECU connector.
<L.H. drive vehicles> Connector: A-143
A-143 (B)
C-103 (B) 2 1
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
<R.H. drive vehicles>
Harness side connector AKA00090 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P1277: Fuel Filter Freeze <Vehicles with fuel filter pressure switch>
Code No. P1298: Variable Geometry Turbocharger Control System Malfunction (high pressure)
<Euro5>
Code No. P1299: Variable Geometry Turbocharger Control System Malfunction (low pressure)
<Euro5>
Code No. P1427: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit Low Input
<Euro5>
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00277 AB
• Short circuit in No. 3 exhaust gas temperature STEP 3. Check No. 3 exhaust gas temperature
sensor (DPF temperature) circuit or connector sensor (DPF temperature) itself.
damage • Check No. 3 exhaust gas temperature sensor
• Failed engine-ECU (DPF temperature) itself (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter (DPF)
DIAGNOSTIC PROCEDURE System − No. 3 exhaust gas temperature sensor
(DPF temperature) Check ).
STEP 1. M.U.T.-III data list Q: Is the check result normal?
• Refer to Data List Reference Table P.13A-542. YES : Go to Step 4 .
a. Item 119: No. 3 exhaust gas temperature sensor NO : Replace the No. 3 exhaust gas temperature
(DPF temperature) sensor (DPF temperature). After replacing
Q: Is the check result normal?
the No. 3 exhaust gas temperature sensor
YES : Intermittent malfunction (Refer to GROUP (DPF temperature), carry out the forcible
00 − How to Use Troubleshooting/ DPF regeneration. (Refer to GROUP 17 −
Inspection Service Points − How to Cope Emission Control − Diesel Particulate Filter
with Intermittent Malfunctions ). (DPF) System − Forcible DPF Regeneration
NO : Go to Step 2 . ).
STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Connector check: C-105 engine-ECU
gas temperature sensor (DPF temperature) connector
connector Connector: C-105
<L.H. drive vehicles>
Connector: A-158
C-105 (B)
2 1 A-158 (B)
<R.H. drive vehicles>
Harness side
connector
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
AKB00278 AB 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P1428: No. 3 Exhaust Gas Temperature Sensor (DPF temperature) Circuit High Input
<Euro5>
A-158
MU802661
No. 3 exhaust gas
temperature sensor
1 2 (DPF temperature)
1 2
B W
A-28
6 12
W-V BR-G
C-105 84 60
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
AKB00277 AB
STEP 2. Connector check: A-158 No. 3 exhaust STEP 4. Perform voltage measurement at A-158
gas temperature sensor (DPF temperature) No. 3 exhaust gas temperature sensor (DPF
connector temperature) connector.
Connector: A-158 Connector: A-158
AKB00278 AB AKB00278 AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-158 (terminal
connector. No. 2) No. 3 exhaust gas temperature sensor
Connector: C-105
(DPF temperature) connector and C-105 (terminal
<L.H. drive vehicles> No. 60) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Harness side connector AKA00089 AB
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 6 .
NO : Repair or replace the connector.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-158 (terminal
connector No. 1) No. 3 exhaust gas temperature sensor
Connector: C-105
(DPF temperature) connector and C-105 (terminal
<L.H. drive vehicles> No. 84) engine-ECU connector.
Connector: A-158
C-105 (B)
Harness side
connector
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AKB00278 AB
Harness side connector AKA00089 AB
Connector: C-105
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 10 .
NO : Repair or replace the connector.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
2 1 A-158 (B)
C-105 (B)
Harness side
connector
<R.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
AKB00278 AB
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: C-105
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 <L.H. drive vehicles>
Harness side connector AKA00089 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Judgement Criterion
STEP 3. Forcible DPF regeneration execution
• The DPF regeneration status continues for 30
• Initialise the DPF-related parts, and then delete
minutes or more.
the diagnosis code (Refer to GROUP 00 − Pre-
Check Condition cautions before Service − Initialisation Procedure
• Ignition switch is in "ON" position for Learning Value in Diesel Particulate Filter
Judgement Criterion (DPF) System ).
• The regeneration with short interval continues for a. Item 42: DPF system malfunction service
specified times. • Carry out the forcible DPF regeneration (Refer to
GROUP 17 − Emission Control − Diesel Particu-
PROBABLE CAUSES late Filter (DPF) System − Forcible DPF Regen-
• Failed No. 2 exhaust gas temperature sensor eration ).
(catalyst temperature) Q: Is the diagnosis code P0420 or P1497 set?
• Failed No. 3 exhaust gas temperature sensor YES : Replace the catalytic converter. When the
(DPF temperature) catalytic converter is replaced, initialise the
• Failed exhaust differential pressure sensor learning value (Refer to GROUP 00 −
• Failed exhaust differential pressure sensor ambi- Precautions before Service − Initialisation
ent air temperature sensor Procedure for Learning Value in Diesel
• Catalytic converter inactive Particulate Filter (DPF) System ). On
• The engine oil-containing ash is loaded to the completion, carry out the forcible DPF
DPF inside. regeneration (Refer to GROUP 17 −
Emission Control − Diesel Particulate Filter
DIAGNOSIS PROCEDURE (DPF) System − Forcible DPF Regeneration
).
STEP 1. M.U.T.-III data list. NO : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 118: No. 2 exhaust gas temperature sen- (Refer to GROUP 00 − Precautions Before
sor (catalyst temperature) Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
b. Item 119: No. 3 exhaust gas temperature sen-
register the injector identification code and
sor (DPF temperature)
learn fuel injection (Refer to GROUP 00 −
c. Item 120: Exhaust differential pressure sensor Precautions Before Service − What The
Q: Are the check results normal? Common Rail Engine Learns ). After
YES : Go to Step 2 . registering the injector identification code,
NO : Perform the diagnosis code classified check carry out the forcible DPF regeneration.
procedure for the sensor that has shown an (Refer to GROUP 17 − Emission Control −
abnormal data value (Refer to Inspection Diesel Particulate Filter (DPF) System −
Chart for Diagnosis Code P.13A-21). Forcible DPF Regeneration ).
DIESEL FUEL
TROUBLESHOOTING
13A-319
YES : Proceed to troubleshooting for black smoke
STEP 4. Forcible DPF regeneration execution
(Refer to Inspection Procedure 13 P.13A-
• Initialise the DPF-related parts, and then delete
479).
the diagnosis code (Refer to GROUP 00 − Pre-
NO : Replace the DPF. When the DPF is
cautions before Service − Initialisation Procedure
replaced, initialise the learning value (Refer
for Learning Value in Diesel Particulate Filter
to GROUP 00 − Precautions Before Service
(DPF) System ).
− Initialisation Procedure For Learning
a. Item 42: DPF system malfunction service
Value in Diesel Particulate Filter (DPF)
• Carry out the forcible DPF regeneration 2 times
System ).
(Refer to GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible DPF
Regeneration ).
NOTE: Carry out the DPF regeneration 2 times
because the assumption of the accumulated
amount of the DPF is not stable.
• M.U.T.-III data list
a. Item 156: Soot loading by differential pressure
OK: 3 g/L or less
Q: Is the check result normal?
A-152
Hall IC
1 2 Battery current sensor
3 4
1 4 3
AKB00279 AB
Harness side
connector
NO : Replace the battery current sensor. 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-152 (GR)
AKB00274 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118
A-152 (GR)
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00274 AB
158 157156 155 154 153 152 151 150 149 148 147 146
STEP 8. Connector check: C-103 engine-ECU STEP 9. Check harness between A-152 (terminal
connector No. 3) battery current sensor connector and C-
Connector: C-103
103 (terminal No. 155) engine-ECU connector.
<L.H. drive vehicles> Connector: A-152
2 1
4 3
Harness side
connector
C-103 (B)
A-152 (GR)
<R.H. drive vehicles>
AKB00274 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
<R.H. drive vehicles>
Harness side connector AKA00090 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
A-152 (GR)
<R.H. drive vehicles>
AKB00274 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
<R.H. drive vehicles>
Harness side connector AKA00090 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
YES : Go to Step 6 .
STEP 12. Check harness between A-152 (terminal
NO : Repair the damaged harness wire.
No. 4) battery current sensor connector and C-
103 (terminal No. 138) engine-ECU connector.
Connector: A-152
2 1
4 3
Harness side
connector
A-152 (GR)
AKB00274 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
TROUBLE JUDGMENT
FUNCTION Check Condition
• Correction data of the injector built in the engine • Ignition switch is in "ON" position.
is written to the engine-ECU.
• The engine-ECU checks whether the correction Judgment Criterion
data thus written is valid. • An error is detected during three-side majority
decision check or upper/lower limit check of an
injector correction value.
DIESEL FUEL
TROUBLESHOOTING
13A-327
PROBABLE CAUSE STEP 2. Rewrite the injector identification code
• Failed engine-ECU data again.
• Rewrite the injector identification code data
DIAGNOSIS PROCEDURE (Refer to GROUP 00− Precautions Before Serv-
ice − Injector Identification Code Registration
STEP 1. Injector identification code data check Procedure ).
• Check whether injector identification code data is • After rewriting the injector identification code data
correctly written to the engine-ECU in M.U.T.-III. again, recheck for abnormal symptoms.
Q: Does trouble symptom persist?
Q: Is the check result normal?
YES : Replace the engine-ECU. When the engine-
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, Writing ). After replacing the engine-ECU,
register the injector identification code and register the injector identification code and
learn fuel injection (Refer to GROUP 00 − learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Precautions Before Service − What The
Common Rail Engine Learns ). After Common Rail Engine Learns ). After
registering the injector identification code, registering the injector identification code,
the vehicle equipped with the DPF carries the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible Particulate Filter (DPF) System − Forcible
DPF Regeneration ). DPF Regeneration ).
NO : The check is end.
NO : Go to Step 2 .
DIAGNOSIS PROCEDURE
FUNCTION
• The engine-ECU checks whether injector correc-
STEP 1. Write the injector identification code
tion data is written to the engine-ECU.
data.
TROUBLE JUDGMENT • Write the injector identification code data (Refer
to GROUP 00 − Precautions Before Service −
Check Condition Injector Identification Code Registration Proce-
• Ignition switch is in "ON" position. dure ).
Judgment Criterion • After writing the injector identification code data,
• No record of writing injector correction data recheck for abnormal symptoms.
Q: Does trouble symptom persist?
PROBABLE CAUSE
• Failed engine-ECU
YES : Replace the engine-ECU. When the engine- registering the injector identification code,
ECU is replaced, write the chassis number the vehicle equipped with the DPF carries
(Refer to GROUP 00 − Precautions Before out the forcible DPF regeneration. (Refer to
Service − How to Perform Chassis Number GROUP 17 − Emission Control − Diesel
Writing ). After replacing the engine-ECU, Particulate Filter (DPF) System − Forcible
register the injector identification code and DPF Regeneration ).
learn fuel injection (Refer to GROUP 00 − NO : The check is end.
Precautions Before Service − What The
Common Rail Engine Learns ). After
13A-328 DIESEL FUEL
TROUBLESHOOTING
Code No. P2118: Throttle Valve Control (DC Motor) Current Malfunction
A-132
(MU805200)
Electronic-controlled
1 2 3 4 5 6 throttle valve
5 6
G-B G
AKA00107 AB
Connector: A-132
C-103 (B)
A-132 (B)
6 5 4 3 2 1 <R.H. drive vehicles>
Harness side
connector AK604705 AB
STEP 4. Check harness between C-103 (terminal STEP 5. Check harness between C-103 (terminal
No. 114) engine-ECU connector and A-132 No. 129) engine-ECU connector and A-132
(terminal No. 6) electronic-controlled throttle (terminal No. 5) electronic-controlled throttle
valve connector. valve connector.
Connector: C-103 Connector: C-103
<L.H. drive vehicles> <L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
• Check output line for short circuit. • Check output line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2122: Accelerator Pedal Position Sensor (main) Circuit Low Input
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
AKA00109 AB
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 1) accelerator pedal position sensor
Connector: C-103
connector and C-103 (terminal No. 149) engine-
<L.H. drive vehicles> ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 5 .
NO : Repair or replace the connector.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
<L.H. drive vehicles> Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair or replace the connector.
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
YES : Go to Step 6 .
STEP 9. Check harness between C-115 (terminal
NO : Repair the damaged harness wire.
No. 2) accelerator pedal position sensor
connector and C-103 (terminal No. 151) engine-
ECU connector. STEP 10. Connector check: C-103 engine-ECU
connector
Connector: C-115
<L.H. drive vehicles> Connector: C-103
<L.H. drive vehicles>
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
<L.H. drive vehicles> 158 157156 155 154 153 152 151 150 149 148 147 146
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
Harness side connector AK700804 AB
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Voltage between terminal No. 3 and earth. Q: Is the check result normal?
OK: 0.7 − 1.3 V YES : Go to Step 13 .
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Go to Step 12 .
13A-338 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Check harness between C-115 (terminal STEP 14. Check harness between C-115 (terminal
No. 3) accelerator pedal position sensor and C- No. 1) accelerator pedal position sensor
103 (terminal No. 150) engine-ECU connector. connector and C-103 (terminal No. 149) engine-
ECU connector.
Connector: C-115
<L.H. drive vehicles> Connector: C-115
<L.H. drive vehicles>
C-115 (B)
C-115 (B)
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector 6 5 4 3 2 1
AK700804 AB
Harness side connector AK700804 AB
Connector: C-103
<L.H. drive vehicles> Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
<R.H. drive vehicles>
<R.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB
Harness side connector
• Check output line for short circuit. AKA00090 AB
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P2123: Accelerator Pedal Position Sensor (main) Circuit High Input
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
AKA00109 AB
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
6 5 4 3 2 1
Harness side connector AK700804 AB
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 2) accelerator pedal position sensor
Connector: C-103
connector and C-103 (terminal No. 151) engine-
<L.H. drive vehicles> ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 5 .
NO : Repair or replace the connector.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P2124: Accelerator Pedal Position Sensor (Main) Circuit High Input Intermittent
(main)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
1 3 2
L-W GR BR-W
AKA00109 AB
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
6 5 4 3 2 1
Harness side connector AK700804 AB
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 2) accelerator pedal position sensor
Connector: C-103
connector and C-103 (terminal No. 151) engine-
<L.H. drive vehicles> ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 5 .
NO : Repair or replace the connector.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P2127: Accelerator Pedal Position Sensor (sub) Circuit Low Input
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
Y-R L B-Y
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 4) accelerator pedal position sensor
Connector: C-103
connector and C-103 (terminal No. 134) engine-
<L.H. drive vehicles> ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 5 .
NO : Repair or replace the connector.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
STEP 7. Perform resistance measurement at C- 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 accelerator pedal position sensor connector. Harness side connector AKA00090 AB
Connector: C-115
<L.H. drive vehicles> Q: Is the check result normal?
YES : Go to Step 9 .
NO : Repair or replace the connector.
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
YES : Go to Step 6 .
STEP 9. Check harness between C-115 (terminal
NO : Repair the damaged harness wire.
No. 5) accelerator pedal position sensor
connector and C-103 (terminal No. 136) engine-
ECU connector. STEP 10. Connector check: C-103 engine-ECU
connector
Connector: C-115
<L.H. drive vehicles> Connector: C-103
<L.H. drive vehicles>
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
Connector: C-103 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
<L.H. drive vehicles> 158 157156 155 154 153 152 151 150 149 148 147 146
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-115 (B)
C-103 (B)
C-115 (B)
C-103 (B)
6 5 4 3 2 1
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
Harness side connector AK700804 AB
130 129 128 127 126 125 124 123 122 121120 119 118
117 116
• Use special tool test harness (MB991658) to con- 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
• Voltage between terminal No. 6 and earth. Q: Is the check result normal?
OK: 0.2 − 0.8 V YES : Go to Step 13 .
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 15 .
NO : Go to Step 12 .
13A-354 DIESEL FUEL
TROUBLESHOOTING
STEP 13. Check harness between C-115 (terminal STEP 14. Check harness between C-115 (terminal
No. 6) accelerator pedal position sensor No. 4) accelerator pedal position sensor
connector and C-103 (terminal No. 135) engine- connector and C-103 (terminal No. 134) engine-
ECU connector. ECU connector.
Connector: C-115 Connector: C-115
<L.H. drive vehicles> <L.H. drive vehicles>
6 5 4 3 2 1 6 5 4 3 2 1
Harness side connector AK700804 AB Harness side connector AK700804 AB
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
• Check output line for short circuit. • Check power supply line for damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 14 . YES : Replace the accelerator pedal position
NO : Repair the damaged harness wire. sensor.
NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-355
YES : Go to Step 6 .
STEP 15. Check harness between C-115 (terminal
NO : Repair the damaged harness wire.
No. 6) accelerator pedal position sensor
connector and C-103 (terminal No. 135) engine-
ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P2128: Accelerator Pedal Position Sensor (sub) Circuit High Input
(sub)
Accelerator
C-115 Hall IC pedal
(MU805200) position
1 2 3 4 5 6 sensor
4 6 5
Y-R L B-Y
C-115 (B)
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
6 5 4 3 2 1
Harness side connector AK700804 AB
STEP 4. Connector check: C-103 engine-ECU STEP 5. Check harness between C-115 (terminal
connector No. 5) accelerator pedal position sensor
Connector: C-103
connector and C-103 (terminal No. 136) engine-
<L.H. drive vehicles> ECU connector.
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
6 5 4 3 2 1
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
Q: Is the check result normal? <L.H. drive vehicles>
YES : Go to Step 5 .
NO : Repair or replace the connector.
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Code No. P2138: Accelerator Pedal Position Sensor (Main and Sub) Range/Performance Problem
Connector: C-115
<L.H. drive vehicles>
C-115 (B)
C-115 (B)
C-115 (B)
C-115 (B) 6 5 4 3 2 1
Harness side connector AK700804 AB
6 5 4 3 2 1
• Disconnect connector, and measure at harness
Harness side connector AK700804 AB side.
• Resistance between terminal No. 2 and earth.
Q: Is the check result normal?
YES : Go to Step 2 . OK: Continuity (2 Ω or less)
NO : Repair or replace the connector. Q: Is the check result normal?
YES : Go to Step 4 .
NO : Go to Step 3 .
DIESEL FUEL
TROUBLESHOOTING
13A-361
YES : Check and repair harness between C-115
STEP 3. Connector check: C-103 engine-ECU
(terminal No. 2) accelerator pedal position
connector
sensor connector and C-103 (terminal No.
Connector: C-103 151) engine-ECU connector.
<L.H. drive vehicles> • Check earthing line for damage.
NO : Repair or replace the connector.
C-115 (B)
C-103 (B)
<R.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
C-115 (B)
C-103 (B)
<R.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
C-115 (B)
C-115 (B)
<R.H. drive vehicles>
6 5 4 3 2 1
Harness side connector AK700804 AB
Connector: C-103
<L.H. drive vehicles>
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
Connector: C-115
<L.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-115 (B)
6 5 4 3 2 1
Harness side connector AK700804 AB
C-115 (B)
C-103 (B)
<R.H. drive vehicles>
<R.H. drive vehicles>
C-115 (B)
6 5 4 3 2 1
C-103 (B)
Harness side connector AK700804 AB
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
Connector: C-103 130 129 128 127 126 125 124 123 122 121120 119 118
117 116
<L.H. drive vehicles> 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
STEP 13. Check harness between C-115 (terminal STEP 14. Connector check: C-103 engine-ECU
No. 6) accelerator pedal position sensor connector
connector and C-103 (terminal No. 135) engine- Connector: C-103
ECU connector. <L.H. drive vehicles>
Connector: C-115
<L.H. drive vehicles>
C-103 (B)
C-115 (B)
C-103 (B)
C-115 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
6 5 4 3 2 1 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AK700804 AB
Harness side connector AKA00090 AB
Connector: C-103
<L.H. drive vehicles> Q: Is the check result normal?
YES : Go to Step 15 .
NO : Repair or replace the connector.
Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Euro5>
DIAGNOSIS PROCEDURE
<R.H. drive vehicles>
WARNING
A high-tension voltage is flowing between
the engine-ECU and the injectors while the
engine is running. Handle them carefully to
avoid receiving electric shocks from the volt-
age.
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connectors: A-42, A-129 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 4. Check harness between C-105 (terminal STEP 5. Check harness between C-105 (terminal
No. 1) engine-ECU connector and A-42 (terminal No. 25) engine-ECU connector and A-129
No. 2) No. 1 injector connector. (terminal No. 2) No. 4 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00186 AB connector AKA00189AB
• Check power supply line for open/short circuit. • Check power supply line for open/short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
Connector: A-42 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2
A-129 (GR)
Harness side
connector AKA00186 AB
NO : Repair the damaged harness wire. • Check earthing line for open circuit.
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Repair the damaged harness wire.
Code No. P2146: Injector Common 1 (cylinder No. 1 and No. 4) Circuit Open <Except Euro5>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 5. Check harness between C-105 (terminal STEP 6. Check harness between C-105 (terminal
No. 1) engine-ECU connector and A-129 (terminal No. 2) engine-ECU connector and A-42 (terminal
No. 2) No. 4 injector connector. No. 1) No. 1 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00189AB connector AKA00186 AB
• Check power supply line for open/short circuit. • Check earthing line for open/short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-373
YES : Go to Step 8 .
STEP 7. Check harness between C-105 (terminal
NO : Repair the damaged harness wire.
No. 27) engine-ECU connector and A-129
(terminal No. 1) No. 4 injector connector.
STEP 8. M.U.T.-III diagnosis code.
Connector: C-105
<L.H. drive vehicles> • After erasing the diagnosis code through M.U.T.-
III, start the engine and confirm whether the diag-
nosis code is output.
Q: Is the diagnosis code set?
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
C-105 (B) (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
<R.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
C-105 (B)
with Intermittent Malfunctions ).
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side
connector AKA00189AB
Code No. P2147: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Earth Short <Euro5>
OPERATION FUNCTION
• Refer to Code No. P0201: No. 1 Injector Circuit • The engine-ECU monitors voltage application to
Malfunction P.13A-158. the injector during no injector energization to
• Refer to Code No. P0204: No. 4 Injector Circuit detect errors in the No. 1 and No. 4 injector drive
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Conditions
• Ignition switch is in "ON" position.
13A-374 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSES
• Short circuit in injector circuit or loose connector
contact
• Failed No. 1 injector
• Failed No. 4 injector
C-105 (B)
• Failed engine-ECU
WARNING
A high-tension voltage is flowing between
the engine-ECU and the injectors while the
engine is running. Handle them carefully to
avoid receiving electric shocks from the volt-
age. C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
STEP 1. Connector check: A-42 No. 1 injector 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00186 AB connector AKA00189AB
• Check earthing line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4 . YES : Go to Step 5 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-376 DIESEL FUEL
TROUBLESHOOTING
STEP 5. Check harness between C-105 (terminal STEP 6. Check harness between C-105 (terminal
No. 1) engine-ECU connector and A-42 (terminal No. 25) engine-ECU connector and A-129
No. 2) No. 1 injector connector. (terminal No. 2) No. 4 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00186 AB connector AKA00189AB
• Check power supply line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2147: Injector Common Circuit Earth Short <Except Euro5>
YES : Go to Step 3.
STEP 4. Check harness between C-105 (terminal
NO : Replace the injector. After replacing the
No. 2) engine-ECU connector and A-42 (terminal
Injector, register the injector identification
No. 1) No. 1 injector connector.
code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service − Connector: C-105
<L.H. drive vehicles>
What The Common Rail Engine Learns ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check earthing line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6. YES : Go to Step 7.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-380 DIESEL FUEL
TROUBLESHOOTING
STEP 7. Check harness between C-105 (terminal STEP 8. Check harness between C-105 (terminal
No. 27) engine-ECU connector and A-129 No. 1) engine-ECU connector and A-42 (terminal
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00189AB connector AKA00186 AB
• Check earthing line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 8. YES : Go to Step 9.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-381
STEP 9. Check harness between C-105 (terminal STEP 10. Check harness between C-105 (terminal
No. 25) engine-ECU connector and A-41 (terminal No. 25) engine-ECU connector and A-130
No. 2) No. 2 injector connector. (terminal No. 2) No. 3 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check power supply line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 10. YES : Go to Step 11.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-382 DIESEL FUEL
TROUBLESHOOTING
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side
connector AKA00189AB
Code No. P2148: Injector Common 1 (Cylinder No. 1 and No. 4) Circuit Battery Short <Euro5>
OPERATION FUNCTION
• Refer to Code No. P0201: No. 1 Injector Circuit • The engine-ECU monitors voltage application to
Malfunction P.13A-158. the injector during no injector energization to
• Refer to Code No. P0204: No. 4 Injector Circuit detect errors in the No. 1 and No. 4 injector drive
Malfunction P.13A-173. <Euro5> circuit.
TROUBLE JUDGMENT
Check Condition
• Ignition switch is in "ON" position.
DIESEL FUEL
TROUBLESHOOTING
13A-383
Judgment Criterion YES : Go to Step 2 .
• Short-circuit to the battery is detected in the injec- NO : Repair or replace the connector.
tor drive circuit.
STEP 2. Connector check: C-105 engine-ECU
PROBABLE CAUSES
connector.
• Short circuit in injector circuit or loose connector
contact Connector: C-105
<L.H. drive vehicles>
• Failed No. 1 injector
• Failed No. 4 injector
• Failed engine-ECU
DIAGNOSIS PROCEDURE
WARNING
C-105 (B)
A high-tension voltage is flowing between
the engine-ECU and the injectors while the
engine is running. Handle them carefully to <R.H. drive vehicles>
avoid receiving electric shocks from the volt-
age.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
A-42 (GR)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 3. Check harness between C-105 (terminal STEP 4. Check harness between C-105 (terminal
No. 2) engine-ECU connector and A-42 (terminal No. 27) engine-ECU connector and A-129
No. 1) No. 1 injector connector. (terminal No. 1) No. 4 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00186 AB connector AKA00189AB
• Check earthing line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4 . YES : Go to Step 5 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-385
STEP 5. Check harness between C-105 (terminal STEP 6. Check harness between C-105 (terminal
No. 1) engine-ECU connector and A-42 (terminal No. 25) engine-ECU connector and A-129
No. 2) No. 1 injector connector. (terminal No. 2) No. 4 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00186 AB connector AKA00189AB
• Check power supply line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2148: Injector Common Circuit Battry Short <Except Euro5>
Harness side
connector AKA00192 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-42
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 5. Check harness between C-105 (terminal STEP 6. Check harness between C-105 (terminal
No. 75) engine-ECU connector and A-41 (terminal No. 50) engine-ECU connector and A-130
No. 1) No. 2 injector connector. (terminal No. 1) No. 3 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check earthing line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6. YES : Go to Step 7.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-389
STEP 7. Check harness between C-105 (terminal STEP 8. Check harness between C-105 (terminal
No. 27) engine-ECU connector and A-129 No. 1) engine-ECU connector and A-42 (terminal
(terminal No. 1) No. 4 injector connector. No. 2) No. 1 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00189AB connector AKA00186 AB
• Check earthing line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 8. YES : Go to Step 9.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-390 DIESEL FUEL
TROUBLESHOOTING
STEP 9. Check harness between C-105 (terminal STEP 10. Check harness between C-105 (terminal
No.25) engine-ECU connector and A-41 (terminal No. 25) engine-ECU connector and A-130
No. 2) No. 2 injector connector. (terminal No. 2) No. 3 injector connector
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check power supply line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 10. YES : Go to Step 11.
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-391
YES : Go to Step 12.
STEP 11. Check harness between C-105 (terminal
NO : Repair the damaged harness wire.
No. 1) engine-ECU connector and A-129 (terminal
No. 2) No. 4 injector connector.
STEP 12. M.U.T.-III diagnosis code.
Connector: C-105
<L.H. drive vehicles> • After erasing the diagnosis code through M.U.T.-
III, start the engine and confirm whether the diag-
nosis code is set.
Q: Is the diagnosis code set?
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
C-105 (B) (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
<R.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
C-105 (B)
with Intermittent Malfunctions ).
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-129
A-129 (GR)
1 2
Harness side
connector AKA00189AB
Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Euro5>
A-41 (GR)
A-130 (GR)
1 2
C-105 (B)
Harness side
connector AKA00191 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00187AB
• Check power supply line for open circuit and • Check earthing line for open/short circuit and
damage. damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-394 DIESEL FUEL
TROUBLESHOOTING
STEP 6. Check harness between C-105 (terminal STEP 7. Check harness between C-105 (terminal
No. 49) engine-ECU connector and A-130 No. 50) engine-ECU connector and A-130
(terminal No. 2) No. 3 injector connector. (terminal No. 1) No. 3 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
1 2 1 2
Harness side Harness side
connector AKA00188 AB connector AKA00188 AB
• Check power supply line for open/short circuit • Check earthing line for open/short circuit and
and damage. damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 7 . YES : Go to Step 8 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2149: Injector Common 2 (cylinder No. 2 and No. 3) Circuit Open <Except Euro5>
YES : Go to Step 3 .
STEP 4. Check harness between C-105 (terminal
NO : Replace the injector. After replacing the
No. 25) engine-ECU connector and A-41 (terminal
Injector, register the injector identification
No. 2) No. 2 injector connector.
code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service − Connector: C-105
<L.H. drive vehicles>
What The Common Rail Engine Learns ).
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-41
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check earthing line for open/short circuit and • Check power supply line for open/short circuit
damage. and damage.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
13A-398 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 8 .
STEP 7. Check harness between C-105 (terminal
NO : Repair the damaged harness wire.
No. 50) engine-ECU connector and A-130
(terminal No. 1) No. 3 injector connector.
STEP 8. M.U.T.-III diagnosis code.
Connector: C-105
<L.H. drive vehicles> • After erasing the diagnosis code through M.U.T.-
III, start the engine and confirm whether the diag-
nosis code is output.
Q: Is the diagnosis code set?
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
C-105 (B) (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
<R.H. drive vehicles> register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
C-105 (B)
with Intermittent Malfunctions ).
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-130
A-130 (GR)
1 2
Harness side
connector AKA00188 AB
Code No. P2150: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Earth Short <Euro5>
OPERATION FUNCTION
• Refer to Code No. P0202: No. 2 Injector Circuit • The engine-ECU monitors voltage application to
Malfunction P.13A-161. <Euro5> the injector during no injector energization to
• Refer to Code No. P0203: No. 3 Injector Circuit detect errors in the No. 2 and No. 3 injector drive
Malfunction P.13A-167. circuit.
Judgment Criterion
• Short-circuit to the earth is detected in the injector STEP 2. Connector check: C-105 engine-ECU
drive circuit. connector.
Connector: C-105
PROBABLE CAUSES <L.H. drive vehicles>
• Short circuit in injector circuit or loose connector
contact
• Failed No. 2 injector
• Failed No. 3 injector
• Failed engine-ECU
C-105 (B)
DIAGNOSIS PROCEDURE
WARNING
<R.H. drive vehicles>
A high-tension voltage is flowing between
the engine-ECU and the injectors while the
engine is running. Handle them carefully to
avoid receiving electric shocks from the volt-
age.
C-105 (B)
STEP 1. Connector check: A-41 No. 2 injector
connector and A-130 No. 3 injector connector.
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Connectors: A-41, A-130
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side
connector AKA00191 AB
STEP 3. Check harness between C-105 (terminal STEP 4. Check harness between C-105 (terminal
No. 75) engine-ECU connector and A-41 (terminal No. 50) engine-ECU connector and A-130
No. 1) No. 2 injector connector. (terminal No. 1) No. 3 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check earthing line for short circuit. • Check earthing line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4 . YES : Go to Step 5 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-401
STEP 5. Check harness between C-105 (terminal STEP 6. Check harness between C-105 (terminal
No. 73) engine-ECU connector and A-41 (terminal No. 49) engine-ECU connector and A-130
No. 2) No. 2 injector connector (terminal No. 2) No. 3 injector connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00187AB connector AKA00188 AB
• Check power supply line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 6 . YES : Go to Step 7 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2151: Injector Common 2 (Cylinder No. 2 and No. 3) Circuit Battery Short <Euro5>
C-105 (B)
C-105 (B)
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB
Harness side connector AKA00089 AB
Q: Is the check result normal?
YES : Go to Step 3 . Connector: A-41
NO : Repair or replace the connector.
A-41 (GR)
1 2
Harness side
connector AKA00187AB
STEP 4. Check harness between C-105 (terminal STEP 5. Check harness between C-105 (terminal
No. 50) engine-ECU connector and A-130 No. 73) engine-ECU connector and A-41 (terminal
(terminal No. 1) No. 3 injector connector. No. 2) No. 2 injector connector
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
A-41 (GR)
A-130 (GR)
1 2 1 2
Harness side Harness side
connector AKA00188 AB connector AKA00187AB
• Check earthing line for short circuit. • Check power supply line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-405
YES : Go to Step 7 .
STEP 6. Check harness between C-105 (terminal
NO : Repair the damaged harness wire.
No. 49) engine-ECU connector and A-130
(terminal No. 2) No. 3 injector connector.
STEP 7. Check Injector itself
Connector: C-105
<L.H. drive vehicles> • Check No. 2 injector and No. 3 injector itself
(Refer to P.13A-595).
Q: Is the check result normal?
YES : Go to Step 8 .
NO : Replace the injector. After replacing the
Injector, register the injector identification
C-105 (B) code and learn fuel injection (Refer to
GROUP 00 − Precautions Before Service −
What The Common Rail Engine Learns ).
<R.H. drive vehicles>
TROUBLE JUDGMENT
Check Condition
• Ignition switch is in "ON" position
Judgment Criterion C-105 (B)
• The EGR valve in sticking state (a high duty state
continues for the predetermined time or more) is
<R.H. drive vehicles>
repeatedly detected.
PROBABLE CAUSES
• Failed EGR valve
• Open/short circuit or harness damage in EGR
valve circuit or loose connector contact
• Failed engine-ECU
C-105 (B)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Q: Is any other diagnosis code than P2413 output? Harness side connector AKA00089 AB
YES : Inspection chart for diagnosis codes (Refer
to P.13A-21). Q: Is the check result normal?
NO : Go to Step 2 . YES : Go to Step 4 .
NO : Repair or replace the connector.
13A-408 DIESEL FUEL
TROUBLESHOOTING
STEP 4. Check harness between C-105 (terminal STEP 5. Check harness between C-105 (terminal
No. 115) engine-ECU connector and A-45 No. 130) engine-ECU connector and A-45
(terminal No. 6) EGR valve assembly connector. (terminal No. 4) EGR valve connector.
Connector: C-105 Connector: C-105
<L.H. drive vehicles> <L.H. drive vehicles>
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
3 2 1 3 2 1
6 5 4 6 5 4
Harness side Harness side
connector AK501331 AB connector AK501331 AB
• Check output line for open/short circuit and dam- • Check output line for open/short circuit and dam-
age. age.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 5 . YES : Go to Step 6 .
NO : Repair the damaged harness wire. NO : Repair the damaged harness wire.
Code No. P2454: Exhaust Differential Pressure Sensor Circuit Low Input <Euro5>
2 1 3
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
<R.H. drive vehicles>
Connector: A-148
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AKB00281AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
• Measure engine-ECU terminal voltage.
• Ignition switch: ON
STEP 3. Perform voltage measurement at A-148 • Voltage between terminal No. 94 and earth.
exhaust differential pressure sensor connector. OK: 4.9 − 5.1 V
Connector: A-148 Q: Is the check result normal?
YES : Go to Step 8 .
NO : Go to Step 5 .
A-148 (B)
3 2 1
Harness side
connector AKB00281AB
STEP 5. Connector check: C-105 engine-ECU STEP 6. Check harness between A-148 (terminal
connector No. 3) exhaust differential pressure sensor
Connector: C-105
connector and C-105 (terminal No. 94) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-148
3 2 1
<R.H. drive vehicles>
Harness side
connector AKB00281AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: A-148
A-148 (B)
3 2 1
Harness side
connector AKB00281AB
STEP 9. Connector check: C-105 engine-ECU STEP 10. Check harness between A-148 (terminal
connector No. 3) exhaust differential pressure sensor
Connector: C-105
connector and C-105 (terminal No. 94) engine-
<L.H. drive vehicles> ECU connector.
Connector: A-148
3 2 1
<R.H. drive vehicles>
Harness side
connector AKB00281AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
C-105 (B)
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Code No. P2455: Exhaust Differential Pressure Sensor Circuit High Input <Euro5>
2 1 3
C-105
80 56 94
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
5V
C-105 (B)
STEP 2. Connector check: A-148 exhaust
differential pressure sensor connector
<R.H. drive vehicles>
Connector: A-148
A-148 (B)
C-105 (B)
3 2 1
Harness side 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
connector AKB00281AB
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Q: Is the check result normal?
YES : Go to Step 3 . Harness side connector AKA00089 AB
NO : Repair or replace the connector.
Q: Is the check result normal?
YES : Go to Step 5 .
STEP 3. Perform resistance measurement at A- NO : Repair or replace the connector.
148 exhaust differential pressure sensor
connector.
Connector: A-148
A-148 (B)
3 2 1
Harness side
connector AKB00281AB
YES : Go to Step 6 .
STEP 5. Check harness between A-148 (terminal
NO : Repair the damaged harness wire.
No. 2) exhaust differential pressure sensor
connector and C-105 (terminal No. 80) engine-
ECU connector. STEP 6. M.U.T.-III data list
• Refer to Data List Reference Table P.13A-542.
Connector: A-148
a. Item 120: exhaust differential pressure sensor
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
A-148 (B) Inspection Service Points − How to Cope
with Intermittent Malfunctions ).
3 2 1 NO : Replace the engine-ECU. When the engine-
Harness side ECU is replaced, write the chassis number
connector AKB00281AB (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Connector: C-105 Writing ). After replacing the engine-ECU,
<L.H. drive vehicles>
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
carry out the forcible DPF regeneration.
C-105 (B) (Refer to GROUP 17 − Emission Control −
Diesel Particulate Filter (DPF) System −
<R.H. drive vehicles>
Forcible DPF Regeneration ).
YES : Go to Step 1 .
STEP 3. M.U.T.-III diagnosis code
NO : The check is end.
• Reconfirm whether the diagnosis codes are out-
put from engine-ECU.
1. Erase the diagnosis codes being output.
2. Ignition switch: "LOCK" (OFF) to ON
3. Confirm whether the diagnosis codes are output.
Q: Are the diagnosis codes output?
YES : After replacing the ETACS-ECU, go to Step YES : Replace the engine-ECU. When the engine-
6. ECU is replaced, write the chassis number
NO : Intermittent malfunction in CAN busline (Refer to GROUP 00 − Precautions Before
between engine-ECU and ETACS-ECU Service − How to Perform Chassis Number
(Refer to GROUP 00 − How to Use Writing ). After replacing the engine-ECU,
Troubleshooting/Inspection Service Points − register the injector identification code and
How to Cope with Intermittent Malfunctions learn fuel injection (Refer to GROUP 00 −
). Precautions Before Service − What The
Common Rail Engine Learns ). After
STEP 5. Reconfirmation of diagnosis codes registering the injector identification code,
• Reconfirm whether the diagnosis codes are out- the vehicle equipped with the DPF carries
put from engine-ECU out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
1. Erase the diagnosis codes being output.
Particulate Filter (DPF) System − Forcible
2. Ignition switch: "LOCK" (OFF) to ON DPF Regeneration ). and then go to Step 6
3. Confirm whether the diagnosis codes are output. .
Q: Is the diagnosis code output? NO : Intermittent malfunction in CAN busline
between engine-ECU and ETACS-ECU
(Refer to GROUP 00 − How to Use
Troubleshooting/Inspection Service Points −
How to Cope with Intermittent Malfunctions
).
YES : Go to Step 1 .
STEP 6. Reconfirmation of diagnosis codes
NO : The check is end.
• Reconfirm whether the diagnosis codes are out-
put from engine-ECU
1. Erase the diagnosis codes being output.
2. Ignition switch: "LOCK" (OFF) to ON
3. Confirm whether the diagnosis codes are output.
Q: Is the diagnosis code output?
CAUTION CAUTION
If Diagnosis Code U1117 is output from engine-
ECU surely perform CAN busline diagnosis. Acc position
On position
CAUTION
Range
Replace ECU after certainly confirming that the Lock (off) "A"
communication circuits are normal. position
NOTE: When the diagnosis codes relating to the Start
CAN communication error are output, make sure of position
the vehicle equipment. When the vehicle is not
equipped with the system the engine-ECU communi-
cates to, the diagnosis code is always output. This is AK503593 AB
Code No.U1190: The Network System Diagnosis Code Output Permitted Signal Can Not Be Received
YES : Go to Step 1 .
STEP 3. M.U.T.-III diagnosis code.
NO : Check end.
• Reconfirm whether the diagnosis codes are out-
put from engine-ECU.
1. Erase the diagnosis codes being output.
2. Ignition switch: "LOCK" (OFF) to "ON".
3. Confirm whether the diagnosis codes are output.
Q: Are the diagnosis codes output?
The engine warning lamp does not illuminate right after the
goes out or is blinking
The engine warning lamp remains illuminating and never
Improper idling
Poor acceleration
White smoke
Black smoke
Battery rundown
Overheating
ignition switch is turned the "ON" position
Trouble symptoms
Probable causes
AK503602
13A-432 DIESEL FUEL
TROUBLESHOOTING
SYMPTOM PROCEDURES
C-103
Fusible link 20
108 109
R B W
J/C (CAN 2) 12
C-01 J/B
15A
11 22 13
C-208
R B
C-53*¹ or
6 7 C-35*²
R B
W-B
11 22
J/C (CAN 1)
C-119
10 21
R-L B-L
C-22
MU803797 6 14 16
1 2 3 4 5 6 7 8
9 10 1112 13 14 1516
4 5
Diagnosis connector
B B
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKA00111AB
Diagnosis
connector
MB991910
MB991824
MB991827
<R.H. drive vehicles> Diagnosis
connector
MB991910
MB991824
MB991827 AK600277 AC
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
9 10111213 141516 9 10111213 141516
C-22 (B)
C-22 (B)
1 2 3 4 5 6 7 8
9 10111213 141516
• Disconnect connector.
• Check open circuit between terminal No. 4 and
earth also between terminal No. 5 and earth.
Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-437
Inspection Procedure 2: The Engine Warning Lamp Does Not Illuminate Right after the Ignition Switch
Is Turned the "ON" Position
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00284 AB
13A-438 DIESEL FUEL
TROUBLESHOOTING
DIAGNOSIS PROCEDURE
<R.H. drive vehicles>
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 2. M.U.T.-III diagnosis code.
Harness side connector AKA00089 AB
Q: Is the diagnosis code set?
YES : Inspection chart for diagnosis code (Refer Connector: C-111
to P.13A-21). <L.H. drive vehicles>
NO : Go to Step 3 .
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
Inspection Procedure 3: The Engine Warning Lamp Remains Illuminating and Never Goes Out or Is
Blinking.
C-307
R LOCK
1 2 3 ST ACC Ignition switch
4 5 6 IG1 IG2
2
L-B
C-207
4
15
7.5A J/B
6
C-209
B-W
12
J/C (5)
C-132
15
B-W
C-112
C-112 36
31 32 33 34 35 36
37 38 39 40 41 42
Combination meter
C-111 Engine
MU801586 warning
lamp
51 52 53 54 55 56 57
58 59 60 61 62 63 64 63
C-111
R-W
C-53*¹ or
C-35*²
23
R-W
C-105 46
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00284 AB
DIESEL FUEL
TROUBLESHOOTING
13A-441
OPERATION STEP 3. Connector check: C-105 engine-ECU
• Engine-ECU has detected failed sensor or failed connector and C-111 combination meter
actuator. Or failure is possibly caused by short connector
circuit or other faults.
Connector: C-105
PROBABLE CAUSES <L.H. drive vehicles>
• Damaged connector (Engine-ECU connector,
combination meter connector)
• Damaged harness (Short circuit between engine-
ECU and combination meter)
• Failed combination meter
• Failed engine-ECU C-105 (B)
DIAGNOSIS PROCEDURE
<R.H. drive vehicles>
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
YES : Go to Step 5 .
STEP 4. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-111 54A − Combination Meter − Check Chart for
<L.H. drive vehicles>
Trouble Symptoms ).
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
• Ignition switch: ON
• Disconnect C-111 combination meter connector
Q: Does the engine warning lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-443
STEP 5. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
YES : Go to Step 6 .
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
R-B
C-207
2
4 J/B
7.5A
5
C-211
W
R-B
B-R A-115
11
A-115
10
B-Y
A-16X
4 2
1 2
3 OFF Starter
relay
4 ON
3 1
B
B-L
B-L
6
A-27 A-115
B-W 8
1 1 G-R C-103
Engine-ECU
Starter
A-16X
2 1
3
4
Relay box's side connector AK501014 AC
STEP 6. Connector check: C-307 ignition switch STEP 7. Check ignition switch.
connector
Connector: A-16X
Connector: C-307
<L.H. drive vehicles>
A-16X
C-307 2 1
3
4
Relay box's side connector AK501014 AC
C-307
C-307
3 2 1
6 5 4
Harness side connector AKB00286 AB
A-16X
2 1
3
4 1
Relay box's side connector Harness side connector AK700920 AB
AK501014 AC
• Disconnect connector, and measure at the har- Q: Is the check result normal?
ness side. YES : Go to Step 11.
• Voltage between terminal No. 4 and earth. NO : Repair or replace.
OK: System voltage
Q: Is the check result normal? STEP 11. Check harness between A-110 (terminal
YES : Go to Step 9. No. 1) starter connector and A-16X (terminal No.
NO : Check and repair harness between A16X 3) starter relay connector.
(terminal No. 4) starter relay connector and
battery. Connector: A-110
• Check power supply line for open/ A-110 (B)
short circuit.
Connector: A-16X
A-16X
2 1
3
4
Relay box's side connector AK501014 AC A-16X
2 1
• Disconnect connector, and measure at harness 3
side. 4
• Resistance between terminal No. 1 and earth. Relay box's side connector AK501014 AC
OK: Continuity (2Ω or less)
NOTE: Before checking harness, check intermediate
Q: Is the check result normal? connector A-27, and repair if necessary.
YES : Go to Step 10. • Check output line for open/short circuit.
NO : Check and repair harness between A16X
(terminal No. 1) starter relay connector and Q: Is the check result normal?
YES : Go to Step 12.
body earth.
NO : Repair the damaged harness wire.
• Check earth line for open circuit and
damage.
13A-448 DIESEL FUEL
TROUBLESHOOTING
STEP 12. Connector check: C-103 engine-ECU STEP 13. Connector check: A-110 starter
connector connector
Connector: C-103 Connector: A-110
<L.H. drive vehicles>
A-110 (B)
C-103 (B) 1
Harness side connector AK700920 AB
<R.H. drive vehicles>
Connector: A-16X
1
Harness side connector AK700920 AB
A-16X
2 1
3
4 1
Relay box's side connector Harness side connector AK700921 AB
AK501014 AC
STEP 18. Connector check: A-16X starter relay STEP 19. Check harness between C-307 (terminal
connector and C-307 Ignition switch connector No. 5) ignition switch connector and A-16X
(terminal No. 2) starter relay connector.
Connector: A-16X
Connector: C-307
<L.H. drive vehicles>
A-16X
2 1 C-307
3
4
Relay box's side connector AK501014 AC
C-307
C-307
Connector: A-16X
C-307
3 2 1 A-16X
2 1
6 5 4 3
Harness side connector AKB00286 AB
4
Relay box's side connector AK501014 AC
Q: Are the check results normal?
YES : Go to Step 19. NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
• Check output line for damage.
Q: Is the check result normal?
YES : Go to Step 20.
NO : Repair the damaged harness wire.
DIESEL FUEL
TROUBLESHOOTING
13A-451
YES : Go to Step 22.
STEP 20. Check harness between A-16X
NO : Repair the damaged harness wire.
(terminal No. 4) starter relay connector and
battery
STEP 22. Check harness between A-10 (terminal
Connector: A-16X
No. 1) starter connector and battery.
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
Relay box's side connector AK501014 AC
1
• Check power supply line for damage. Harness side connector AK700920 AB
Q: Is the check result normal?
• Check power supply line for damage.
YES : Go to Step 21.
NO : Repair the damaged harness wire. Q: Is the check result normal?
YES : Replace the starter.
NO : Repair the damaged harness wire.
STEP 21. Check harness between A-16X
(terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter relay connector
Connector: A-16X
A-16X
2 1
3
4
Relay box's side connector AK501014 AC
Connector: A-110
A-110 (B)
1
Harness side connector AK700920 AB
5
R-B
C-207
2
4
J/B
7.5A
C-211
5
R-B
A-115
11
W R-B
B-10
5
R-B
10 B-14
MU802645
B-R
Inhibitor P 1 2 3 4 5
switch
R 6 7 8 9 10
D N
9
B-Y
B-10
6
B-Y
A-115
10
A-16X B-Y
4 2
1 2
3 OFF Starter
ON
relay
4
3 1
B-L B
B-L
6 A-115
A-27 8
B-W
1 1 G-R C-103
111
103104105106107108109110 111112113 114115
A-110 101 102 118119120121122123124125126127128 129130
ON
A-10 OFF (MU801211) 116 117
1 1 131132133134135136137138139140 141142143
144 145 146147148149150151152153154155156 157158
Engine-ECU
Starter
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple AKB00287 AB
DIESEL FUEL
TROUBLESHOOTING
13A-453
COMMENT ON TROUBLE SYMPTOM STEP 4. Check starter relay
• Failure is possibly caused by failed starter itself • Check starter relay (Refer to GROUP 16 − Start-
or failed related circuit. ing System − Starter Relay Check ).
PROBABLE CAUSES Q: Is the check result normal?
• Failed battery YES : Go to Step 5.
• Failed inhibitor switch NO : Replace the starter relay.
• Failed starter motor
• Failed starter relay STEP 5. Perform voltage measurement at A-16X
• Open/short circuit in starter associated circuit or starter relay connector.
loose connector contact
• Failed engine-ECU Connector: A-16X
DIAGNOSIS PROCEDURE
NO : Check battery (Refer to GROUP 54A − • Disconnect connector, and measure at the har-
Battery-On-vehicle Service − Battery Test ). ness side.
• Ignition switch: ST
• Voltage between terminal No. 2 and earth.
STEP 2. M.U.T.-III data list
• Item 40: Starter switch OK: System voltage
OK: Q: Is the check result normal?
ON (Ignition switch: ST) YES : Go to Step 11.
OFF (Ignition switch: ON) NO : Go to Step 6.
B-14 (B)
A-16X AK700823AB
2 1
3
4
Q: Is the check result normal?
YES : Go to Step 7.
Relay box's side connector AK501014 AC NO : Repair or replace.
STEP 8. Perform voltage measurement at B-14 STEP 9. Connector check: C-307 ignition switch
inhibitor switch connector connector
Connector: B-14 Connector: C-307
5 4 3 2 1 <L.H. drive vehicles>
10 9 8 7 6
Harness side
connector
C-307
B-14 (B)
AK700823AB
<R.H. drive vehicles>
Connector: A-16X
C-307
A-16X
2 1
3
4
Relay box's side connector AK501014 AC 3 2 1
• Disconnect connector, and measure at the har- 6 5 4
ness side. Harness side connector AKB00286 AB
• Ignition switch: ST
• Voltage between terminal No. 10 and earth. Q: Is the check result normal?
OK: System voltage YES : Go to Step 10.
NO : Repair or replace.
Q: Is the check result normal?
YES : Check intermediate connectors A-115 and
B-10, and repair if necessary. If starter relay
connector are normal, check and repair
harness between A-16X (terminal No. 2)
starter relay connector and B-14 (terminal
No. 9) inhibitor switch connector.
• Check power supply line for open/
short circuit.
NO : Go to Step 9.
DIESEL FUEL
TROUBLESHOOTING
13A-455
STEP 10. Check ignition switch STEP 11. Perform voltage measurement at A-16X
Connector: B-14
starter relay connector.
5 4 3 2 1
Connector: A-16X
10 9 8 7 6
Harness side
connector
A-16X
B-14 (B) 2 1
3
4
AK700823AB
Relay box's side connector AK501014 AC
Connector: C-307
<L.H. drive vehicles> • Disconnect connector, and measure at the har-
ness side.
• Voltage between terminal No. 4 and earth.
OK: System voltage
C-307
Q: Is the check result normal?
YES : Go to Step 12.
NO : Check and repair harness between A-16X
(terminal No. 4) starter relay connector and
battery.
<R.H. drive vehicles> • Check power supply line for open/
short circuit.
3 2 1
6 5 4
A-16X
Harness side connector 2 1
AKB00286 AB
3
• Check ignition switch (Refer to GROUP 54A − 4
Ignition switch − Inspection ). Relay box's side connector AK501014 AC
STEP 13. Connector check: A-16X starter relay STEP 15. Check harness between A-110 (terminal
connector No. 1) starter connector and A-16X (terminal No.
3) starter relay connector.
Connector: A-16X
Connector: A-110
A-110 (B)
A-16X
2 1
3
4
1
Relay box's side connector AK501014 AC
Harness side connector AK700920 AB
Q: Is the check result normal?
YES : Go to Step 14. Connector: A-16X
NO : Repair or replace.
C-105 (B)
1
Harness side connector AK700920 AB
<R.H. drive vehicles>
Q: Is the check result normal?
YES : Go to Step 18.
NO : Repair or replace.
Connector: A-16X
1
Harness side connector AK700920 AB
STEP 19. Connector check: A-16X starter relay STEP 20. Connector check: A-10 starter
connector connector
Connector: A-16X Connector: A-10
A-10
A-16X
2 1
3
4 1
Relay box's side connector Harness side connector AK700921 AB
AK501014 AC
B-14 (B)
B-14 (B)
AK700823AB
AK700823AB
Connector: C-307
<L.H. drive vehicles> Connector: C-307
<L.H. drive vehicles>
C-307
C-307
C-307
C-307
3 2 1
6 5 4 3 2 1
Harness side connector 6 5 4
AKB00286 AB
Harness side connector AKB00286 AB
Q: Are the check results normal?
YES : Go to Step 23. NOTE: Before checking harness, check starter relay
NO : Repair or replace. connectors A-115, C-207 and C-211, and repair if
necessary.
• Check power supply line for damage.
Q: Is the check result normal?
YES : Go to Step 24.
NO : Repair the damaged harness wire.
13A-460 DIESEL FUEL
TROUBLESHOOTING
STEP 24. Connector check: A-16X starter relay STEP 26. Check harness between A-16X
connector (terminal No. 3) starter relay connector and A-110
(terminal No. 1) starter connector
Connector: A-16X
Connector: A-16X
A-16X
2 1
A-16X
3 2 1
4 3
Relay box's side connector 4
AK501014 AC
Relay box's side connector AK501014 AC
Q: Is the check result normal?
YES : Go to Step 25. Connector: A-110
NO : Repair or replace.
A-110 (B)
Connector: B-14
5 4 3 2 1 STEP 27. Check harness between A-10 (terminal
10 9 8 7 6 No. 1) starter connector and battery.
Harness side
connector Connector: A-10
A-10
B-14 (B)
AK700823AB
YES : Go to Step 15 .
STEP 10. M.U.T.-III actuator test.
NO : Proceed to the diagnostic code procedure
• Refer to Actuator Test Reference Table P.13A-
for the sensor that does not output
574.
waveforms (Refer to Inspection Chart for
a. Item 19: Suction control valve Diagnosis Code P.13A-21).
Q: Is the check result normal?
YES : Go to Step 11 .
STEP 15. Check compression pressure.
NO : Replace the suction control valve. After
• Check compression pressure (Refer to GROUP
replacing the suction control valve, learn the
11A − On-vehicle Service − Compression Pres-
supply pump (Refer to GROUP 00 −
sure Check ).
Precautions Before Service − What The
Common Rail Engine Learns ). Q: Is the check result normal?
YES : Go to Step 16 .
NO : Check and repair the engine itself.
STEP 11. Check suction control value itself.
• Check suction control value itself (Refer to
P.13A-596). STEP 16. Check injector itself.
• Check injector itself (Refer to P.13A-595).
Q: Is the check result normal?
YES : Go to Step 12 . Q: Is the check result normal?
NO : Replace the suction control valve. After YES : Go to Step 17 .
replacing the suction control valve, learn the NO : Replace the injector at the failed cylinder.
supply pump (Refer to GROUP 00 − After replacing the Injector, register the
Precautions Before Service − What The injector identification code and learn fuel
Common Rail Engine Learns ). injection (Refer to GROUP 00 − Precautions
Before Service − What The Common Rail
Engine Learns ).
STEP 12. M.U.T.-III data list.
• Refer to Data List Reference Table P.13A-542.
STEP 17. M.U.T.-III data list.
a. Item 63: Rail pressure sensor
• Refer to Data List Reference Table P.13A-542.
b. Item 64: Rail pressure target
a. Item 5: Barometric pressure sensor
Q: Are the check results normal? b. Item 7: Engine coolant temperature sensor
YES : Go to Step 14 .
c. Item 8: EGR gas temperature sensor
NO : Go to Step 13 .
<Euro5>
d. Item 8: Intake air temperature sensor No. 2
STEP 13. Replace the rail pressure sensor. <Except Euro5>
• Replace the common-rail assembly. e. Item 21: Fuel temperature sensor
Q: Does trouble symptom persist? f. Item 43: Intake air temperature sensor No. 1
YES : Go to Step 18 .
Q: Are the check results normal?
NO : The procedure is complete.
YES : Go to Step 18 .
NO : Perform the diagnosis code classified check
STEP 14. Check the waveforms of crank angle procedure for the sensor that has shown an
sensor and camshaft position sensor. abnormal data value (Refer to Inspection
• Check the waveforms during cranking. Chart for Diagnosis Code P.13A-21).
Q: Are waveforms being output?
STEP 18. Check the trouble symptoms.
Q: Does trouble symptom persist?
DIESEL FUEL
TROUBLESHOOTING
13A-463
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
YES : Go to Step 11 .
STEP 4. Check injector identification code.
NO : The procedure is complete.
• Check injector identification code (Refer to
GROUP 00 − Precautions Before Service − Injec-
tor Identification code Registration Procedure ). STEP 11. M.U.T.-III actuator test.
• Refer to Actuator Test Reference Table P.13A-
Q: Is the check result normal?
574.
YES : Go to Step 5 .
NO : Register the injector ID. a. Item 19: Suction control valve
Q: Is the check result normal?
STEP 5. Supply pump correction learning. YES : Go to Step 12 .
NO : Replace the suction control valve. After
• Carry out the supply pump correction learning
(Refer to GROUP 00 − Precautions Before Serv- replacing the suction control valve, learn the
ice − Supply Pump Correction Learning ). supply pump (Refer to GROUP 00 −
Precautions Before Service − What The
Q: Does trouble symptom persist? Common Rail Engine Learns ).
YES : Go to Step 6 .
NO : The procedure is complete.
STEP 12. Check suction control valve itself.
• Check suction control value itself (Refer to
STEP 6. Small injection quantity learning.
P.13A-596).
• Carry out the small injection quantity learning
procedure (Refer to GROUP 00 − Precautions Q: Is the check result normal?
Before Service − Small Injection Quantity Learn- YES : Go to Step 13 .
ing Procedure ). NO : Replace the suction control valve. After
replacing the suction control valve, learn the
Q: Does trouble symptom persist? supply pump (Refer to GROUP 00 −
YES : Go to Step 7 . Precautions Before Service − What The
NO : The procedure is complete.
Common Rail Engine Learns ).
YES : Go to Step 17 .
STEP 5. Check fuel supply line.
NO : The procedure is complete.
• Check for fuel leakage and clogging.
• Check fuel filter for clogging.
STEP 11. Check the waveforms of crank angle
Q: Is the check result normal?
sensor and camshaft position sensor.
YES : Go to Step 6 .
NO : Repair or replace the failed item.
• Check the output waveforms on an oscilloscope
(Refer to P.13A-586).
Q: Is the check result normal?
STEP 6. Priming (air bleeding)
YES : Go to Step 12 .
• Bleed air.
NO : Proceed to the inspection procedure by
Q: Does trouble symptom persist? diagnosis code for the abnormal waveform
YES : Go to Step 7 . (Refer to Inspection Chart for Diagnosis
NO : The procedure is complete. Code P.13A-21).
STEP 10. Replace the rail pressure sensor. STEP 15. Check injector itself.
• Replace the common-rail assembly. • Check injector itself (Refer to P.13A-595).
Q: Does trouble symptom persist? Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-467
YES : Go to Step 16 . YES : Go to Step 17 .
NO : Replace the injector at the failed cylinder. NO : Perform the diagnosis code classified check
After replacing the Injector, register the procedure for the sensor that has shown an
injector identification code and learn fuel abnormal data value (Refer to Inspection
injection (Refer to GROUP 00 − Precautions Chart for Diagnosis Code P.13A-21).
Before Service − What The Common Rail
Engine Learns ). STEP 17. Check the trouble symptoms.
Q: Does trouble symptom persist?
STEP 16. M.U.T.-III data list. YES : Replace the engine-ECU. When the engine-
• Refer to Data List Reference Table P.13A-542. ECU is replaced, write the chassis number
a. Item 5: Barometric pressure sensor (Refer to GROUP 00 − Precautions Before
b. Item 6: Manifold absolute pressure sensor Service − How to Perform Chassis Number
c. Item 7: Engine coolant temperature sensor Writing ). After replacing the engine-ECU,
d. Item 8: EGR gas temperature sensor register the injector identification code and
<Euro5> learn fuel injection (Refer to GROUP 00 −
e. Item 8: Intake air temperature sensor No. 2 Precautions Before Service − What The
<Except Euro5> Common Rail Engine Learns ). After
f. Item 9: Accelerator pedal position sensor registering the injector identification code,
the vehicle equipped with the DPF carries
g. Item 21: Fuel temperature sensor
out the forcible DPF regeneration. (Refer to
h. Item 43: Intake air temperature sensor No. 1
GROUP 17 − Emission Control − Diesel
i. Item 45: Throttle position sensor Particulate Filter (DPF) System − Forcible
Q: Are the check results normal? DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
STEP 18. Check compression pressure. STEP 20. Check the trouble symptoms.
• Check compression pressure (Refer to GROUP Q: Does trouble symptom persist?
11A − On-vehicle Service − Compression Pres- YES : Replace the engine-ECU. When the engine-
sure Check ). ECU is replaced, write the chassis number
Q: Is the check result normal? (Refer to GROUP 00 − Precautions Before
YES : Go to Step 19 . Service − How to Perform Chassis Number
NO : Check and repair the engine itself. Writing ). After replacing the engine-ECU,
register the injector identification code and
STEP 19. Check injector itself. learn fuel injection (Refer to GROUP 00 −
• Check injector itself (Refer to P.13A-595). Precautions Before Service − What The
Common Rail Engine Learns ). After
Q: Is the check result normal? registering the injector identification code,
YES : Go to Step 20 . the vehicle equipped with the DPF carries
NO : Replace the injector at the failed cylinder. out the forcible DPF regeneration. (Refer to
After replacing the Injector, register the GROUP 17 − Emission Control − Diesel
injector identification code and learn fuel Particulate Filter (DPF) System − Forcible
injection (Refer to GROUP 00 − Precautions DPF Regeneration ).
Before Service − What The Common Rail NO : Intermittent malfunction (Refer to GROUP
Engine Learns ). 00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
YES : Go to Step 16 .
STEP 12. M.U.T.-III data list.
NO : Replace the injector at the failed cylinder.
• Refer to Data List Reference Table P.13A-542.
After replacing the Injector, register the
a. Item 63: Rail pressure sensor injector identification code and learn fuel
b. Item 64: Rail pressure target injection (Refer to GROUP 00 − Precautions
Q: Are the check results normal? Before Service − What The Common Rail
YES : Go to Step 14 . Engine Learns ).
NO : Go to Step 13 .
STEP 16. Check the trouble symptoms.
STEP 13. Replace the rail pressure sensor. Q: Does trouble symptom persist?
• Replace the common-rail assembly. YES : Replace the engine-ECU. When the engine-
Q: Does trouble symptom persist? ECU is replaced, write the chassis number
YES : Go to Step 16 . (Refer to GROUP 00 − Precautions Before
NO : The procedure is complete. Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
STEP 14. Check compression pressure. register the injector identification code and
• Check compression pressure (Refer to GROUP learn fuel injection (Refer to GROUP 00 −
11A − On-vehicle Service − Compression Pres- Precautions Before Service − What The
sure Check ). Common Rail Engine Learns ). After
registering the injector identification code,
Q: Is the check result normal? the vehicle equipped with the DPF carries
YES : Go to Step 15 . out the forcible DPF regeneration. (Refer to
NO : Check and repair the engine itself. GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
STEP 15. Check injector itself. DPF Regeneration ).
• Check injector itself (Refer to P.13A-595). NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Q: Is the check result normal?
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
STEP 11. Check valve clearance. STEP 13. Check the trouble symptoms.
• Check valve clearance (Refer to GROUP 11A − Q: Does trouble symptom persist?
On-vehicle Service − Valve Clearance Check and YES : Replace the engine-ECU. When the engine-
Adjustment ). ECU is replaced, write the chassis number
Q: Is the check result normal? (Refer to GROUP 00 − Precautions Before
YES : Go to Step 12 . Service − How to Perform Chassis Number
NO : Adjust the valve clearance. Writing ). After replacing the engine-ECU,
register the injector identification code and
STEP 12. Check injector itself. learn fuel injection (Refer to GROUP 00 −
• Check injector itself (Refer to P.13A-595). Precautions Before Service − What The
Common Rail Engine Learns ). After
Q: Is the check result normal? registering the injector identification code,
YES : Go to Step 13 . the vehicle equipped with the DPF carries
NO : Replace the injector at the failed cylinder. out the forcible DPF regeneration. (Refer to
After replacing the Injector, register the GROUP 17 − Emission Control − Diesel
injector identification code and learn fuel Particulate Filter (DPF) System − Forcible
injection (Refer to GROUP 00 − Precautions DPF Regeneration ).
Before Service − What The Common Rail NO : Intermittent malfunction (Refer to GROUP
Engine Learns ). 00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
Connector: A-122
STEP 5. Connector check: C-111 combination
meter connector
Connector: C-111
<L.H. drive vehicles>
C-111
M
4 3 2 1 A-122 (GR)
Harness side
connector AKB00292 AB
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
M
4 3 2 1 A-122 (GR)
Harness side
connector AKB00292 AB
Connector: C-111
<L.H. drive vehicles> C-103 (B)
C-103 (B)
<R.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
C-111 158 157156 155 154 153 152 151 150 149 148 147 146
C-103 (B)
C-103 (B)
<R.H. drive vehicles>
<R.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Harness side connector AKA00090 AB
Harness side connector
• Disconnect connector, and measure at harness AKA00090 AB
STEP 10. Connector check: C-111 combination STEP 11. Check harness between A-122 (terminal
meter connector No. 3) alternator connector and C-111 (terminal
Connector: C-111 No. 52) combination meter connector.
<L.H. drive vehicles>
Connector: A-122
C-111
M
4 3 2 1 A-122 (GR)
Harness side
<R.H. drive vehicles> connector AKB00292 AB
Connector: C-111
<L.H. drive vehicles>
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB <R.H. drive vehicles>
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Fusible link 23
W-R
Ignition switch
C-307
LOCK
10 R
Relay
20A box ST ACC 1 2 3
IG1 IG2 4 5 6
W-B 2
A-115 L-B
3 C-207
4
9
J/B
W-B W-B 7.5A
4 1
A-20X 14
C-208
1 2 Engine
OFF control W
3 relay C-53*¹
ON
4 or
C-35*²
3 2 8
R
Y-G B-W
R R C-103
101 102 118 104 C-103
B B B
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI:Silver
AKB00288 AB
Connector: A-20X
A-20X
2 1 C-103 (B)
3
4 <R.H. drive vehicles>
Relay box's side
connector AK501321 AC
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
C-103 (B) 117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Harness side connector AKA00090 AB
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 • Disconnect connector, and measure at harness
side.
Harness side connector AKA00090 AB
• Short-circuit terminal No. 118 to earth.
• Disconnect connector, and measure at harness • Voltage between terminal No. 101 and earth also
side. between terminal No. 102 and earth.
• Voltage between terminal No. 118 and earth. OK: System voltage
OK: System voltage
Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 8 .
YES : Go to Step 7 . NO : Repair the harness wire.
NO : Repair the harness wire.
13A-490 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 9 .
STEP 8. Check for open circuit between engine-
NO : Repair the harness wire.
ECU connector C-103 and earth.
Connector: C-103
<L.H. drive vehicles> STEP 9. Connector check: C-103 engine-ECU
connector.
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
C-103 (B)
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Harness side connector AKA00090 AB 117 116
• Disconnect connector, and measure at harness 143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
side.
Harness side connector
• Check open circuit between terminal No. 145 and AKA00090 AB
115 114 113 112 111 110 109 108 107 106 105 104 103 115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Fusible link 23
W-R
10 Relay
20A box
W-B
A-115
3
W-B
C-103 103
AKA00116 AB
DIAGNOSIS PROCEDURE
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Connector: A-115
<L.H. drive vehicles>
C-103 (B)
A-115
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
Inspection Service Points − How to Cope
145 144
158 157156 155 154 153 152 151 150 149 148 147 146
with Intermittent Malfunction ).
Harness side connector AKA00090 AB
Connector: A-115
<L.H. drive vehicles>
A-115
A-115
1 2 3 4
5 6 7 8 9 10
Harness side connector
AK700922 AB
• Disconnect connector.
DIESEL FUEL
TROUBLESHOOTING
13A-495
Inspection Procedure 18: 1st and 2nd Rail Switch System <M/T>
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
10
L-Y
1
B-06
MU802662
ON 1st and 2nd rail switch
1 2 OFF
G-Y
C-29
4
G-Y
A-115
6
G-Y
C-105 11
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
B-06 (GR)
1 2
Harness side
connector AK503584AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
L-B
C-207
4
21
J/B
7.5A
2
C-208
L-Y
C-30
10
L-Y
2
B-02
MU802601
ON Back-up lamp switch
1 2 OFF
R-G
C-29
13
R-G
A-28
9
R-G
C-105 9
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
B-02 (B)
2 1
Harness side
connector AK501385AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Inspection Procedure 20: 4LLC Switch System <M/T-High power engine vehicle>
C-105
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
13
L-B
A-115
7
L-R
C-29
5
L-R
B-05
MU802653 4LLC switch
OFF ON
1
AKB00291 AB
STEP 2. Connectors check: B-05 4LLC switch STEP 3. check harness between C-105 (terminal
connector and C-105 engine-ECU connector No. 13) engine-ECU connector and B-05 (terminal
Connector: B-05
No. 1) 4LLC switch connector.
Connector: B-05
B-05
B-05
1
Harness side 1
connector Harness side
connector
AK801710AB
AK801710AB
Connector: C-105
<L.H. drive vehicles> Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB
Harness side connector AKA00089 AB
Q: Are the check results normal?
YES : Go to Step 3 . NOTE: Before checking harness, check intermediate
NO : Repair or replace. connectors C-29 and A-115, and repair if necessary.
Q: Is the check result normal?
DIESEL FUEL
TROUBLESHOOTING
13A-505
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Repair the harness wire.
13A-506 DIESEL FUEL
TROUBLESHOOTING
Inspection Procedure 21: Condenser Fan Relay System <Vehicles with A/C condenser fan>
Ignition switch
C-307
R LOCK
1 2 3 ST ACC
IG1 IG2
4 5 6
L-R
Fusible link 20
C-207
6
W
16 J/B
7.5A
5 Relay
20A box 9
C-210
L-R
4
1
A-14X
1 2
OFF Condenser fan relay
3
ON
4
2
3
L-B LG-R
A-115
A-120 2 1
MU802601
A/C condenser
1 2 M fan motor LG-R
21 C-105
1
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
B
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
B 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Engine-ECU
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B) 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
<R.H. drive vehicles> 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
BR-W
C-105
8
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
C-105 (B) 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Ignition switch
C-307
LOCK
R
1 2 3 ST ACC
IG1 IG2
4 5 6
4
Fusible link 20
L-R
C-207
W 6
16 J/B
4 Relay
box 7.5A
10A
9
C-210
B-O L-R
A-115 A-28
4 7
B-O L-R
4 1
A-21X
L-W O
A-27
5
L-W
C-105
1 19
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
A-33
MU802655
A/C 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
compressor 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
1 clutch assembly
Engine-ECU
AKB00294 AB
13A-512 DIESEL FUEL
TROUBLESHOOTING
PROBABLE CAUSES
• Failed A/C compressor relay
• Failed A/C compressor assembly
• Damaged harness (Open circuit between A/C C-105 (B)
compressor relay and condenser fan relay, A/C
compressor relay and engine-ECU, A/C com-
<R.H. drive vehicles>
pressor relay and A/C compressor, and open cir-
cuit between A/C compressor relay and relay
box)
• Damaged connector (A/C compressor relay con-
nector, A/C compressor connector, Engine-ECU
connector)
• Failed engine-ECU C-105 (B)
DIAGNOSIS PROCEDURE 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
STEP 1. M.U.T.-III data list 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
• Refer to Data List Reference Table P.13A-542. Harness side connector AKA00089 AB
a. Item 25: A/C switch
b. Item 26: A/C load signal Q: Is the check result normal?
c. Item 27: A/C relay YES : Go to Step 3.
NO : Repair or replace.
Q: Are the check results normal?
YES : Go to Step 2.
NO : Check A/C system (Refer to GROUP 55A − STEP 3. Check the trouble symptoms.
Troubleshooting − Trouble Symptom Chart Q: Does trouble symptom persist?
<Manual A/C>, GROUP 55B − YES : Replace the engine-ECU. When the engine-
Troubleshooting − Trouble Symptom Chart ECU is replaced, write the chassis number
<Automatic A/C>). (Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
DIESEL FUEL
TROUBLESHOOTING
13A-513
C-103
127
B-R
A-115
5
B-R
A-27
8
B-R
A-134
(MU801211) Power steering fluid
pressure switch
1 OFF ON
AKA00105 AB
YES : Go to Step 2 .
STEP 3. Perform voltage measurement at C-103
NO : Repair or replace.
engine-ECU connector.
Connector: C-103
STEP 2. Perform voltage measurement at A-134 <L.H. drive vehicles>
power steering fluid pressure switch connector.
Connector: A-134
A-134 (B)
C-103 (B)
117 116
YES : Go to Step 8 . 143 142 141 140 139138 137 136 135 134 133 132 131
145 144
NO : Go to Step 3 . 158 157156 155 154 153 152 151 150 149 148 147 146
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
Connector: A-134
C-103 (B)
A-134 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
1
Harness side Harness side connector AKA00090 AB
connector AK501383 AB
Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 6 .
NO : Repair or replace the connector.
13A-516 DIESEL FUEL
TROUBLESHOOTING
C-103 (B)
C-103 (B)
<R.H. drive vehicles>
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
YES : Go to Step 7 . 158 157156 155 154 153 152 151 150 149 148 147 146
145 144
A-134 (B)
1
C-103 (B) Harness side
connector AK501383 AB
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
YES : Go to Step 7 .
STEP 11. Connector check: C-103 engine-ECU
NO : Repair or replace.
connector
Connector: C-103
<L.H. drive vehicles>
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
L-B
C-207
4
15
J/B 7.5A
6
W R C-209
B-W
12
J/C (5)
C-132
15
A-11 A-11 B-W
1 1 C-112
1 A-112 36
MU802601 C-112
Glow
plug 31 32 33 34 35 36
OFF 1 2
relay ON
37 38 39 40 41 42
A-111 C-111
1 Combination Glow MU801586
1 A-111 2 meter
51 52 53 54 55 56 57
51 58 59 60 61 62 63 64
L C-111
W-R B-R
C-53*¹ or
24 C-35*²
L
1 20 22
A-06
1 Glow
plugs Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles C-105
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKA00122 AB
• Damaged harness (Open or short circuit between STEP 2. Connector check: C-105 engine-ECU
engine-ECU and glow plug relay, and open or connector and C-111 combination meter
short circuit between glow plug relay and glow connector.
plug, Open circuit between engine control relay
and glow plug relay, engine control relay and fusi- Connector: C-105
<L.H. drive vehicles>
ble link, and open circuit between engine-ECU
and combination meter)
• Damaged connector (Engine-ECU connector,
glow plug relay connector, combination meter
connector)
• Failed engine-ECU
C-105 (B)
DIAGNOSIS PROCEDURE
<R.H. drive vehicles>
STEP 1. Check the glow indicator lamp
illuminates.
• Ignition switch: ON
• Engine coolant temperature: 40°C or lower
Q: Is the glow indicator lamp illuminates?
YES : Go to Step 4 . C-105 (B)
NO : Go to Step 2 .
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-111
<L.H. drive vehicles>
C-111
C-111
57 56 55 54 53 52 51
64 63 62 61 60 59 58
Harness side connector AK700806 AB
A-11
2 1
A-112 Harness side connector AK501004 AB
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 STEP 5. Check the glow plug relay itself.
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
• Check the glow plug relay itself (Refer to GROUP
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
16 − Glow System − On-vehicle Service − Glow
Harness side connector AKA00089 AB Plug Relay Check ).
• Disconnect connector, and measurement at har- Q: Is the check result normal?
ness side. YES : Go to Step 6 .
• Ignition switch: ON NO : Replace the glow plug relay.
• Voltage between terminal No. 22 and earth.
OK: System voltage STEP 6. Perform voltage measurement at A-11
Q: Is the check result normal?
glow plug relay connector.
YES : Replace the engine-ECU. When the engine- Connector: A-11 AC501628
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU, A-11
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The Fuel filter
Common Rail Engine Learns ). 1
NO : Check intermediate connector C-53 <L. H. Harness side connector AK501005 AB
drive vehicles> or C-35 <R. H. drive • Disconnect connector, and measurement at har-
vehicles>, and repair if necessary. If ness side.
intermediate connector is normal, check and • Voltage between terminal No. 1 and earth.
repair harness between C-111 (terminal No.
51) combination meter connector and C-105 OK: System voltage
(terminal No. 28) engine-ECU connector. Q: Is the check result normal?
YES : Go to Step 7 .
NO : Check harness between fusible link No. 24
and A-11 (terminal No. 1) glow plug relay
connector.
13A-522 DIESEL FUEL
TROUBLESHOOTING
YES : Go to Step 9 .
STEP 7. Perform voltage measurement at A-112
NO : Replace the glow plug.
glow plug relay connector.
Connector: A-112 AC501628
STEP 9. Check harness between A-111 (terminal
No. 1) glow plug relay connector and A-06
(terminal No. 1) glow plug connector.
Connector: A-111 AC501628
A-111 (GR)
A-112 (B)
Fuel filter
2 1
Harness side connector AK501006 AB
Connector: C-105
<L.H. drive vehicles>
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Inspection Procedure 26: PTC Heater Relay System <Vehicle with PTC Heater>
L-R C-207
6
16
J/B
7.5A
9
C-210
L-R
R R A-28
7
L-R
C-148
L-R 4
L-R
PTC heater 2 3 2 3 PTC heater
relay 1 relay 2
A-140X A-141X
ON ON
2 OFF OFF 2
1 3 1 3
4 4
4 1 4 1
B-L B-Y
2 2 A/C switch module <Manual A/C>
Y-G or A/C-ECU <Automatic A/C>
Y-L
C-149 C-150
PTC C-148 PTC C-148
Heater 1 2 Heater 2 1
1 2 1 2 L-W
1 1 C-52
3
B Y-GR B G-O
L-W
43 44 6
Engine-ECU
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
C-105
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00307 AB
DIESEL FUEL
TROUBLESHOOTING
13A-525
OPERATION YES : Go to Step 2 .
• When the PTC heater operation request signal NO : Check PTC heater system (Refer to
(battery voltage) is input into the engine-ECU GROUP 55A − Troubleshooting − Trouble
(terminal No. 6) from the A/C switch module Symptom Chart <manual A/C>, GROUP
<manual A/C> or A/C-ECU <automatic A/C>, the 55B − Troubleshooting − Trouble Symptom
engine-ECU turns ON the PTC heater relay 1 and Chart <automatic A/C>).
2 after satisfying all the operation conditions.
Operation conditions of PTC heater relay 1 STEP 2. PTC heater 1 operation check
a. Engine coolant temperature is under 80°C Connector: C-105
b. 2 seconds later after the engine has start up. <L.H. drive vehicles>
c. The PTC heater request signal has been input
continuously 2 seconds or more
d. The battery voltage continues to be 12.3 V or
more for 12 seconds or more.
Operation conditions of PTC heater relay 2
a. Engine coolant temperature is under 75°C. C-105 (B)
b. The PTC heater 1 has been ON continuously
45 seconds or more. <R.H. drive vehicles>
c. Heater switch (warm up switch) is ON or vehi-
cle speed is 20km/h or more.
d. The battery voltage continues to be 12.9 V or
more for 12 seconds or more.
PROBABLE CAUSES
• Failed PTC heater relay C-105 (B)
• Failed PTC heater
• Damaged harness (Open circuit between PTC 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
heater and body earth, and open circuit between Harness side connector AKA00089 AB
PTC heater relay and fusible link 25.
• Damaged connector (PTC heater relay connec- • Disconnect the C-105 connector.
tor, PTC heater connector, engine-ECU connec- • Using the jumper wire, connect terminal No. 43 to
tor). earth.
• Failed engine-ECU OK: The PTC heater 1 operates.
Q: Is the check result normal?
DIAGNOSIS PROCEDURE YES : Go to Step 3 .
NO : Check PTC heater system (Refer to
STEP 1. M.U.T.-III data list GROUP 55A − Troubleshooting − Trouble
• Refer to Data List Reference Table P.13A-542. Symptom Chart <manual A/C>, GROUP
a. Item 76: PTC heater relay 1 55B − Troubleshooting − Trouble Symptom
Chart <automatic A/C>).
b. Item 77: PTC heater relay 2
Q: Is the check result normal?
13A-526 DIESEL FUEL
TROUBLESHOOTING
STEP 3. PTC heater 2 operation check. STEP 4. Connector check: C-105 engine-ECU
Connector: C-105
connector.
<L.H. drive vehicles> Connector: C-105
<L.H. drive vehicles>
C-105 (B)
C-105 (B)
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Harness side connector AKA00089 AB
Harness side connector
• Disconnect the C-105 connector. AKA00089 AB
• Using the jumper wire, connect terminal No. 44 to Q: Is the check result normal?
earth. YES : Go to Step 5 .
OK: The PTC heater 2 operates. NO : Repair or replace.
Q: Is the check result normal?
YES : Go to Step 4 . STEP 5. Check the trouble symptoms.
NO : Check PTC heater system (Refer to
Q: Does the trouble symptom persist?
GROUP 55A − Troubleshooting − Trouble
YES : Replace the engine-ECU. When the engine-
Symptom Chart <manual A/C>, GROUP
ECU is replaced, write the chassis number
55B − Troubleshooting − Trouble Symptom
(Refer to GROUP 00 − Precautions Before
Chart <automatic A/C>).
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
out the forcible DPF regeneration. (Refer to
GROUP 17 − Emission Control − Diesel
Particulate Filter (DPF) System − Forcible
DPF Regeneration ).
NO : Intermittent malfunction (Refer to GROUP
00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope
with Intermittent Malfunction ).
DIESEL FUEL
TROUBLESHOOTING
13A-527
Blower switch
L-B
10
J/C (9)
C-10
3
L-B
C-52*¹ or
C-34*²
1*¹ or
4*²
G-Y
C-103 125
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00331 AB
5 4 3 2 1
5 4 3 2 1 12 11 10 9 8 7 6 AB
AKB00330 AB
C-10 (GR)
C-103 (B)
5 4 3 2 1
<R.H. drive vehicles>
12 11 10 9 8 7 6 AB
C-10 (GR)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
145 144
AKB00330 AB
158 157156 155 154 153 152 151 150 149 148 147 146
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
5 4 3 2 1
C-103 (B) 12 11 10 9 8 7 6 AB
C-10 (GR)
C-103 (B)
AKB00330 AB
115 114 113 112 111 110 109 108 107 106 105 104 103
102 101
130 129 128 127 126 125 124 123 122 121120 119 118 Connector: C-103
117 116
<L.H. drive vehicles>
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
C-103 (B)
C-103 (B)
115 114 113 112 111 110 109 108 107 106 105 104 103
130 129 128 127 126 125 124 123 122 121120 119 118
102 101
117 116
143 142 141 140 139138 137 136 135 134 133 132 131
158 157156 155 154 153 152 151 150 149 148 147 146
145 144
Rear window
defogger relay
J/B
19
7.5A
10
C-208
*1 *2
L-O
10
11
L-O
C-53*¹ or
C-35*²
19
B-G
C-105 10
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00332 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
C-105 (B)
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
STEP 4. Connector check: C-208 junction block STEP 5. Check harness between C-208 (terminal
connector. No. 10) junction block connector and C-105
Connector: C-208
(terminal No. 10) engine-ECU connector.
<L. H. drive vehicles> Connector: C-208
Junction block (Front view) <L. H. drive vehicles>
C-208 Junction block (Front view)
C-208
C-208
C-208
AKB00333 AB
AKB00333 AB
Q: Is the check result normal?
YES : Go to Step 5. Connector: C-105
NO : Repair or replace the connector. <L.H. drive vehicles>
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-208
AKB00333 AB
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-113
Combination meter
1 2 3 4 5 6 7 8 9 10 11 12
DPF
13 14 15 16 17 18 19 20 21 22 23 24
lamp
1
C-113
G-R
C-53*¹ or
C-35*²
17
V-W
C-105 47
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
Engine-ECU
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96
NOTE
*1: L.H. drive vehicles
*2: R.H. drive vehicles
Wire colour code
B: Black LG: Light green G: Green L: Blue W: White Y: Yellow SB: Sky blue BR: Brown O: Orange GR: Grey
R: Red P: Pink V: Violet PU: Purple SI: Silver
AKB00340 AB
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
<L.H. drive vehicles>
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
YES : Go to Step 6 .
STEP 5. Check combination meter.
NO : Check combination meter (Refer to GROUP
Connector: C-113 54A − Combination Meter − Check Chart for
<L.H. drive vehicles>
Trouble Symptoms ).
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
• Ignition switch: ON
• Disconnect C-113 combination meter connector
Q: Does the DPF lamp go out?
DIESEL FUEL
TROUBLESHOOTING
13A-539
STEP 6. Perform resistance measurement for OK: 1 kΩ or more
short circuit at C-105 engine-ECU connector. Q: Is the check result normal?
YES : Go to Step 7 .
Connector: C-105
<L.H. drive vehicles> NO : Repair the harness wire.
C-105 (B)
C-105 (B)
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
Connector: C-113
<L.H. drive vehicles>
C-113
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
STEP 7. Perform resistance measurement for • Resistance between C-105 engine-ECU connec-
open circuit at between C-105 engine-ECU tor terminal No. 47 and C-113 combination con-
connector and C-113 combination meter nector terminal No. 1.
connector. OK: Continuity (2 Ω or less)
Connector: C-105 Q: Is the check result normal?
<L.H. drive vehicles> YES : Go to Step 8 .
NO : Check the intermediate connector C-53 <L.
H. drive vehicles>, C-35 <R. H. drive
vehicles>, and repair if necessary. If
intermediate connector is normal, repair the
harness wire.
C-105 (B)
STEP 8. Check the trouble symptoms.
<R.H. drive vehicles> Q: Does trouble symptom persist?
YES : Replace the engine-ECU. When the engine-
ECU is replaced, write the chassis number
(Refer to GROUP 00 − Precautions Before
Service − How to Perform Chassis Number
Writing ). After replacing the engine-ECU,
register the injector identification code and
C-105 (B) learn fuel injection (Refer to GROUP 00 −
Precautions Before Service − What The
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
Common Rail Engine Learns ). After
registering the injector identification code,
the vehicle equipped with the DPF carries
72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
C-113
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
13 Accelerato Learning value of not depressed Ignition switch: ON 700 − 1,300mV
r pedal accelerator pedal state is shown
position
sensor
(main)
learned
closed
position
46 Throttle Learning value of fully closed Ignition switch: ON 9 deg or less
position throttle valve state is shown
sensor
learned
closed
position
57 Fuel Indicates the final injection • Engine: After warm-up, idle 3 − 10 mm3/st
quantity quantity operation
final • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
58 Fuel Indicates the pre injection quantity • Engine: After warm-up, idle 0.5 − 3 mm3/st
quantity operation
pre • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
59 Fuel Indicates the limit of injection Engine: After warm-up, 2,000r/ 35 mm3/st or
quantity quantity determined by the min more
smoke charging pressure
limit
60 Fuel Indicates the pilot injection Ignition switch: When engine 40 − 50 mm3/st
quantity quantity determined by water ON coolant
start temperature temperature
is 0°C
When engine 30 − 40 mm3/st
coolant
temperature
is 70°C
61 Fuel Interval between end of pilot Engine: After warm-up 200 − 2,000 us
injection injection and start of main injection
interval
pilot
13A-556 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
62 Fuel Main injection timing Engine: After warm-up, idle −3 to 4°CA
injection operation
timing
main
65 Supply Although the fuel discharge Ignition switch: ON 2*
pump quantity is decided depending on
learned the drive current of the suction
status control valve of the supply pump,
learning is executed in idle state
because there is a machine
difference. The learned status is
indicated.
78 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 1 cylinder at 25 MPa
pressure 1
− No. 1
cylinder
79 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 2 cylinder at 25 MPa
pressure 1
− No. 2
cylinder
80 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 3 cylinder at 25 MPa
pressure 1
− No. 3
cylinder
81 Small Indicates the final learned value of Ignition switch: ON −0.41 to 0.36
injection the small injection quantity of No. ms
quantity at 4 cylinder at 25 MPa
pressure 1
− No. 4
cylinder
82 Small Indicates the final learned value of Ignition switch: ON −0.47 to 0.43
injection the small injection quantity of No. ms
quantity at 1 cylinder at 40 MPa
pressure 2
− No. 1
cylinder
83 Small Indicates the final learned value of Ignition switch: ON −0.47 to 0.43
injection the small injection quantity of No. ms
quantity at 2 cylinder at 40 MPa
pressure 2
− No. 2
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-557
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
84 Small Indicates the final learned value of Ignition switch: ON −0.47 to 0.43
injection the small injection quantity of No. ms
quantity at 3 cylinder at 40 MPa
pressure 2
− No. 3
cylinder
85 Small Indicates the final learned value of Ignition switch: ON −0.47 to 0.43
injection the small injection quantity of No. ms
quantity at 4 cylinder at 40 MPa
pressure 2
− No. 4
cylinder
86 Small Indicates the final learned value of Ignition switch: ON −0.29 to 0.32
injection the small injection quantity of No. ms
quantity at 1 cylinder at 70 MPa
pressure 3
− No. 1
cylinder
87 Small Indicates the final learned value of Ignition switch: ON −0.29 to 0.32
injection the small injection quantity of No. ms
quantity at 2 cylinder at 70 MPa
pressure 3
− No. 2
cylinder
88 Small Indicates the final learned value of Ignition switch: ON −0.29 to 0.32
injection the small injection quantity of No. ms
quantity at 3 cylinder at 70 MPa
pressure 3
− No. 3
cylinder
89 Small Indicates the final learned value of Ignition switch: ON −0.29 to 0.32
injection the small injection quantity of No. ms
quantity at 4 cylinder at 70 MPa
pressure 3
− No. 4
cylinder
90 Small Indicates the final learned value of Ignition switch: ON −0.13 to 0.17
injection the small injection quantity of No. ms
quantity at 1 cylinder at 100 MPa
pressure 4
− No. 1
cylinder
13A-558 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
91 Small Indicates the final learned value of Ignition switch: ON −0.13 to 0.17
injection the small injection quantity of No. ms
quantity at 2 cylinder at 100 MPa
pressure 4
− No. 2
cylinder
92 Small Indicates the final learned value of Ignition switch: ON −0.13 to 0.17
injection the small injection quantity of No. ms
quantity at 3 cylinder at 100 MPa
pressure 4
− No. 3
cylinder
93 Small Indicates the final learned value of Ignition switch: ON −0.13 to 0.17
injection the small injection quantity of No. ms
quantity at 4 cylinder at 100 MPa
pressure 4
− No. 4
cylinder
94 Small Indicates the final learned value of Ignition switch: ON −0.16 to 0.17
injection the small injection quantity of No. ms
quantity at 1 cylinder at 150 MPa
pressure 5
− No. 1
cylinder
95 Small Indicates the final learned value of Ignition switch: ON −0.16 to 0.17
injection the small injection quantity of No. ms
quantity at 2 cylinder at 150 MPa
pressure 5
− No. 2
cylinder
96 Small Indicates the final learned value of Ignition switch: ON −0.16 to 0.17
injection the small injection quantity of No. ms
quantity at 3 cylinder at 150 MPa
pressure 5
− No. 3
cylinder
97 Small Indicates the final learned value of Ignition switch: ON −0.16 to 0.17
injection the small injection quantity of No. ms
quantity at 4 cylinder at 150 MPa
pressure 5
− No. 4
cylinder
DIESEL FUEL
TROUBLESHOOTING
13A-559
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
106 Idle speed Target torque for idle speed control • Engine: After warm-up, idle 50 − 120 Nm
control (ISC) operation
torque • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
116 Request • Indicates the DPF regeneration Ignition switch: ON Changes
of mode request mode. depending on
DPF Not request: Not reached to the the vehicle
regenerati load amount which requires the status.
on regeneration
<Euro5> Distance1: State in which the
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
126 No. 2 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.2 exhaust gas temperature
re sensor sensor (catalyst temperature).
(catalyst
temperatu
re) max
value
<Euro5>
13A-560 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
127 No. 3 Indicates the highest temperature Ignition switch: ON −200 to
exhaust of the temperatures, saved in the 1,075°C
gas engine-ECU, that are detected by
temperatu the No.3 exhaust gas temperature
re sensor sensor (DPF temperature).
(DPF
temperatu
re) max
value
<Euro5>
128 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at No. 3 the time of the highest km
exhaust temperature of the temperatures,
gas saved in the engine-ECU, that are
temperatu detected by the No.3 exhaust gas
re sensor temperature sensor (DPF
(DPF temperature).
temperatu
re) max
value
<Euro5>
145 Odometer Indicates the total driving distance Ignition switch: ON 0 − 1,999,999
calculated saved to the odometer. km
by engine-
ECU
148 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
DPF times saved to the engine-ECU.
regenerati
on
<Euro5>
151 Status of Indicates the calibrated value to Ignition switch: ON 0−3
soot load calculate the soot load amount by
by the difference pressure.
differential
pressure
<Euro5>
153 Soot Indicates the driving distance after Ignition switch: ON 0 − 2,550 km
loading by the last DPF regeneration.
distance 1
<Euro5>
154 Soot Indicates the driving distance Ignition switch: ON 0 − 2,550 km
loading by calculated by subtracting the
distance 2 driving distance on natural
<Euro5> regeneration from the distance
after the last DPF regeneration.
DIESEL FUEL
TROUBLESHOOTING
13A-561
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
155 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the quantity survey.
accumulat
ion
<Euro5>
156 Soot Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
loading by calculated by the difference
differential pressure.
pressure
<Euro5>
160 Last DPF • Last DPF regeneration request Ignition switch: ON Displays the
regenerati mode last DPF
on mode Not request: Not reached to the regeneration
<Euro5> load amount which requires the request mode.
regeneration
Distance1: State in which the
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
190 Odometer Indicates the driving distance for Ignition switch: ON 0 − 1,999,999
for DPF by the mounted DPF. km
engine-
ECU
<Euro5>
191 Nonunifor Indicates the non-uniform soot Ignition switch: ON 0 − 100 g
m soot load amount.
accumulat
ion
<Euro5>
13A-562 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
192 Max value Indicates the maximum Ignition switch: ON or DPF −400 to 2,150
of DPF temperature of last DPF regeneration °C
temperatu regeneration saved to the engine
re (last ECU.
DPF
regenerati
on)
<Euro5>
193 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance1" launches.
distance 1
<Euro5>
194 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
on start request mode of "Summ"
accumulat launches.
ion
<Euro5>
195 DPF Indicates the soot load amount Ignition switch: ON 0 − 12.75 g/L
regenerati where the DPF regeneration
on start request mode of "Pressure
differential difference" launches.
pressure
<Euro5>
196 DPF Indicates the distance where the Ignition switch: ON 0 − 2,550 km
regenerati DPF regeneration request mode of
on start "Distance2" launches.
distance 2
<Euro5>
197 DPF Indicates the present estimated Ignition switch: ON or DPF −400 to 2,150
temperatu DPF centre temperature. regeneration °C
re
<Euro5>
198 Engine oil Indicates the estimated engine oil Engine: Idle operation −1,000 to 1,500
level level difference. cc
calculated
<Euro5>
199 Engine oil Indicates the estimated descend Engine: Idle operation −1,000 to 1,500
consumpti of the engine oil level. cc
on
calculate
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-563
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
200 Fuel Indicates the estimated ascend of Engine: Idle operation −1,000 to 1,500
dilution engine oil level. cc
calculated
by engine-
ECU
<Euro5>
201 Pre- Indicates the target amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on remain regeneration step 1.
soot value
<Euro5>
202 Pre- Indicates the current amount of Ignition switch: ON 0 − 12.75 g
regenerati burned soot in the DPF
on soot regeneration step 1.
value
<Euro5>
204 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 2 times before DPF
on mode 2 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 2 times
<Euro5> Distance1: State in which the before
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
13A-564 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
205 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 3 times before DPF
on mode 3 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 3 times
<Euro5> Distance1: State in which the before.
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
206 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 4 times before DPF
on mode 4 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 4 times
<Euro5> Distance1: State in which the before.
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure difference: State in which
the regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
DIESEL FUEL
TROUBLESHOOTING
13A-565
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
207 DPF • DPF regeneration request Ignition switch: ON Displays the
regenerati mode of 5 times before DPF
on mode 5 Not request: Not reached to the regeneration
times load amount which requires the request mode
before regeneration of 5 times
<Euro5> Distance1: State in which the before.
regeneration is required by the
actual driving distance
Distance2: State in which the
regeneration is required by the
distance calculated by subtracting
the distance on the natural
regeneration during driving from
the actual driving distance
Summ: State in which the
regeneration is required by the
load amount calculated by the
quantity survey
Pressure diff.: State in which the
regeneration is required by the
load amount calculated by the
difference pressure
Manual: State in which the
regeneration is forcibly performed
by the M.U.T.-III.
208 Short Indicates the times of DPF Ignition switch: ON Displays the
interval regeneration performed under the regeneration
DPF distance of 10 km or less after the times.
regenerati last DPF regeneration.
on count
<Euro5>
217 Variable Indicates the target boost Engine: Excessive acceleration 0 − 340 kPa
geometry pressure. after warm-up
turbochar
ger
feedback
target
boost
pressure
<Euro5>
219 Fuel Indicates the main injection Engine: Idle operation 0 − 90 mm3/st
injection quantity of the injector.
quantity
main
220 Fuel Indicates the after injection Engine: Idle operation or DPF 0 − 25.5 mm3/
injection quantity. regeneration st
quantity
after
13A-566 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
221 Fuel Indicates the 1st post injection On DPF regeneration 0 − 25.5 mm3/
injection quantity on the DPF regeneration. st
quantity
post 1
222 Fuel Indicates the 2nd post injection On DPF regeneration 0 − 25.5 mm3/
injection quantity on the DPF regeneration. st
quantity
post 2
223 Fuel Indicates the 3rd post injection On DPF regeneration 0 − 25.5 mm3/
injection quantity on the DPF regeneration. st
quantity
post 3
224 Differentia Indicates the temperature when Ignition switch: ON −35 to −26°C
l pressure the compensation amount (M0) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M0)
<Euro5>
225 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M0) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M0) differential pressure sensor
<Euro5> ambient air temperature is
between −35 and −26°C.
226 Differentia Indicates the temperature when Ignition switch: ON −25 to −16 °C
l pressure the compensation amount (M1) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M1)
<Euro5>
227 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M1) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M1) differential pressure sensor
<Euro5> ambient air temperature is
between −25 and −16°C.
229 Differentia Indicates the temperature when Ignition switch: ON −15 to −6°C
l pressure the compensation amount (M2) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M2)
<Euro5>
230 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M2) of exhaust differential kPa
learning pressure sensor when exhaust
zero (M2) differential pressure sensor
<Euro5> ambient air temperature is
between −15 and −6°C.
DIESEL FUEL
TROUBLESHOOTING
13A-567
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
231 Differentia Indicates the temperature when Ignition switch: ON −5 to 4 °C
l pressure the compensation amount (M3) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M3)
<Euro5>
232 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M3) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M3) differential pressure sensor
<Euro5> ambient air temperature is
between −5 and 4°C.
234 Differentia Indicates the temperature when Ignition switch: ON 5 to 14°C
l pressure the compensation amount (M4) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M4)
<Euro5>
235 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M4) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M4) differential pressure sensor
<Euro5> ambient air temperature is
between 5 and 14°C.
236 Differentia Indicates the temperature when Ignition switch: ON 15 to 24°C
l pressure the compensation amount (M5) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M5)
<Euro5>
237 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M5) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M5) differential pressure sensor
<Euro5> ambient air temperature is
between 15 and 24°C.
239 Differentia Indicates the temperature when Ignition switch: ON 25 to 34°C
l pressure the compensation amount (M6) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M6)
<Euro5>
240 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M6) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M6) differential pressure sensor
<Euro5> ambient air temperature is
between 25 to 34°C.
13A-568 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
241 Differentia Indicates the temperature when Ignition switch: ON 35 to 44 °C
l pressure the compensation amount (M7) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M7)
<Euro5>
242 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M7) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M7) differential pressure sensor
<Euro5> ambient air temperature is
between 35 and 44°C.
244 Differentia Indicates the temperature when Ignition switch: ON 45 to 54°C
l pressure the compensation amount (M8) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M8)
<Euro5>
245 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M8) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M8) differential pressure sensor
<Euro5> ambient air temperature is
between 45 and 54°C.
246 Differentia Indicates the temperature when Ignition switch: ON 55 to 64°C
l pressure the compensation amount (M9) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M9)
<Euro5>
247 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M9) of exhaust differential kPa
learning pressure sensor when the exhaust
zero (M9) differential pressure sensor
<Euro5> ambient air temperature is
between 55 and 64°C.
249 Differentia Indicates the temperature when Ignition switch: ON 65 to 74°C
l pressure the compensation amount (M10)
learning of exhaust differential pressure
temperatu sensor was saved.
re (M10)
<Euro5>
250 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M10) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M10) sensor ambient air temperature is
<Euro5> between 65 to 74°C.
DIESEL FUEL
TROUBLESHOOTING
13A-569
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
251 Differentia Indicates the temperature when Ignition switch: ON 75 to 84 °C
l pressure the compensation amount (M11) of
learning exhaust differential pressure
temperatu sensor was saved.
re (M11)
<Euro5>
252 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M11) of exhaust kPa
learning differential pressure sensor when
zero (M11) the exhaust differential pressure
<Euro5> sensor ambient air temperature is
between 75 to 84°C.
254 Differentia Indicates the temperature when Ignition switch: ON 85 to 94°C
l pressure the compensation amount (M12)
learning of exhaust differential pressure
temperatu sensor was saved.
re (M12)
<Euro5>
255 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M12) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M12) sensor ambient air temperature is
<Euro5> between 85 and 94°C.
256 Differentia Indicates the temperature when Ignition switch: ON 95 to 104°C
l pressure the compensation amount (M13)
learning of exhaust differential pressure
temperatu sensor was saved.
re (M13)
<Euro5>
257 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M13) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M13) sensor ambient air temperature is
<Euro5> between 95 and 104°C.
259 Differentia Indicates the temperature when Ignition switch: ON 105 to 114°C
l pressure the compensation amount (M14)
learning of exhaust differential pressure
temperatu sensor was saved.
re (M14)
<Euro5>
260 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M14) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M14) sensor ambient air temperature is
<Euro5> between 105 and 114°C.
13A-570 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
261 Differentia Indicates the temperature when Ignition switch: ON 115 to 124°C
l pressure the compensation amount (M15)
learning of exhaust differential pressure
temperatu sensor was saved.
re (M15)
<Euro5>
262 Differentia Indicates the compensation Ignition switch: ON −5.12 to 5.08
l pressure amount (M15) of exhaust kPa
learning differential pressure sensor when
zero the exhaust differential pressure
(M15) sensor ambient air temperature is
<Euro5> between 115 and 124°C.
318 DPF Indicating DPF regeneration On DPF regeneration Indicating DPF
regenerati remaining time. If DPF regeneration
on temperature is low, numerical remaining time
remaining value is not reduced.
time
<Euro5>
321 DPF Showing whether DPF Ignition switch: ON ON (during
regenerati regeneration is being performed or DPF
on not. regeneration),
<Euro5> OFF (during
not DPF
regeneration)
328 DPF Showing whether engine-ECU Ignition switch: ON ON (during
regenerati requires DPF regeneration or not. DPF
on request regeneration
<Euro5> request), OFF
(during not
DPF
regeneration
request)
377 Max value Indicating maximum temperature Ignition switch: ON −400 to 2,150
of DPF of DPF regeneration stored in °C
temperatu engine-ECU
re
<Euro5>
384 Odometer Indicates the driving distance at Ignition switch: ON 0 − 1,999,999
at DPF the maximum DPF temperature km
temperatu saved to the engine-ECU.
re max
value
<Euro5>
391 Count of Indicates the DPF regeneration Ignition switch: ON 0 − 65,535
Regenerat request times saved to the engine-
ion ECU.
Request
<Euro5>
DIESEL FUEL
TROUBLESHOOTING
13A-571
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
404 Battery Indicates the learning value of Ignition switch: ON −6 to 6 A
current battery current sensor calibration.
sensor
(learning
value)
<Euro5>
435 Last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery is judged to be low at
deteriorat the last time.
ed
odometer
<Euro5>
436 2nd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat two times before.
ed
odometer
<Euro5>
437 3rd last Indicates the travel distance when Ignition switch: ON 0 − 262,140 km
battery the battery was judged to be low
deteriorat three times before.
ed
odometer
<Euro5>
452 Battery • Indicates learning conditions of Ignition switch: ON Varies
current battery current sensor depending on
sensor calibration. the learning
(learning • Message "Completed" means conditions
value of learning has been completed.
neutral Message "Not completed"
point) means learning has been not
<Euro5> completed.
454 Battery Indicates the battery deterioration. Ignition switch: ON ON
degrade (deteriorated)*2
judgement , OFF (not
flag deteriorated)
<Euro5>
455 Battery Indicates the battery full charge Ignition switch: ON ON (the battery
full-charge control is being taken. full charge
mode flag control is being
<Euro5> taken.),
OFF (the
battery full
charge control
is not taken.)
13A-572 DIESEL FUEL
TROUBLESHOOTING
Ite Inspectio Explanation of M.U.T. display Guideline for inspection Display range,
m n item numerical
No. value
488 Brake Shows the driving distance when Ignition switch: ON 0 − 1,999,999
override the engine-ECU activates the km
operated previous brake override control.
odometer
<Euro5>
489 Fuel Indicates the final target torque • Engine: After warm-up, idle 0 − 60 Nm
torque operation
target • Lights and all accessories:
OFF
• Transmission: Neutral <M/T>
or P range <A/T>
490 Fuel Indicates the pilot injection • Engine: After warm-up, idle 0 − 3 mm3/st
injection quantity operation
quantity • Lights and all accessories:
pilot 1 OFF
• Transmission: Neutral <M/T>
or P range <A/T>
491 Fuel Indicates the pilot injection • Engine: After warm-up, idle 0 − 3 mm3/st
injection quantity operation
quantity • Lights and all accessories:
pilot 2 OFF
• Transmission: Neutral <M/T>
or P range <A/T>
492 Fuel Indicates the pilot injection • Engine: After warm-up, idle 0 − 3 mm3/st
injection quantity operation
quantity • Lights and all accessories:
pilot 3 OFF
• Transmission: Neutral <M/T>
or P range <A/T>
NOTE: *1: This item is indicated as follows. FF: Initial condition, 0: Non-learning state, 1: Temporary learning
completed status, 2: Learning completed status, 3: Non-learning state.
NOTE: *2: The deterioration level does not request that the battery must be replaced soon.
DIESEL FUEL
TROUBLESHOOTING
13A-573
Actuator Test Reference Table
M1133004400711
Item Check item Drive Inspection Value to be determined Code No. or Reference
No. contents conditions as normal inspection page
procedure
No.
1 Engine Turn the Ignition switch: The warning lamp turns Procedure P.13A-
check lamp warning ON on. No. 2, 3 438,
lamp on or P.13A-441
off
2 Glow lamp Turn the Ignition switch: The glow lamp turns on. − −
glow lamp ON
on or off
3 Glow plug Turning the Ignition switch: Battery charge is − −
relay relay from ON energized to the glow plug
OFF to ON when the glow plug relay
is ON.
4 A/C relay Turning the Ignition switch: The A/C compressor Procedure P.13A-512
relay from ON clutch makes an audible No. 23
OFF to ON sound.
5 Condenser Turning the Ignition switch: The condenser fan rotates Procedure P.13A-507
fan relay relay from ON No. 21
<Vehicles OFF to ON
with A/C
condenser
fan>
15 Injector No. 1 Cut off No. 1 • Ignition ON → Engine is Code No. P.13A-158
injector switch: ON OFF changed P0201
• Engine: Idling (becomes
• Vehicle unstable)
speed: 0 km/
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
16 Injector No. 2 Cut off No. 2 • Ignition ON → Engine is Code No. P.13A-161
injector switch: ON OFF changed P0202 <Euro5>,
• Engine: Idling (becomes P.13A-164
• Vehicle unstable) <Except
speed: 0 km/ Euro5>
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
13A-574 DIESEL FUEL
TROUBLESHOOTING
Item Check item Drive Inspection Value to be determined Code No. or Reference
No. contents conditions as normal inspection page
procedure
No.
17 Injector No. 3 Cut off No. 3 • Ignition ON → Engine is Code No. P.13A-167
injector switch: ON OFF changed P0203 <Euro5>,
• Engine: Idling (becomes P.13A-170
• Vehicle unstable) <Except
speed: 0 km/ Euro5>
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
18 Injector No. 4 Cut off No. 4 • Ignition ON → Engine is Code No. P.13A-173
injector switch: ON OFF changed P0204 <Euro5>,
• Engine: Idling (becomes P.13A-176
• Vehicle unstable) <Except
speed: 0 km/ Euro5>
h
• Ignition OFF → The solenoid
switch: ON ON of Injector is
• Engine: not driven.
running
19 Suction Turn the • Ignition The suction control valve Code No. P.13A-26,
control valve suction switch: ON of supply pump is driven. P0003, P.13A-29,
control valve • Engine: not P0004, P.13A-63
from OFF to running P0089 <Euro5>
ON <Euro5>
P.13A-63,
P0089,
P.13A-
P0628,
276,
P0629
<Except P.13A-279
Euro5> <Except
Euro5>
25 EGR valve 0 Lift position • Ignition EGR valve lift driven into − −
% reaches 0 % switch: ON 0% position
• Engine: Idling
• Vehicle
speed: 0 km/
h
26 EGR valve Lift position • Ignition EGR valve lift driven into − −
50 % reaches 50 switch: ON 50% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
DIESEL FUEL
TROUBLESHOOTING
13A-575
Item Check item Drive Inspection Value to be determined Code No. or Reference
No. contents conditions as normal inspection page
procedure
No.
27 EGR valve Lift position • Ignition EGR valve lift driven into − −
100 % reaches 100 switch: ON 100% position
% • Engine: Idling
• Vehicle
speed: 0 km/
h
28 Throttle Throttle • Ignition Throttle valve is driven − −
valve 0 deg valve is 0 switch: ON into 0 deg position
deg open • Engine: not
running
29 Throttle Throttle • Ignition Throttle valve is driven − −
valve 45 deg valve is 45 switch: ON into 45 deg position
deg open • Engine: not
running
30 Throttle Throttle • Ignition Throttle valve is driven − −
valve 90 deg valve is 90 switch: ON into 90 deg position
deg open • Engine: not
running
36 Variable Turn the Engine: Idling Variable geometry Code No. P.13A-34,
geometry variable actuator is operated. P0047, P.13A-40
control geometry P0048
solenoid control
valve solenoid
<Euro5> valve from
OFF to ON
44 DPF lamp Turn the Ignition switch: Turn the DPF lamp on. Procedure P.13A-537
<Euro5> DPF lamp ON No. 29
on
D-213 D-215
1 2 3 4 5 6 7 8 9 10 111213141516171819 20 21 22 23 24 92103104105106107108109110
93 94 95 96 97 98111112113100 114115
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
10191
102 99 129130101
118119120121122123124125126127128
102 103 104 105 106 107 108 109
116 117 110 111
112 113 114 115 116 117 118 119
49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 131132133134135136137138139140 141142143
128 129 130
73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 144120
145121146147148149150151152153154155156
122 123 124 125 126 127 157158
AK800887AB
D-215 D-213
115 114 113 112 111 110 109 108 107 106 105 104 103 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
130 129 128 127 126 125 124 123 122 121120 119 118
102 101 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
117 116
143 142 141 140 139138 137 136 135 134 133 132 131 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49
158 157156 155 154 153 152 151 150 149 148 147 146
145 144 96 95 94 93 92 91 90 89 88 87 86 85 84 83 82 81 80 79 78 77 76 75 74 73
AK800888 AB
1 2 3
Camshaft position
sensor connector
AK501436 AB
1. Disconnect the camshaft position sensor harness (MB991709) in between (All terminals
connector and connect the special tool test should be connected).
13A-586 DIESEL FUEL
TROUBLESHOOTING
2. Connect the oscilloscope special pattern pickup to 2. Connect the oscilloscope special pattern pickup to
camshaft position sensor terminal No. 2. engine-ECU terminal No. 67 (When checking the
3. Disconnect the crank angle sensor intermediate crank angle sensor signal wave pattern.)
connector and connect the special tool test
harness (MB991709) in between. Standard Wave Pattern
4. Connect the oscilloscope special pattern pickup to Observation conditions
crank angle sensor terminal No. 2. Function Special patterns
Alternate Method (Test harness not available) Pattern height Low
1. Connect the oscilloscope special pattern pickup to Pattern selector Display
engine-ECU terminal No. 66 (When checking the Engine speed Idle
camshaft position sensor signal wave pattern.)
Crank angle
sensor output
wave pattern 5
Camshaft
position 5
sensor output
wave pattern
0
Time
AK501437AB
AK501439
AK501438
Example 2
Cause of problem
Example 1
Loose timing belt
Cause of problem Abnormality in sensor disk
Sensor interface malfunction
Wave pattern characteristics
DIESEL FUEL
TROUBLESHOOTING
13A-587
Wave pattern is displaced to the left or right. 1. Disconnect the suction control valve connector,
and then connect the special tool test harness
SUCTION CONTROL VALVE (MB991658) in between (All terminals should be
Measurement Method connected).
2. Connect the oscilloscope special pattern pickup to
Oscilloscope terminal No. 1, of the suction control valve
connector.
AK900016 AB
Time
0
AK501441 AB
Observation conditions
Function Special patterns
Pattern height Variable
Variable knob Adjust while viewing
the wave pattern
Pattern selector Display
Engine Idle
Engine load is high
AK501442 AB
ON-VEHICLE SERVICE
EVACUATION OF WATER FROM FUEL
Hand pump
FILTER
M1133001200406
Air plug
<Vehicles with steel fuel filter case>
Water is in the fuel filter when fuel filter indicator
lamp illuminates. Evacuate water by the following
procedures.
Drain plug
Hand pump
ACB01923AB
9. Connect the M.U.T.-III main harness A to the 16.Turn the ignition switch to the "LOCK" (OFF)
diagnosis connector of the vehicle. position, and stop the engine.
10.Turn the V.C.I. power switch to the "ON" position. 17.Disconnecting the M.U.T.-III is the reverse of the
NOTE: When the V.C.I. is energized, the V.C.I. connecting sequence.
indicator lamp will be illuminated in a green col- 18.Check the colour change of the oil leak detection
our. agent at the flare nut and pipe of the fuel injection
11.Start the M.U.T.-III system on the personal pipe to check if the fuel is leaking from the fuel
computer and turn the ignition switch to the "ON" injection pipe connection at the fuel injector
position. assembly side.
12.Start the engine, and let it run at idle. 19.Visually check other fuel line connections for fuel
13.Select "MPI/GDI/DIESEL" from System select leak.
Screen of the M.U.T.-III. 20.If the fuel is leaking, replace the fuel injection pipe
and the fuel supply pump pipe. (Refer to P.13A-
14.Select "SPECIAL FUNCTION" from MPI/GDI/
DIESEL Screen. 604.)
15.Select "FUEL LEAKAGE CHECK" from Test 21.If the fuel is not leaking, wipe off the oil leak
Screen. Carry out the fuel leakage check (during detection agent using parts cleaner (MZ100387)
the test, the engine speed and the fuel pressure is or equivalent completely.
2,000 r/min and 180 MPa for 20 seconds 22.Install the engine cover assembly upper (Refer to
respectively) five times in a row (20 seconds × 5 GROUP 11A − Engine Assembly ).
times = 100 seconds).
COMPONENT LOCATION
M1133004700660
A B C D E F G H I
J K L M N O P Q
AKB00282AB
13A-592 DIESEL FUEL
ON-VEHICLE SERVICE
R S T R S T T
U V W X Y Z Z Y X U W V
a b
AKB00329 AB
DIESEL FUEL
ON-VEHICLE SERVICE
13A-593
ENGINE CONTROL RELAY CONTINUITY 1. Remove the engine coolant temperature sensor
CHECK using the special tool engine coolant temperature
M1133008300459 sensor wrench (MB992042).
Engine control
relay
1 2
3
4
Equipment side
connector AK501444 AB AKX01622
Tester Battery Voltage Normal State 2. With temperature sensing portion of engine
Connection coolant temperature sensor immersed in hot
Terminal water, check resistance.
1−2 No voltage Continuity Standard value:
3−4 No voltage No continuity 14 − 17 kΩ (at −20°C)
5.1 − 6.5 kΩ (at 0°C)
Voltage (Connect Continuity (2 Ω
2.1 − 2.7 kΩ (at 20°C)
positive (+) terminal of or less)
0.9 − 1.3 kΩ (at 40°C)
battery to terminal No.
0.48 − 0.68 kΩ (at 60°C)
1 and negative (−)
0.26 − 0.36 kΩ (at 80°C)
terminal of battery to
terminal No. 2.) 3. If the resistance deviates from the standard value
greatly, replace the sensor.
ENGINE COOLANT TEMPERATURE
SENSOR CHECK
M1133005000404
Engine coolant
temperature sensor
AKX01623AD
1 2
4. Apply sealant to threaded portion.
Equipment side
connector AK501445AB Specified sealant:
3M NUT Locking Part No. 4171 or equivalent
5. Tighten the engine coolant temperature sensor to
MB992042 the specified torque, using engine coolant
temperature sensor wrench, special tool
(MB992042).
Tightening torque: 29 ± 10 N⋅m
AK503116 AC
13A-594 DIESEL FUEL
ON-VEHICLE SERVICE
INJECTOR CHECK
M1133008100314
Injector
No. 1 intake
1 2 air temperature
sensor AK603026AB
Equipment side
connector AKA00359AB 4. Measure resistance while heating the sensor
using a hair drier.
1. Disconnect the injector connector.
Normal condition:
2. Measure the resistance between terminals No. 1
and No. 2. Temperature (°C) Resistance (kΩ)
Standard value: Approximately 0.45 Ω (at Higher Smaller
20°C)
5. If the value deviates from the standard value or
3. If not within the standard value, replace the the resistance remains unchanged, replace the air
injector. After replacing the injector, register the flow sensor assembly.
injector identification code and learn fuel injection.
6. Install the air flow sensor and tighten it to the
(Refer to GROUP 00 − Precautions Before
specified torque.
Service − What The common Rail Engine Learns
). Tightening torque: 0.7 ± 0.1 N⋅m
INTAKE AIR TEMPERATURE SENSOR No. INTAKE AIR TEMPERATURE SENSOR No.
1 CHECK 2 CHECK <Except Euro5>
M1133010400301
M1133010300296
Intake air temperature
1 2 3 4 5 sensor No.2
Equipment side
connector
Equipment side
connector AK501450 AB
AKA00360 AB
1. Disconnect the air flow sensor connector. 1. Disconnect the intake air temperature sensor No.
2 connector.
2. Measure resistance between terminals No. 1 and
No. 2. 2. Measure resistance between terminals No. 1 and
No. 2.
Standard value:
13 − 17 kΩ (at −20°C) Standard value:
5.4 − 6.6 kΩ (at 0°C) 13 − 18 kΩ (at −20°C)
2.3 − 3.0 kΩ (at 20°C) 5.1 − 6.9 kΩ (at 0°C)
1.0 − 1.5 kΩ (at 40°C) 2.0 − 3.0 kΩ (at 20°C)
0.56 − 0.76 kΩ (at 60°C) 0.9 − 1.5 kΩ (at 40°C)
0.31 − 0.43 kΩ (at 80°C) 0.40 − 0.78 kΩ (at 60°C)
0.23 − 0.42 kΩ (at 80°C)
3. Remove the air flow sensor
3. Remove the intake air temperature sensor No. 2
DIESEL FUEL
ON-VEHICLE SERVICE
13A-595
FUEL TEMPERATURE SENSOR CHECK
Intake air temperature M1133006800317
sensor No.2
1 2
Equipment side
connector
AK501451AB
AK501452 AB
<Except Euro5>
10 ± 2 N·m
10 ± 2 N·m
2 AC502869AE
13A-598 DIESEL FUEL
FUEL INJECTOR
23 ± 6 N·m 12
12
9N
11 N
7 10 N
13 16
15 ± 2 N·m
15 ± 2 N·m 10 ± 1 N·m to +120˚ – +125˚
N 15
(Engine oil)
17
13 18
14
19
N 15
20 N
10 ± 2 N·m
10 ± 2 N·m
3 AC805674 AD
9
5 2 8
4
3 AC900203 AB
MB990784
AC900204AB
Fuel injector
Injector supporter
AC502873AB
Pivot boss
8. Using special tool angle gauge (MB991614),
Nozzle tighten the injector holder bolt in the illustrated
gasket sequence by a further 120° to 125°.
AC502872 AB
2. Install the nozzle gasket, fuel injector, pivot boss, >>B<< SEMI-CIRCULAR PACKING
and injector supporter to the cylinder head as INSTALLATION
shown in the figure.
3. Apply a small amount of engine oil to the seat
surface and thread of injector holder bolt, and Semi-circular packing
then temporarily tighten the bolt to the cylinder
head.
4. Set the fuel leak-off gasket to the fuel leakage
pipe, and temporarily tighten to the fuel injector
and to the cylinder head using the eye bolt.
5. Tighten the eye bolt of the fuel injector side to the
specified torque. AC502874AB
Cylinder head
AC502875AB >>D<< OIL SEAL INSTALLATION
AC502876AB
2
6 9 3
Socket wrench
7
8
Oil seal Rocker cover
4 10 1 5
AC502871AC
(Engine oil)
3. Tighten the rocker cover assembly mounting bolts AC502877AB
to the specified torque in the order shown in the Apply engine oil to the oil seal outer surface and
figure. drive in with a socket wrench.
Tightening torque: 3.0 ± 1.0 N⋅m
DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
13A-603
COMMON RAIL AND SUPPLY PUMP
REMOVAL AND INSTALLATION
M1133009600389
CAUTION
• The reinstallation histories of the removed fuel injection pipe and fuel supply pump pipe are up to
five times. To count how many times the fuel injection pipe and fuel supply pump pipe are rein-
stalled, record the number of the reinstallation histories on the service booklet by adding this lat-
est number of the histories, which is usually "1", to the previous one. Use a new fuel injection pipe
or fuel supply pump pipe when the total reinstallation history numbers reach five times, or when
the fuel injector assembly, common rail assembly or supply pump assembly is replaced. In this
case, record " a new fuel injection pipe or fuel supply pump pipe, the number of the reinstallation
histories is zero" on the service booklet.
• If a fuel leak is present in the fuel injection pipe and fuel supply pump pipe once, do not reuse it
and replace with a new one.
• If the fuel injector assembly, common rail assembly or supply pump assembly is replaced, the
contact surface (seal surface) between the fuel injection pipe and fuel supply pump pipe, and the
other side component is changed, do not reuse the fuel injection pipe and fuel supply pump pipe
and replace with a new one.
• When the injection pipe is reinstalled, confirm there is no foreign material on the seal surface or in
the pipe and then install it not to deviate from the axis, fitting the seal surface.
Pre-removal Operation Post-installation Operation
• Inlet Manifold Removal (Refer to GROUP 15 − Inlet Mani- • Inlet Manifold Installation (Refer to GROUP 15 − Inlet
fold ). Manifold ).
• Fuel Line Leak Check (Refer to P.13A-590).
<Except Euro5>
20 ± 2 N·m
11 N
17 ± 2 N·m 6
35 ± 5 N·m
8 N
12 10
10 ± 2 N·m 35 ± 5 10 ± 2 N·m
N·m
10 ± 2 N·m
7 35 ± 5 N·m
2 6 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
9
64 ± 5 N·m
24 ± 4 N·m
24 ± 4 N·m
5
AC502865 AG
13A-604 DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
20 ± 2 N·m
12 N
20 ± 2 N·m 6
35 ± 5 N·m
9N
13 11
35 ± 5
10 ± 2 N·m N·m 10 ± 2 N·m
10 ± 2 N·m
35 ± 5
8 N·m 6 35 ± 5 N·m
10 ± 2 N·m
2 7 35 ± 5 N·m
10 ± 2 N·m 10 ± 2 N·m
4N
1
3 35 ± 5 N·m
10
64 ± 5 N·m 24 ± 4 N·m
24 ± 4 N·m
5
AC805678 AB
DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
13A-605
Supply pump assembly removal 1. Using special tool sprocket holder (MB992048),
steps lock the injection pump sprocket, and then loosen
• When the supply pump assembly the injection pump sprocket mounting nut.
is replaced, perform the supply
pump learning.(Refer to GROUP Injection pump
00 − Precautions before Service, sprocket MB992098
What the Common Rail Engine
Learns ) <Installation only>.
• Timing belt (Refer to GROUP 11A
− Timing belt ).
<<A>> >>D<< 1. Injection pump sprocket
MB992099
2. Fuel return hose
3. Fuel inline hose
<<B>> >>C<< 4. Fuel supply pump pipe AC502178 AB
>>C<< 5. Supply pump assembly
Fuel injection pipe removal 2. Using the special tools below, remove the
steps injection pump sprocket.
2. Fuel return hose • Injection pump sprocket puller (MB992098)
3. Fuel inline hose • Crank pulley puller (MB992099)
<<B>> >>B<< 4. Fuel supply pump pipe
<<C>> >>B<< 6. Fuel injection pipe
Common rail assembly removal <<B>> FUEL SUPPLY PUMP PIPE REMOVAL
steps CAUTION
2. Fuel return hose When removing the fuel supply pump pipe, the
3. Fuel inline hose fuel pressure in the fuel line is high. Thus, wait
<<B>> >>C<< 4. Fuel supply pump pipe for 3 minutes or longer after the engine stops,
<<C>> >>A<< 6. Fuel injection pipe
and cover the fuel supply pump pipe with a rag or
7. Fuel injection pipe bracket
>>A<<
similar materials to prevent the fuel splash, and
8. Eye bolt
>>A<< 9. Fuel return gasket then disconnect the fuel supply pump pipe.
>>A<< 10. Common rail assembly
>>A<<
<<C>> FUEL INJECTION PIPE REMOVAL
11. Eye bolt
>>A<< 12. Fuel return gasket
>>A<< 13. Fuel return pipe
AC901507AB
AC503013 AB
13A-606 DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
AK600656 AB
Common rail
Fuel return pipe assembly
AC502866AB
Common rail
8. Tighten the fuel return pipe to the specified
torque.
AC502867AB Tightening torque: 10 ± 2 N⋅m
9. Tighten the bolts of the fuel injection pipe to the
3. Temporarily tighten the common rail assembly
specified torque.
with bolts, holding the common rail assembly.
Tightening torque: 10 ± 2 N⋅m
4. Align the fuel injection pipe centre axis with the
other side components (fuel injector assembly 10.Tighten the common rail assembly side flare nut
and common rail assembly) centre axis to install in the fuel supply pump pipe and the supply pump
the fuel injection pipe. Then, tighten the flare nut assembly side flare nut alternately in several
temporarily until the tip of pipe (seal surface) steps to the specified torque.
contacts with the other side components. Tightening torque: 35 ± 5 N⋅m
NOTE: When the fuel injection pipe is installed,
tighten the flare nut while shaking the pipe lightly
to align the centre axis of both components.
DIESEL FUEL
COMMON RAIL AND SUPPLY PUMP
13A-607
>>B<< FUEL INJECTION PIPE/FUEL SUPPLY
PUMP PIPE INSTALLATION
CAUTION
MB992188
Pressure
sensor
Pressure limiter
AK600656 AB
Common rail
AC502867AB
3. Tighten the common rail assembly side flare nut in >>D<< INJECTION PUMP SPROCKET
the fuel supply pump pipe and the supply pump INSTALLATION
assembly side flare nut alternately in several
Injection pump
steps to the specified torque. MB992048 sprocket
Tightening torque: 35 ± 5 N⋅m
4. Tighten the supply pump assembly bolts to the
specified torque.
Tightening torque: 24 ± 4 N⋅m
5. Tighten the fuel supply pump pipe bolt.
AC503013 AB
48 ± 6 N·m
(Engine oil)
N7
2 N 6
5
1
8.9 ± 1.9 N·m
4
N3
(Engine oil)
AC704545 AC
13 ± 2 N·m
5N
3
6.0 ± 1.0 N·m
AC502843AD
Throttle body
gasket
Throttle body AC502844AB
(Engine oil)
3N
2
11 ± 1 N·m
AC502938 AC
44 ± 8 N·m
N 5
(Engine oil)
4
11 ± 1 N·m
3 2
1
22 ± 4 N·m AC805916 AC
DIESEL FUEL
ENGINE-ECU
13A-613
Removal steps REMOVAL SERVICE POINT
<<A>> 1. A/C compressor assembly <<A>> A/C COMPRESSOR ASSEMBLY
2. A/C compressor bracket assembly REMOVAL
3. Crankshaft position sensor
connector 1. With the hose installed, remove the A/C
4. Crankshaft position sensor compressor assembly from the bracket.
5. O-ring 2. After removing the A/C compressor assembly,
secure it with a cord in the location where the
removal and installation of the crankshaft position
sensor cannot be hindered.
ENGINE-ECU
REMOVAL AND INSTALLATION
M1133009200767
CAUTION
• After having replaced the engine-ECU, use the M.U.T.-III to register the chassis number. [Refer to
GROUP 00 − Precautions before Service, How to perform chassis number (Chassis No.) writing ].
• When the engine-ECU is replaced, register the injector identification code and perform the small
injection quantity learning. (Refer to GROUP 00 − Precautions before Service, What the Common
Rail Engine Learns ).
• When the engine-ECU is replaced, make the battery current sensor learn the neutral point by
using M.U.T.-III (Refer to GROUP 00 − Precautions before Service, Battery Current Sensor Calibra-
tion ) <Euro5>.
<LH drive vehicles>
AC508203 AD
8
5.0 ± 2.0 N·m
5 3
5.0 ± 2.0 N·m
7.5 ± 1.5 N·m
2
1
AC805918 AB
Removal steps 1. Drill in the break off bolt a hole deep enough for
1. Scuff plate the tap to stand.
2. Cowl side trim 2. Use the recommended tool screw extractor set
<<A>> >>A<< 3. Brake off bolt (MB992678) or equivalent to remove the break off
4. ECU cover
bolt.
5. Engine-ECU connectors
6. Engine-ECU
7. ECU lower bracket INSTALLATION SERVICE POINT
8. ECU upper bracket >>A<< BREAK OFF BOLT INSTALLATION <RH
DRIVE VEHICLES>
REMOVAL SERVICE POINT Tighten the break off bolt until its head is broken off.
<<A>> BREAK OFF BOLT REMOVAL <RH DRIVE
VEHICLES>
GROUP 13B
FUEL SUPPLY
CONTENTS
GENERAL INFORMATION
M1135000100725
Fuel tank is mounted on the front of the rear axle to
reduce the shock at impact. A fuel cut valve, which
prevents fuel leakage when the vehicle banks or rolls
over, has been located inside the fuel tank for fewer
openings and hose bonding points on the fuel tank
top surface.
SPECIAL TOOLS
M1135000601143
B992145
B992264
B992265
B992266
ON-VEHICLE SERVICE
FUEL LEAK CHECK OF FUEL TANK
M1135005900566 MB992145
CAUTION
Always check the fuel leak of fuel tank with the
vehicle loaded. If it is checked with the fuel tank
removed, the fuel tank may be damaged.
AC600149 AC
FUEL SUPPLY
ON-VEHICLE SERVICE
13B-3
1. Remove the fuel tank cap, install special tool fuel 5. Leave it for approximately 3 minutes and check
leak check cap (MB992145). that the pressure is not weakened.
6. If the pressure is weakened, apply soapy water to
each part with pressurized state and check the
leak while confirming if air bubbles are seen.
MB992145 Pressure
gauge
FUEL DRAINING
M1135006900321
CAUTION
• Working area should be airy and kept from
flame.
• Prepare a fire extinguisher before working.
• Install the earth lines to the vehicle and fuel
Trigonal joint tank to prevent static electricity, and water the
work place to keep the footing from slipping.
• Touch the vehicle with hands to release the
Air gun charged static.
• Keep the drained fuel in the safety place.
Fuel hose
AC600150AB
AC711418 AC
Fuel hose
3. Remove the splash shield rear (LH) (Refer to
GROUP 42 − Splash Shield ), and block the fuel
tank hose. Fuel hose
(bore: 7.6 mm)
CAUTION AC711667AB
• Do not pressurize suddenly.
• Do not pressurize 11.76 kPa or more to pre- 2. Connect the special tools fuel hand pump
vent the damage of components. (MB992264), fuel hose adaptor A (MB992265)
4. Pressurize while checking the pressure gauge and two fuel hoses (Inner diameter 7.6 ± 0.4 mm)
and hold if it reaches from 9.80 to 11.76 kPa. to the disconnected fuel hose.
3. Operate the special tool (MB992264) to drain fuel
from the fuel tank.
13B-4 FUEL SUPPLY
FUEL TANK
FUEL TANK
REMOVAL AND INSTALLATION
M1135001902913
18
20
17
11
9
12 N 19
4 16
3
2 15
10
5
14
1
13
6N
55 ± 3 N·m
N 6
55 ± 3 N·m
AC805923 AB
Self-locking nut
Transmission jack
AC504246AB AC505408 AC
1. Support the fuel tank assembly using the When tightening the self-locking nut, be careful
transmission jack, and remove self-locking nuts. not to let the nut touch the bent part of the rein-
forcement of the fuel lower protector and the fuel
2. Using the transmission jack while taking care of
tank.
the fuel harness, lower the fuel tank assembly
until the fuel harness installation position over the DISASSEMBLY AND REASSEMBLY
fuel tank assembly can be checked. M1135051100251
AC611598AB
FUEL FILTER
REMOVAL AND INSTALLATION <Vehicles with steel fuel filter case>
M1135002800559
Post-installation Operation
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
1 1
7N
5.0 ± 1.0 N·m
6
N5
12 ± 2 N·m
2
4
6.0 ± 1.0 N·m
AC807196 AB
AC502833AB
Fix the fuel filter body to a vice, and then remove the
fuel filter using an oil filter wrench.
20 – 25 mm
AC503372AB
Post-installation Operation
• Evacuation of Air from Fuel Line (Refer to GROUP 13A −
On-vehicle Service, Evacuation of Air from Fuel Line ).
2 11 ± 2 N·m
N 6
1
N 7
11 ± 2 N·m
N 4
8 11 ± 2 N·m
ACB01919AB
Mark
OPEN
Fastener
nut
ACB01912 AB ACB01914AB
2. Insert a flat-tipped screwdriver into the groove of 2. Securely tighten the fastener nut until the mark is
the fastener nut. in the position shown in the figure (until it clicks in
3. Loosen the fastener nut using the flat-tipped place).
screwdriver until it can be loosened by hand.
>>B<< FUEL LINE HOSE CONNECTION
<<B>> FUEL FILTER CAP REMOVAL
Under 2 mm
Fastener
nut ACB02187AB
ACB01912 AB Securely insert the fuel line hose to the fuel filter and
install the hose clip in the position shown in the fig-
1. Insert a flat-tipped screwdriver into the groove of ure.
the fastener nut.
2. Loosen the fastener nut using the flat-tipped INSPECTION
screwdriver until it can be loosened by hand. M1135002900233
1 2
Float
ACB01913 AC502835 AC
1. Install the fuel filter cap by aligning the marks on 2. There should be continuity when the float is
the fuel filter cap and the fuel filter case. raised, while there is no continuity when it is
lowered.
3. Replace the fuel filter assembly if it is faulty.
13B-10 FUEL SUPPLY
FUEL FILTER
<Vehicles with plastic fuel filter case> 3. Replace the fuel filter assembly if it is faulty.
WATER LEVEL SWITCH CHECK
1. Connect the circuit tester to the water level switch. FUEL FILTER VACUUM SWITCH CHECK
Float
ACB01916AB
ACB01915AB
GROUP 14
ENGINE COOLING
CONTENTS
GENERAL INFORMATION
M1141000101824
The cooling system is designed to keep every part of ature, the thermostat opens to circulate the coolant
the engine at appropriate temperature in whatever through the radiator as well so that the heat
condition the engine may be operated. The cooling absorbed by the coolant may be radiated into the air.
method is of the water-cooled, pressure forced circu- The water pump is of the centrifugal type and is
lation type in which the water pump pressurizes cool- driven by the drive belt from the crankshaft. The radi-
ant and circulates it throughout the engine. If the ator is the corrugated fin, cross-flow type.
coolant temperature exceeds the prescribed temper-
Item Specification
Radiator Performance kJ/h 244,300
Built-in A/T oil cooler Performance kJ/h 6,800
SERVICE SPECIFICATIONS
M1141000300739
LUBRICANT
M1141000400662
SEALANTS
M1141000501576
MB991871
MB992042
ON-VEHICLE SERVICE
ENGINE COOLANT LEAK CHECK 2. If there is leakage, repair or replace the
M1141001000515 appropriate part.
WARNING
When pressure testing the cooling system, RADIATOR CAP VALVE OPENING
slowly release cooling system pressure to PRESSURE CHECK
avoid getting burned by hot coolant. M1141001300646
NOTE: Be sure that the cap is clean before test-
CAUTION
ing. Rust or other foreign material on the cap seal
• Be sure to completely clean away any mois-
will cause an improper reading.
ture from the places checked.
• When the tester is taken out, be careful not to
spill any coolant.
• Be careful when installing and removing the Cap adapter
tester and when testing not to deform the
filler neck of the radiator.
Cap adapter
Adapter AC211643 AB
MB991871
WATER PUMP COOLANT LEAK CHECK
M1141008600392
If a residue of the coolant draining is found on the
drain hole, the vapour hole and the installation sur-
face of the water pump, check the water pump leak-
age by following method.
1. Wipe off the residue of the coolant draining on the
water pump.
AC503144AB
ENGINE COOLING
ON-VEHICLE SERVICE
14-5
WARNING 3. Install the radiator tester and pressures at 100
Make sure that the coolant is cold when kPa.
removing the radiator cap. 4. Hold the pressurized state for 20 minutes, and
check that the water leakage from the drain hole,
2. Remove the radiator cap.
the vapour hole or the installation surface of the
CAUTION water pump.
Do not pressures 100 kPa or more. 5. Remove the radiator tester, and install the radiator
cap.
6. Warm up the engine, let it idle for 20 minutes and
Cap adapter
stop it.
Adapter 7. Stop the engine.
8. Check that the water leakage from the drain hole,
the vapour hole or the installation surface of the
water pump.
9. If the water leakage is found in step 4 or 8,
replace the water pump (Refer to P.14-9).
ACX01844 AC
14-6 ENGINE COOLING
RADIATOR FAN
RADIATOR FAN
REMOVAL AND INSTALLATION
M1141002100872
2
4 5 3
11 ± 1 N·m
11 ± 1 N·m
1
AC805946 AB
11 ± 1 N·m 2 3 AC502980
24 ± 3 N·m
4 5
AC507713 AB
Removal steps Make mating marks on the radiator lower hose and
<<A>> >>A<< 1. Radiator lower hose connection the hose clip as shown to install them in the original
2. Battery wiring harness connection position. Disconnect the radiator lower hose.
3. Harness bracket
4. Water pump inlet hose fitting INSTALLATION SERVICE POINT
5. Thermostat
>>A<< RADIATOR LOWER HOSE CONNECTION
REMOVAL SERVICE POINT Protrusion
<<A>> RADIATOR LOWER HOSE DISCONNEC-
TION
INSPECTION
M1141002500676
THERMOSTAT CHECK
Valve lift
ACX00401AC
N 5
2N
1
10 ± 2 N·m
4N
3
24 ± 3 N·m
AC502983AB
Water pipe
AC103005AG
<Except Euro5>
3.0 ± 0.5 N·m
1
11 ± 1 N·m
53 ± 7 N·m
5 13 11 ± 1 N·m
N 6 7
24 ± 3 N·m
12
4
N 14 39 ± 5 N·m 2
11 53 ± 7 N·m
N3
10
8
24 ± 3 N·m
9 54 ± 4 N·m
AC502984 AB
24 ± 3 N·m
15 24 ± 3 N·m
24 ± 3 N·m
17
50 ± 5 N·m
22 N 21
16
11 ± 1 N·m
18
19
20 24 ± 3 N·m 30 ± 9 N·m
AC502985AD
<Euro5>
24 ± 3 N·m 5 4
2
1
N 6
39 ± 5 N·m 11 ± 1 N·m
3 9
8
24 ± 3 N·m
54 ± 4 N·m
7
AC805754 AB
23 ± 6 N·m
18
19
19
20
17 N
16
11 ± 1 N·m
11
10
15
13
14 24 ± 3 N·m 12
30 ± 9 N·m
AC805755 AC
AC606081AE
MB992042
Make mating marks on the radiator upper hose and
the hose clip as shown to install them in the original
position. Disconnect the radiator upper hose.
AC502986AB
O-ring
RADIATOR
REMOVAL AND INSTALLATION
M1141001503393
11 11 ± 2 N·m
3 16
11 ± 2 N·m
4 6
10 11 ± 2 N·m
14
15 13
15 5
2N 5.0 ± 1.0 N·m
1
7
17
42 ± 8 N·m
AC903736 AB
Protrusion
Mating marks
Pipe, fitting, or etc. Mating marks
AC606081AE AC606082 AU
GROUP 15
INTAKE AND
EXHAUST
CONTENTS
GENERAL INFORMATION
M1151000101568
The exhaust pipe is divided into three parts.
SERVICE SPECIFICATIONS
M1151000302189
MB991911
MB991825
MB991826
MB991955
ON-VEHICLE SERVICE
TURBOCHARGER SUPERCHARGING 1. Set the vehicle to the pre-inspection condition.
PRESSURE CHECK
M1151001001069
CAUTION
Conduct the driving test in a location where driv-
ing at full acceleration can be done with safety.
Two person should be in the vehicle when the
test is conducted; the person in the passenger
seat should read the indications shown by the
M.U.T.-III.
15-4 INTAKE AND EXHAUST
ON-VEHICLE SERVICE
MB991827 AK600277AB
CHECK <EURO5>
M1151011000249 Variable geometry
control solenoid valve
AK801719 AB
Variable geometry
actuator
1 2
AK802451AB
6V
CAUTION AK603599AB
In order to avoid damage to the diaphragm, do
not apply a vacuum of 60 kPa or higher. 3. Connect a hand vacuum pump to nipple (A) of the
2. By applying the vacuum pressure until the VG variable geometry solenoid valve.
actuator link touches the stopper bolt, fully shrink 4. As described in the chart below, check
the actuator rod. The vacuum pressure is airtightness by applying a vacuum with voltage
approximately 55 kPa at that time. applied directly from the battery to the variable
3. Leak the vacuum pressure gradually as much as geometry solenoid valve, and without applying
possible to check the vacuum pressure when the voltage.
VG actuator rod moves approximately 1.5 mm in Battery positive Nipple (B) Normal
the extension direction. voltage condition condition
Standard value: Approximately 45.4 − 49.2 Applied Open Vacuum leaks
kPa
Closed Vacuum
maintained
Not applied Open Vacuum
maintained
15-6 INTAKE AND EXHAUST
AIR CLEANER
1 2
AK603600AB
AIR CLEANER
REMOVAL AND INSTALLATION
M1151002103485
2 3
5 4N
6
11
13
12
AC903806AB
INTAKE AND EXHAUST
AIR CLEANER
15-7
Removal steps INSTALLATION SERVICE POINTS
1. Air cleaner element >>A<< VACUUM HOSE CONNECTION
2. Air flow sensor connector
connection Air intake hose
3. Air flow sensor Vacuum hose
4. Air flow sensor O-ring
5. Harness clamp
6. Air cleaner cover
7. Breather hose connection
8. Blow-by hose heater connector
<Vehicles for cold zone>
>>A<< 9. Vacuum hose connection <Euro5> White marking
10. Air intake hose
ACB00064AB
11. Radiator condenser tank hose
connection Clamp vacuum hose with clip of air intake hose
12. Air cleaner intake duct beside white marking as shown.
13. Air cleaner body
15-8 INTAKE AND EXHAUST
INTERCOOLER
INTERCOOLER
REMOVAL AND INSTALLATION <Except Euro5>
M1151002401208
CAUTION
• Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
• As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar-
bon.
• Working area should be airy and kept from flame.
Pre-removal Operation Post-installation Operation
• Air Cleaner Intake Duct Removal (Refer to P.15-6). • Air Cleaner Intake Duct Installation (Refer to P.15-6).
12 ± 2 N·m
8
7
9.0 ± 1.0 N·m
AC804002AB
Throttle body
A/C compressor assembly
suction pipe
Matching
mark
Turbocharger
assembly
Matching
mark
View A Intercooler
outlet air hose
View B
Intercooler
Power steering Intercooler
inlet air hose
suction hose outlet air pipe
Radiator
upper hose
Matching
marks
Matching
marks
Intercooler Intercooler
inlet air pipe outlet air hose
AC804003AB
Intercooler
outlet air hose
Intercooler
outlet air pipe
Matching
marks Matching
marks
Intercooler
outlet air hose
Intercooler
assembly
AC804005AB
15-10 INTAKE AND EXHAUST
INTERCOOLER
Intercooler
inlet air hose
15 mm or more
Radiator
upper hose
A/C compressor
suction pipe
Power steering
suction hose
Intercooler
outlet air hose
20 mm or more 20 mm or more
View B View A
AC804004AB
2. Install the intercooler air hose to the intercooler air 5. After installing the intercooler inlet air hose, check
pipe with the matching marks aligned as shown in that the clearance between the intercooler inlet air
the figure. hose and the A/C compressor suction pipe is 20
3. When installing the intercooler air hose to the mm or more (View B).
throttle body assembly or the turbocharger 6. After installing the intercooler inlet air hose, check
assembly, install the intercooler air hose with its that the clearance between the intercooler inlet air
matching mark located as shown in the figure. hose and the power steering suction hose is 20
4. After installing the intercooler outlet air hose, mm or more (View B).
check that the clearance between the intercooler
outlet air hose and the radiator upper hose is 15
mm or more (View A).
INTAKE AND EXHAUST
INTERCOOLER
15-11
7. Insert intercooler air hose to stopper end and not
Bulge 5 ± 1 mm Stopper end overlap with stopper.
Stopper 8. Place the hose clamp as shown in the figure so
that it does not overlap with the bulge and the
stopper end. When installing the hose clamp to
the intercooler air pipe or intercooler assembly,
Intercooler Intercooler set the hose clamp 5 ± 1 mm away from the
air hose air pipe stopper end. When installing the hose clamp to
the throttle body assembly or turbocharger
Hose clamp
AC712053 AB assembly, set the hose clamp 4 ± 1 mm away
from the stopper end.
Stopper end Bulge
5 ± 1 mm
>>B<< INTERCOOLER INLET AIR PIPE GASKET
Intercooler INSTALLATION
Intercooler outlet
assembly air hose
Protrusion
Hose clamp
Stopper AC712054 AB
4 ± 1 mm Bulge
Stopper end
AC504286AC
Stopper Install the intercooler inlet air pipe gasket as its pro-
trusion is in the direction shown.
Intercooler
outlet
air hose
Throttle body
Hose clamp
assembly AC804006 AB
Intercooler Turbocharger
inlet air assembly
hose
Stopper
Stopper end
Bulge 4 ± 1 mm
Hose clamp
AC804007AB
15-12 INTAKE AND EXHAUST
INTERCOOLER
CAUTION
• Degrease the air hose and air pipe by isopropyl alcohol, parts cleaner (MZ100387) or equivalent.
• As for the parts cleaner, use the petroleum cleaner whose major component is aliphatic hydrocar-
bon.
• Working area should be airy and kept from flame.
Pre-removal Operation Post-installation Operation
• Air Cleaner Intake Duct Removal (Refer to P.15-6). • Air Cleaner Intake Duct Installation (Refer to P.15-6).
12 ± 2 N·m
8
7
9.0 ± 1.0 N·m
AC804002AB
Throttle body
assembly
Matching
Turbocharger mark
assembly
Matching
mark Intercooler
outlet air hose
Intercooler
inlet air hose Intercooler
outlet air pipe
Matching
marks
Matching
marks
Intercooler Intercooler
inlet air pipe outlet air hose
ACB00692AB
Intercooler
outlet air hose
Intercooler
outlet air pipe
Matching
marks Matching
marks
Intercooler
outlet air hose
Intercooler
assembly
ACB00693AB
15-14 INTAKE AND EXHAUST
INTERCOOLER
2. Install the intercooler air hose to the intercooler air 4. Insert intercooler air hose to stopper end and not
pipe with the matching marks aligned as shown in overlap with stopper.
the figure. 5. Place the hose clamp as shown in the figure so
3. When installing the intercooler air hose to the that it does not overlap with the bulge and the
throttle body assembly or the turbocharger stopper end. When installing the hose clamp to
assembly, install the intercooler air hose with its the intercooler air pipe or intercooler assembly,
matching mark located as shown in the figure. set the hose clamp 5 ± 1 mm away from the
stopper end. When installing the hose clamp to
Bulge 5 ± 1 mm Stopper end the throttle body assembly or turbocharger
assembly, set the hose clamp 4 ± 1 mm away
Stopper
from the stopper end.
Intercooler
Intercooler outlet
assembly air hose
AC504286AC
4 ± 1 mm Bulge
Stopper end
Stopper
Intercooler
outlet
air hose
Throttle body
Hose clamp
assembly AC804006 AB
Turbocharger assembly
Stopper end
Bulge Stopper
Intercooler
inlet air
hose
4 ± 1 mm
Hose clamp
ACB00694AB
INTAKE AND EXHAUST
INLET MANIFOLD
15-15
INLET MANIFOLD
REMOVAL AND INSTALLATION
M1151003004655
<Except Euro5>
15-16 INTAKE AND EXHAUST
INLET MANIFOLD
1 3
5.0 ± 1.0 N·m
5.0 ± 1.0 N·m
2
24 ± 3 N·m
20 ± 2 N·m
24 ± 3 N·m
4
N 5
24 ± 3 N·m 7
24 ± 3 N·m 14 ± 1 N·m
24 ± 3 N·m
24 ± 3 N·m 6
24 ± 3 N·m
10
24 ± 3 N·m
9
N 11
N 12 8
24 ± 4 N·m
ACB00688 AB
1
3
5.0 ± 1.0 N·m
20 ± 4 N·m 2
24 ± 3 N·m
4
20 ± 2 N·m
24 ± 3 N·m
24 ± 3 N·m 6
24 ± 3 N·m
24 ± 3 N·m
24 ± 3 N·m 5
24 ± 3 N·m
24 ± 3 N·m
8
N 10
N 11 7
24 ± 4 N·m
ACB00689 AB
Side A
Inlet
manifold AC502862AB
17 ± 2 N·m
17 ± 2 N·m 14 ± 1 N·m
11 ± 1 N·m
53 ± 7 N·m 2N
9.0 ± 1.0 N·m
N 2 15
59 ± 10 N·m
1
11 ± 1 N·m
12 N
3
N 8 4
53 ± 7 N·m
7 18 ± 2 N·m
6 18 N 30 ± 2 N·m
18 N
13 17 5N
N 10 19 20 N
N 16
9 14 N
18 ± 2 N·m
9.0 ± 1.0 N·m
30 ± 2 N·m 18 N
9.0 ± 1.0 N·m
N 11
AC804075 AC
Section A-A
Oil return
pipe
A
Projection
AC502996AB
Projection
Position the projection as shown in the illustration.
A
AC502995AB
INTAKE AND EXHAUST
EXHAUST MANIFOLD AND TURBOCHARGER
15-21
REMOVAL AND INSTALLATION <Euro5>
M1151008901364
14 ± 1 N·m
2 3.0 ± 0.5 N·m
24 ± 3 N·m
17 ± 2 N·m
17 ± 2 N·m
3 4N
N4 9.0 ± 1.0 N·m
59 ± 10 N·m 5
N 11 9.0 ± 1.0 N·m
13 24 ± 3 N·m 1
14 N 6
7
34 ± 3 N·m 14 ± 1 N·m
N 18 59 ± 10 N·m
N 12
10 62 ± 5 N·m
18 N 15
9
14 ± 1 N·m
16 8
17
N 18 19
34 ± 3 N·m
62 ± 5 N·m
N 20
AC900935AC
26
25 N
11 ± 1 N·m
24
N 22
AC805771 AC
<Except Euro5>
Pre-removal Operation Post-installation Operation
• Under Skid Plate and Engine Room Under Cover • Under Skid Plate and Engine Room Under Cover Installa-
Removal (Refer to GROUP 51 − Under Cover ). tion (Refer to GROUP 51 − Under Cover ).
N 5
N 2
57 ± 7 N·m
6
25 ± 4 N·m
4
25 ± 4 N·m 1 3N
49 ± 5 N·m
ACB00721 AB
10
5 N 8
N 2 4 6
57 ± 7 N·m 7
36 ± 4 N·m
9
25 ± 4 N·m
25 ± 4 N·m 1 3N
49 ± 5 N·m
ACB00722 AB
GROUP 16
ENGINE
ELECTRICAL
CONTENTS
CHARGING SYSTEM
GENERAL INFORMATION
M1161000102045
The charging system uses the alternator output to When the ignition switch is turned on, current flows in
keep the battery charged at a constant level under the field coil and initial excitation of the field coil
various electrical loads. occurs.
OPERATION When the stator coil begins to generate power after
the engine is started, the field coil is excited by the
Voltage output current of the stator coil.
The alternator output voltage rises as the field cur-
rent increases and it falls as the field current
decreases. When the battery voltage (alternator "S"
Approximately terminal voltage) reaches a regulated voltage of
14.4 V
approximately 14.4 V, the field current is cut off.
When the battery voltage drops below the regulated
Time
voltage, the voltage regulator regulates the output
voltage to a constant level by controlling the field cur-
AK400075AB
rent.
Rotation of the excited field coil generates AC volt- In addition, when the field current is constant, the
age in the stator. alternator output voltage rises as the engine speed
This alternating current is rectified through diodes to increases.
DC voltage having a waveform shown in the illustra- CAUTION
tion.
When the specified alternator is not used, each
The average output voltage fluctuates slightly with
ECU would probably fail.
the alternator load condition.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-3
<Except Euro 5>
Alternator
B
Stator
coil
Field coil S
+
L
Voltage
regulator Charging
warning lamp Ignition
switch Battery
Combination
meter
–
AK403859 AB
<Euro 5>
Alternator
Engine-ECU
G
Field coil S
L Ignition
Voltage Charging
regulator FR switch-IG
warning lamp
Combination
meter Battery
AK802592AE
ALTERNATOR SPECIFICATIONS
16-4 ENGINE ELECTRICAL
CHARGING SYSTEM
SERVICE SPECIFICATIONS
M1161000301370
MB991911
MB991825
MB991826
MB991955
ON-VEHICLE SERVICE
Ammeter (clamp-type)
Alternator
Voltmeter (digital-type)
Battery
"B" terminal
AK203361AD
This test determines whether the wiring from the 5. Connect a digital-type voltmeter between the
alternator "B" terminal to the battery (+) terminal alternator "B" terminal and the battery (+)
(including the fusible line) is in a good condition or terminal. [Connect the (+) lead of the voltmeter to
not. the "B" terminal and connect the (−) lead of the
1. Always be sure to check the following before the voltmeter to the battery (+) cable].
test. 6. Reconnect the negative battery cable.
• Alternator installation 7. Connect the M.U.T.-III or tachometer
• Drive belt tension
8. Leave the hood open.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
nator and Power Steering Oil Pump Drive Belt 9. Start the engine.
Tension Check and Adjustment ). 10.With the engine running at 2,500 r/min, turn the
• Fusible link headlamps and other lamps on and off to adjust
• Abnormal noise from the alternator while the the alternator load so that the value displayed on
engine is running the ammeter is slightly above 30 A.
2. Turn the ignition switch to the "LOCK" (OFF) Adjust the engine speed by gradually decreasing
position. it until the value displayed on the ammeter is 30
3. Disconnect the negative battery cable. A. Take a reading of the value displayed on the
4. Connect a clamp-type DC test ammeter with a voltmeter at this time.
range of 0 − 100 A to the alternator "B" terminal Limit: Maximum 0.3 V
output wire. NOTE: When the alternator output is high and the
NOTE: The way of disconnecting the alternator value displayed on the ammeter does not
output wire and of connecting the ammeter is pos- decrease until 30 A, set the value to 40 A. Read
sibly not found the problem that the output current the value displayed on the voltmeter at this time.
is dropping due to the insufficient connection When the value range is 40 A, the limit is maxi-
between terminal "B" and the output wire. mum 0.4 V.
ENGINE ELECTRICAL
CHARGING SYSTEM
16-7
11.If the value displayed on the voltmeter is above 12.After the test, run the engine at idle.
the limit value, there is probably a malfunction in 13.Turn off all lamps.
the alternator output wire, so check the wiring 14.Turn the ignition switch to the "LOCK" (OFF)
between the alternator "B" terminal and the position.
battery (+) terminal (including fusible link).
15.Remove the M.U.T.-III or tachometer.
If a terminal is not sufficiently tight or if the 16.Disconnect the negative battery cable.
harness has become discoloured due to
overheating, repair and then test again. 17.Disconnect the ammeter and voltmeter.
18.Connect the negative battery cable.
Load
Ammeter
Voltmeter (clamp-type)
– +
Combination meter
Ignition Charging
switch-IG warning lamp B
L
S
G
Alternator
+
Engine-ECU
Battery <Euro 5>
AKB00234 AB
This test determines whether the alternator output • Drive belt tension
current is normal. (Refer to GROUP 11A − On-Vehicle Service − Alter-
1. Before the test, always be sure to check the nator and Power Steering Oil Pump Drive Belt
following. Tension Check and Adjustment .)
• Alternator installation • Fusible link
• Battery (Refer to GROUP 54A − Battery − On- • Abnormal noise from the alternator while the
Vehicle Service − Battery Test .) engine is running.
NOTE: The battery should be slightly discharged. 2. Turn the ignition switch to the "LOCK" (OFF)
The load needed by a fully-charged battery is position.
insufficient for an accurate test. 3. Disconnect the negative battery cable.
16-8 ENGINE ELECTRICAL
CHARGING SYSTEM
Load
Ammeter (clamp-type)
Combination meter
L Alternator
S
G
+ Black
Voltmeter (digital-type)
+ –
AKB00235 AB
This test determines whether the voltage regulator 4. Use the special tool Alternator test harness
correctly controlling the alternator output voltage. (MB991519) to connect a digital voltmeter
1. Always be sure to check the following before the between the alternator "S" terminal and earth
test. [Connect the (+) lead of the voltmeter to the "S"
• Alternator installation terminal, and then connect the (−) lead of the
• Check that the battery installed in the vehicle is voltmeter to a secure earth or to the battery (−)
fully charged. terminal].
(Refer to GROUP 54A − Battery − On-Vehicle Serv- 5. Connect a clamp-type DC test ammeter to the
ice − Battery Test .) alternator "B" terminal output wire.
• Drive belt tension 6. Reconnect the negative battery cable.
(Refer to GROUP 11A − On-Vehicle Service − Alter-
7. Connect the M.U.T.-III or tachometer.
nator and Power Steering Oil Pump Drive Belt
Tension Check and Adjustment .) 8. Turn the ignition switch to the "ON" position and
• Fusible link check that the reading on the voltmeter is equal to
• Abnormal noise from the alternator while the the battery voltage.
engine is running NOTE: If the voltage is 0 V, the cause is probably
2. Turn the ignition switch to the "LOCK" (OFF) an open circuit in the wire or fusible link between
position. the alternator "S" terminal and the battery (+) ter-
3. Disconnect the negative battery cable. minal.
9. Turn all lamps and accessories off.
10.Start the engine.
NOTE: Do not drive the vehicle after the engine
starts.
11.Increase the engine speed to 2,500 r/min.
16-10 ENGINE ELECTRICAL
CHARGING SYSTEM
12.Read the value displayed on the voltmeter when 14.After the test, lower the engine speed to the idle
the alternator output current alternator becomes speed.
10 A or less. 15.Turn the ignition switch to the "LOCK" (OFF)
13.If the voltage reading conforms to the value in the position.
voltage regulation, then the voltage regulator is 16.Remove the M.U.T.-III or tachometer.
operating normally. 17.Disconnect the negative battery cable.
If the voltage is not within the standard value, 18.Disconnect the ammeter and voltmeter.
there is a malfunction of the voltage regulator or of 19.Remove the special tool, and return the connector
the alternator. to the original condition.
20.Connect the negative battery cable.
Voltage Regulation Table
STANDARD VALUE:
Inspection terminal Voltage regulator ambient Voltage V
temperature °C
Terminal "S" −20 14.2 − 15.4
20 13.9 − 14.9
60 13.4 − 14.6
80 13.1 − 14.5
CH1
STANDARD WAVEFORM
Observation Conditions
Function Special pattern
Pattern height Variable
Variable knob Adjust while viewing the waveform.
Pattern selector Raster
Engine speed Curb idle speed
ENGINE ELECTRICAL
CHARGING SYSTEM
16-11
0.4
0.2
Voltage
at alternator 0
"B" terminal
-0.2
-0.4
Time
AK701886AB
AK701862
AK703778
AK502669
AK703780
AK502670
AK703781
AK502671
AK703782
AK502672
ENGINE ELECTRICAL
CHARGING SYSTEM
16-13
ALTERNATOR ASSEMBLY
CAUTION
When the specified alternator is not used, each ECU would probably fail.
Pre-removal Operation Post-installation Operation
• Air Cleaner Assembly Removal (Refer to GROUP 15 − Air • A/C Compressor Drive Belt, Alternator and Power Steer-
Cleaner ). ing Oil Pump Drive Belt Installation (Refer to GROUP 11A
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Crankshaft Pulley ).
Intercooler ) <Except Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• Intercooler Inlet Air Hose Removal (Refer to GROUP 15 − − Intercooler ) <Except Euro5>.
Intercooler ) <Euro5>. • Intercooler Inlet Air Hose Installation (Refer to GROUP 15
• A/C Compressor Drive Belt, Alternator and Power Steer- − Intercooler ) <Euro5>.
ing Oil Pump Drive Belt Removal (Refer to GROUP 11A − • Air Cleaner Assembly Installation (Refer to GROUP 15 −
Crankshaft Pulley ). Air Cleaner ).
• Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check (Refer to GROUP 11A − On-vehicle Service,
Alternator and Power Steering Oil Pump Drive Belt Ten-
sion Check ).
• A/C Compressor Drive Belt Tension Check and Adjust-
ment (Refer to GROUP 11A − On-vehicle Service, A/C
Compressor Drive Belt Tension Check and Adjustment ).
14 ± 4 N·m
3 2
1
44 ± 10 N·m
23 ± 2 N·m
AC503001AC
REMOVAL SERVICE POINT 1. Remove the rubber shield from the wheelhouse
<<A>> ALTERNATOR ASSEMBLY REMOVAL (RH), and put the pipe, hose, etc. to side so that
they will not be a hindrance when removing and
installing the alternator assembly.
2. Remove the alternator assembly from the
wheelhouse (RH).
ACB00699AB
STARTING SYSTEM
GENERAL INFORMATION
M1161000100845
If the ignition switch is turned to the "START" posi- When the ignition switch is returned to the "ON" posi-
tion, current flows in the pull-in and holding coils pro- tion after starting the engine, the starter clutch is dis-
vided inside magnetic switch, attracting the plunger, engaged from the ring gear.
When the plunger is attracted, the lever connected to An overrunning clutch is provided between the pinion
the plunger is actuated to engage the starter clutch. and the armature shaft, to prevent damage to the
On the other hand, attracting the plunger will turn on starter.
the magnetic switch, allowing the "B" terminal and
"M" terminal to conduct. Thus, current flows to
engage the starter motor.
ENGINE ELECTRICAL
STARTING SYSTEM
16-15
SYSTEM DIAGRAM
Pull-in coil
Lever
B Overrunning clutch
Ignition switch - ST M
Pinion gear
S
+ Armature
Battery
AK500030 AB
SERVICE SPECIFICATIONS
M1161000300689
AC503883 AB
2
11 ± 1 N·m 3
30 ± 3 N·m
AC601313AD
ACB00700AB
Switch
B
battery S
M
Starter Wire
motor
AKX00199
AK403864 AB
5. If the pinion gap is out of specification, adjust by
1. Disconnect the field coil wire from the M-terminal adding or removing gasket(s) between the
of the magnetic switch. magnetic switch and front bracket.
2. Connect a 12-volt battery between the S-terminal
and M-terminal.
MAGNETIC SWITCH PULL-IN TEST
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
3. Set the switch to "ON", and the pinion will move B
out.
Battery M S
Stopper
Starter Wire
motor
AK403868 AB
MAGNETIC SWITCH HOLD-IN TEST 2. Connect a voltmeter (15-volt scale) across the
starter motor.
3. Rotate the rheostat to full-resistance position.
B
4. Connect the battery cable from the negative
battery terminal to the starter motor body.
Battery S 5. Adjust the rheostat until the battery positive
M voltage shown on the voltmeter is 11 V.
Starter
6. Confirm that the maximum amperage is within the
Wire
motor specifications and that the starter motor turns
smoothly and freely.
AK403869 AB
Current: Maximum 130 A
1. Disconnect the field coil wire from the M-terminal
of the magnetic switch. MAGNETIC SWITCH RETURN TEST
CAUTION
This test must be performed quickly (in less than
10 seconds) to prevent the coil from burning.
B
2. Connect a 12-volt battery between the S-terminal
and body. S
Battery
3. Manually pull out the pinion as far as the pinion M
stopper position.
Starter Wire
4. If the pinion remains out, everything is in order. If motor
the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch. AK403871 AB
GLOW SYSTEM
GENERAL INFORMATION The glow control unit carries out the duty control to
M1164000100178 the energization of the glow plug, in accordance with
GLOW SYSTEM <EURO5> the signal from the engine-ECU.This achieves the
GLOW CONTROL optimum voltage of the glow plug in accordance with
The glow control unit of the glow system employs the the engine conditions at the after glow to stabilize the
method of energizing the glow plug of each cylinder combustion. Also the combustion noise or hydrocar-
respectively. bon (HC) emissions are reduced.
ENGINE ELECTRICAL
GLOW SYSTEM
16-19
System Configuration Diagram
Combination
Glow indicator meter
Engine control relay lamp
Battery
Engine coolant
temperature sensor
Manifold absolute
Power pressure sensor
MOSFET
AKB00122 AB
The engine-ECU determines the glow start, the glow Glow Indicator Lamp Control
time and the energization duty cycle of the glow plug. When the engine coolant temperature is below a pre-
The engine-ECU outputs the PWM signal of the glow determined level, engine-ECU illuminates the glow
operation request to the glow control unit when the indicator lamp. This causes the glow indicator lamp
following conditions are satisfied. to illuminate, in order to inform the driver of the timing
for starting the engine.
Before starting (Pre-glow control)
• Ignition switch: ON GLOW CONTROL UNIT
• Engine coolant temperature is 60°C or less.
Under the conditions of the engine not starting, the
maximum energization time of the glow plug (duty of
100%) is 20 seconds.
While running a cold engine (After-glow control)
• Ignition switch: ON
• Engine coolant temperature is 70°C or less.
• Engine speed is 350 r/min or more.
NOTE: The glow duty is determined in accordance
with the engine coolant temperature and the intake AKB00123
air temperature (at the air flow sensor). The glow control unit is installed to the fuel filter pro-
The maximum energization time of the glow plug is tector. The engine-ECU supplies the power to the
300 seconds. control part of the glow control unit when the ignition
switch is turned ON. The energization to the glow
plug from the battery is controlled by installing the
power-MOSFET (Metal Oxide Semiconductor Field
16-20 ENGINE ELECTRICAL
GLOW SYSTEM
GLOW PLUG
Driving current (A)
5
When 11 V is applied
AK802950 AB 0
30
Energization time (s)
The glow plug is installed to each cylinder of the cyl- AK802953AB
inder head. The glow plug performs preheating of the
combustion chamber with the ceramic heating ele- The self control resistance is built in the ceramic
ment on the acral part. The heating temperature of heating element of the glow plug. When the current
the glow plug is changed by adjusting the voltage is going through the glow plug, the heating element
applied to the glow plug through the duty control of heats up and the self control resistance increases,
the glow control unit. too.This gradually decreases the current going
through the heating element to restrict the amount of
heating the glow plug.
Battery
Engine
control
relay
Ignition
switch
Engine-ECU
Glow plug
OFF relay
ON
Engine coolant
temperature sensor
Glow lamp
Ignition switch-IG
Ignition switch-ST
Glow plugs
Crank angle sensor
AK403873AB
SERVICE SPECIFICATION
M1164000300194
<EURO5>
Item Standard value
Glow plug resistance (at 20°C) Ω 0.6 − 1.4
<EXCEPT EURO5>
Item Standard value
Resistance between glow plug plate and glow plug body (parallel 0.15 − 0.25
resistance for 4 glow plugs) (at 20°C) Ω
Voltage between glow plug plate and Immediately after ignition 9 − 11 (Drops to 0 V after 4 − 8
glow plug body V switch is turned to ON seconds have passed)
(without starting the engine)
While engine is cranking 6 or more
While engine is warning up 12 − 15 (Drops to 0 V when the
engine coolant temperature
increases to 60°C or more or if
180 seconds have passed since
the engine was started)
Glow plug relay resistance (at 20°C) Ω 18 − 22
Glow plug resistance (at 20°C) Ω 0.6 − 1.0
16-22 ENGINE ELECTRICAL
GLOW SYSTEM
ON-VEHICLE SERVICE
(+)
AK403892AC
Ignition START
switch
ON
OFF
T1
Glow ON
lamp
OFF
T2 T3
Glow plug ON
relay
OFF
T3: Glow plug relay drive time after engine starts (after glow)
NOTE
After glow time T3 becomes longer as the engine coolant temperature drops
AK403877 AG
AK403878AB
16-24 ENGINE ELECTRICAL
GLOW SYSTEM
B G C E
B terminal
G terminal
C E
AK403881AB
GLOW PLUG CHECK <EXCEPT EURO5> 1. Remove the glow plug plate.
M1164003400316
2. Measure the resistance between the glow plug
terminals and the body.
Standard value: 0.6 − 1.0 Ω (at 20°C)
1
17 ± 2 N·m
AC503049AE
2
3
AC807146 AB
16-26 ENGINE ELECTRICAL
GLOW SYSTEM
ACB00697AB
Removal Set the connector of the glow control unit to the area
>>A<< 1. Glow control unit shown in the figure, and tighten the mounting nut to
the specified torque.
INSTALLATION SERVICE POINT Tightening torque: 9.0 ± 1.0 N⋅m
>>A<< GLOW CONTROL UNIT INSTALLATION
4˚
30˚ ACB00698 AB
17-1
GROUP 17
ENGINE AND
EMISSION
CONTROL
CONTENTS
AIR FLOW SENSOR CHECK . . . . . . . . . . . 17-40 NO. 2 EXHAUST GAS TEMPERATURE SENSOR
CRANK ANGLE SENSOR CHECK. . . . . . . 17-40 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-47
ENGINE COOLANT TEMPERATURE SENSOR NO. 3 EXHAUST GAS TEMPERATURE SENSOR
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-40 CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-48
AIR TEMPERATURE SENSOR CHECK . . 17-40 CHECK AT THE ENGINE ECU TERMINALS
...................................... 17-48
CHECK AT THE ENGINE ECU TERMINALS
...................................... 17-40 DIESEL PARTICULATE FILTER (DPF) <Euro5>
...................................... 17-49
EGR VALVE AND EGR COOLER . . . . . . . 17-41
DIESEL PARTICULATE FILTER (DPF) REMOVAL
EGR VALVE AND EGR COOLER REMOVAL AND
AND INSTALLATION . . . . . . . . . . . . . . . . . 17-49
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . 17-41
DIESEL PARTICULATE FILTER (DPF) SYSTEM
DIESEL PARTICULATE FILTER (DPF) SYSTEM
SENSORS <Euro5> . . . . . . . . . . . . . . . . . . 17-49
<Euro5> . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-43
DIESEL PARTICULATE FILTER (DPF) SYSTEM
GENERAL INFORMATION (DPF SYSTEM)
SENSORS REMOVAL AND INSTALLATION
...................................... 17-43
...................................... 17-49
COMPONENT LOCATION (DPF SYSTEM) 17-45
CATALYTIC CONVERTER . . . . . . . . . . . . . 17-50
FORCIBLE DPF REGENERATION . . . . . . 17-46
CATALYTIC CONVERTER REMOVAL AND
NO. 1 EXHAUST GAS TEMPERATURE SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 17-50
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-47
ENGINE AND EMISSION CONTROL
ENGINE CONTROL
17-3
ENGINE CONTROL
GENERAL INFORMATION This system detects the amount of the accelerator
M1171000101162 pedal movement by using an accelerator pedal posi-
For the accelerator system, a common rail fuel con- tion sensor in the accelerator pedal assembly for
trol system has been adopted, eliminating of an electronic control of the fuel injection.
accelerator cable.
CONSTRUCTION DIAGRAM
Accelerator pedal
arm stopper
AC501713 AB
17-4 ENGINE AND EMISSION CONTROL
ENGINE CONTROL
ACCELERATOR PEDAL
CAUTION
• Never loosen the screw fixing the accelerator pedal assembly resin cover. If the screw is loos-
ened, the sensor position which exists inside the resin cover is off and the accelerator pedal posi-
tion sensor does not work normally.
• Do not remove the accelerator pedal pad. If the pad is removed and installed, excessive force may
damage accelerator pedal position sensor.
Pre-removal and Post-installation Operation
Instrument Panel Driver’s Side Under Cover Removal and
Installation (Refer to GROUP 52A − Instrument Panel ).
13 ± 2 N·m
13 ± 2 N·m
N 3
AC501727 AD
Body
AC600545 AD
CRUISE CONTROL
GENERAL INFORMATION For this cruise control system, in conjunction with the
M1172000101228 common rail fuel control system, the engine-ECU
By using the cruise control system, the driver can electronically controls the fuel injection system.
drive at preferred speeds in a range of approximately
40 to 200 km/h without depressing the accelerator CONSTRUCTION DIAGRAM
pedal.
Hydraulic unit
assembly
(integrated with
ASTC-ECU)
Engine-ECU
AC500966AJ
AC509982AG
17-6 ENGINE AND EMISSION CONTROL
CRUISE CONTROL
A/T-ECU
AC509994AC AC900932 AB
A/T-ECU
Diagnosis connector
AC801078AB AC501596AC
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-7
SPECIAL TOOLS
M1172000601740
17-8 ENGINE AND EMISSION CONTROL
CRUISE CONTROL
MB991910
DO NOT USE
MB991911
MB991825
MB991826
MB991955
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-9
Tool Number Name Use
MB991223 Harness set Making voltage and resistance
a
a: MB991219 a: Check harness measurement during
b: MB991220 b: LED harness troubleshooting
c: MB991221 c: LED harness adapter a: Connector pin contact
d: MB991222 d: Probe pressure inspection
b b: Power circuit inspection
c: Power circuit inspection
d: Commercial tester
connection
c
d
DO NOT USE
MB991223BF
MB992006
MB992044
CRUISE
CONTROL
SWITCH
CLOCK
SPRING
ENGINE-ECU
NOTE
: LH drive vehicles
: RH drive vehicles
Connector: C-103 <LH drive vehicles> Connector: C-103 <RH drive vehicles>
C-103 (B)
C-103 (B)
ACA01401 AB ACA01402 AB
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-11
Connectors: C-306, C-309, C-310 DIAGNOSIS PROCEDURE
<LH drive vehicles>
STEP 4. Connector check: C-103 engine-ECU STEP 8. Check the clock spring.
connector. Refer to GROUP 52B − Driver’s, Front Passenger’s
Q: Is the check result normal?
Air Bag Module(s) and Clock Spring Inspection .
YES : Go to Step 5. Q: Is the check result normal?
NO : Repair or replace the damaged connector. YES : Go to Step 9.
Then go to Step 26. NO : Replace the clock spring [Refer to GROUP
52B − Driver’s, Front Passenger’s Air Bag
STEP 5. Check the harness wire for short circuit Module(s) and Clock Spring ]. Then go to
to earth between engine-ECU connector C-103 Step 26.
terminal No.139 and cruise control switch
connector C-309 terminal No.3. STEP 9. Check the cruise control switch.
(1) Disconnect engine-ECU connector C-103 and Refer to P.17-32.
measure at the harness connector side (Refer to Q: Is the check result normal?
GROUP 13A − Engine-ECU ). YES : Go to Step 13.
(2) Turn the ignition switch to the "LOCK" (OFF) NO : Replace the cruise control switch (Refer to
position. P.17-33). Then go to Step 26.
(3) Measure the continuity between engine-ECU
connector C-103 terminal No.139 and earth.
STEP 10. Connectors check: C-103 engine-ECU
OK: open circuit
connector, C-309 cruise control switch
Q: Is the check result normal? connector, C-306 and C-310 clock spring
YES : Go to Step 24 . connectors and C-53 <LHD> or C-35 <RHD>
NO : Go to Step 6. intermediate connector.
Q: Is the check result normal?
STEP 6. Connectors check: C-309 cruise control YES : Go to Step 11.
switch connector, C-306 and C-310 clock spring NO : Repair or replace the damaged connector.
connectors and C-53 <LHD> or C-35 <RHD> Then go to Step 26.
intermediate connector.
Q: Is the check result normal? STEP 11. Check the harness wire between
YES : Go to Step 7. engine-ECU connector C-103 terminal No.139
NO : Repair or replace the damaged connector. and clock spring connector C-306 terminal No.5,
Then go to Step 26. and between clock spring connector C-310
terminal No.2 and cruise control switch
STEP 7. Check the harness wire between engine- connector C-309 terminal No.3.
ECU connector C-103 terminal No.139 and clock • Check harness wire for open circuit and damage.
spring connector C-306 terminal No.5, and Q: Is the check result normal?
between clock spring connector C-310 terminal YES : Go to Step 12.
No.2 and cruise control switch connector C-309 NO : Repair or replace the damaged harness
terminal No.3. wire. Then go to Step 26.
• Check harness wire for short circuit and damage.
Q: Is the check result normal? STEP 12. Check the clock spring.
YES : Go to Step 8. Refer to GROUP 52B − Driver’s, Front Passenger’s
NO : Repair or replace the damaged harness Air Bag Module(s) and Clock Spring Inspection .
wire. Then go to Step 26.
Q: Is the check result normal?
YES : Go to Step 13.
NO : Replace the clock spring [Refer to GROUP
52B − Driver’s, Front Passenger’s Air Bag
Module(s) and Clock Spring ]. Then go to
Step 26.
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-13
STEP 13. Check the data list. STEP 16. Connector check: C-103 engine-ECU
Using M.U.T.-III, check the data list (Refer to P.17-29 connector.
− data list reference table). Q: Is the check result normal?
• Item 136: "ON/OFF" switch YES : Go to Step 24.
• Item 137: "CANCEL" switch NO : Repair or replace the damaged connector.
• Item 138: "COAST/SET" switch Then go to Step 26.
• Item 139: "ACC/RES" switch
Q: Is the check result normal? STEP 17. Connectors check: C-309 cruise control
YES : Go to Step 25. switch connector, C-306 and C-310 clock spring
NO : Go to Step 14. connectors and C-53 <LHD> or C-35 <RHD>
intermediate connector.
STEP 14. Measure the terminal voltage at cruise Q: Is the check result normal?
control switch connector C-309. YES : Go to Step 18.
(1) Remove the cruise control switch from the NO : Repair or replace the damaged connector.
steering wheel with the cruise control switch Then go to Step 26.
connector connected (Refer to P.17-33).
(2) Connect the negative battery terminal that was
disconnected when the driver's air bag module STEP 18. Check the harness wire between
was removed. engine-ECU connector C-103 terminal No.154
(3) Turn the ignition switch to the "ON" position. and clock spring connector C-306 terminal No.4,
(4) Push the "ON/OFF" switch with cruise control and between clock spring connector C-310
switch connector C-309 connected, and measure terminal No.3 and cruise control switch
the terminal voltage between cruise control connector C-309 terminal No.2.
switch connector C-309 terminal No.2 and earth. • Check harness wire for open circuit and damage.
OK: 0 − 0.5 V Q: Is the check result normal?
YES : Go to Step 19.
Q: Is the check result normal? NO : Repair or replace the damaged harness
YES : Go to Step 20. wire. Then go to Step 26.
NO : Go to Step 15.
STEP 21. Check the harness wire between (2) Turn the ignition switch to the "ON" position, and
engine-ECU connector C-103 terminal No.154 push the "ON/OFF" switch to turn the cruise
and clock spring connector C-306 terminal No.4, control system to ON (turn ON the cruise control
and between clock spring connector C-310 indicator lamp).
terminal No.3 and cruise control switch (3) After turning the cruise control system to ON,
connector C-309 terminal No.2. when 2 minutes or more has elapsed without
• Check harness wire for short circuit and damage. operating the cruise control switches, use the
M.U.T.-III to read the diagnosis code of the cruise
Q: Is the check result normal? control system (Refer to P.17-9).
YES : Go to Step 22.
NO : Repair or replace the damaged harness Q: Is diagnosis code No.P1564 set?
wire. Then go to Step 26. YES : Replace the engine-ECU (Refer to GROUP
13A − Engine-ECU ). Then go to Step 26.
NO : It can be assumed that this malfunction is
STEP 22. Check the clock spring. intermittent (Refer to GROUP 00 − How to
Refer to GROUP 52B − Driver’s, Front Passenger’s Use Troubleshooting/Inspection Service
Air Bag Module(s) and Clock Spring Inspection . Points, How to Cope with Intermittent
Q: Is the check result normal? Malfunction ).
YES : Go to Step 23.
NO : Replace the clock spring [Refer to GROUP STEP 26. Check the data list.
52B − Driver’s, Front Passenger’s Air Bag Using M.U.T.-III, check the data list (Refer to P.17-29
Module(s) and Clock Spring ]. Then go to − data list reference table).
Step 26. • Item 136: "ON/OFF" switch
• Item 137: "CANCEL" switch
STEP 23. Check the cruise control switch. • Item 138: "COAST/SET" switch
Refer to P.17-32. • Item 139: "ACC/RES" switch
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 24. YES : Go to Step 27.
NO : Replace the cruise control switch (Refer to NO : Return to Step 2.
P.17-33). Then go to Step 26.
STEP 27. Read the diagnosis code.
STEP 24. Check the data list. (1) Use the M.U.T.-III, erase the diagnosis code of
Using M.U.T.-III, check the data list (Refer to P.17-29 the cruise control system (Refer to P.17-9).
− data list reference table). (2) Turn the ignition switch to the "ON" position, and
• Item 136: "ON/OFF" switch push the "ON/OFF" switch to turn the cruise
• Item 137: "CANCEL" switch control system to ON (turn ON the cruise control
• Item 138: "COAST/SET" switch indicator lamp).
• Item 139: "ACC/RES" switch (3) After turning the cruise control system to ON,
when 2 minutes or more has elapsed without
Q: Is the check result normal? operating the cruise control switches, use the
YES : Go to Step 25.
M.U.T.-III to read the diagnosis code of the cruise
NO : Replace the engine-ECU (Refer to GROUP
control system (Refer to P.17-9).
13A − Engine-ECU ). Then go to Step 26.
Q: Is diagnosis code No.P1564 set?
YES : Return to Step 1.
STEP 25. Read the diagnosis code. NO : The procedure is complete.
(1) Use the M.U.T.-III, erase the diagnosis code of
the cruise control system (Refer to P.17-9).
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-15
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
NOTE
: LH drive vehicles
ENGINE-ECU : RH drive vehicles
RELAY
BOX
STOP LAMP
SWITCH
STOP LAMP
ENGINE-ECU
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple SI : Silver
ACB01742
Connectors: C-10, C-114 <LH drive vehicles> Connectors: C-10, C-114, C-120
<RH drive vehicles>
C-10 (GR)
C-114 C-114
C-10 (GR)
C-120 (L)
ACA01405 AB ACA01406 AB
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-17
Connector: C-105 <RH drive vehicles> STEP 2. Check the stop lamp operation.
Check the stop lamp operation.
OK:
Brake pedal depressed: Stop lamp will illumi-
nate.
Brake pedal not depressed: Stop lamp does
not illuminate.
C-105 (B) Q: Is the check result normal?
ACA01402 AC YES : Go to Step 3.
NO : Go to Step 6.
OPERATION
• For the stop lamp switch, two switches, a stop STEP 3. Connectors check: C-103 engine-ECU
lamp switch for the stop lamp illumination and a connector, C-10 J/C (9) and C-53 <LHD> or C-35
brake switch exclusively for the cruise control <RHD> intermediate connector.
system, are incorporated to improve the reliabil- Q: Is the check result normal?
ity. YES : Go to Step 4.
• The engine-ECU connector C-103 terminal NO : Repair or replace the damaged connector.
No.125 and terminal No.126 monitor the state of Then go to Step 22.
the stop lamp switch and brake switch.
• The stop lamp switch and brake switch turn ON/
STEP 4. Check the harness wire between engine-
OFF when the brake pedal is depressed/
ECU connector C-103 terminal No.125 and C-10
released, and the input signal to the engine-ECU
J/C (9) terminal No.6 <LHD>, or between engine-
changes. According to this change, the engine-
ECU connector C-103 terminal No.125 and C-10
ECU judges the state of the stop lamp switch and
J/C (9) terminal No.2 <RHD>.
the brake switch.
• Check harness wire for open/short circuit and
DIAGNOSIS CODE SET CONDITIONS damage.
STEP 9. Check the fuse No.12 at the relay box in STEP 15. Connectors check: C-103 engine-ECU
engine compartment. connector <EURO 5>, C-105 engine-ECU
connector <Except EURO 5>, C-53 <LHD> or C-35
Q: Is the check result normal?
<RHD> intermediate connector and C-114 stop
YES : Go to Step 13.
NO : Check the stop lamp system harness and
lamp switch connector.
replace the fuse. Then go to Step 22. Q: Is the check result normal?
YES : Go to Step 16.
NO : Repair or replace the damaged connector.
STEP 10. Connectors check: C-114 stop lamp
Then go to Step 22.
switch connector and C-10 J/C (9).
Q: Is the check result normal?
STEP 16. Check the harness wire between
YES : Go to Step 11.
NO : Repair or replace the damaged connector.
engine-ECU connector C-103 terminal No.126
Then go to Step 22. <EURO 5>, engine-ECU connector C-105 terminal
No.7 <Except EURO 5> and stop lamp switch
connector C-114 terminal No.3.
STEP 11. Check the harness wire between stop • Check harness wire for open/short circuit and
lamp switch connector C-114 terminal No.1 and damage.
C-10 J/C (9) terminal No.7.
Q: Is the check result normal?
• Check harness wire for open/short circuit and
YES : Go to Step 17.
damage.
NO : Repair or replace the damaged harness
Q: Is the check result normal? wire. Then go to Step 22.
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-19
STEP 17. Connectors check: C-114 stop lamp push the "ON/OFF" switch to turn the cruise
switch connector and C-120 J/C (1) <RHD>. control system to ON (turn ON the cruise control
indicator lamp).
Q: Is the check result normal? (3) With the cruise control switches not operated,
YES : Go to Step 18. depress the brake pedal for several seconds, and
NO : Repair or replace the damaged connector. then use the M.U.T.-III to read the diagnosis code
Then go to Step 22. of the cruise control system (Refer to P.17-9).
Q: Is diagnosis code No.P1571 set?
STEP 18. Check the harness wire between stop YES : Replace the engine-ECU (Refer to GROUP
lamp switch connector C-114 terminal No.4 and 13A − Engine-ECU ). Then go to Step 22.
earth. NO : It can be assumed that this malfunction is
• Check harness wire for open/short circuit and intermittent (Refer to GROUP 00 − How to
damage. Use Troubleshooting/Inspection Service
Q: Is the check result normal? Points, How to Cope with Intermittent
YES : Go to Step 19. Malfunction ).
NO : Repair or replace the damaged harness
wire. Then go to Step 22. STEP 22. Check the data list.
Using M.U.T.-III, check the data list (Refer to P.17-29
STEP 19. Check the stop lamp switch. − data list reference table).
Refer to GROUP 35A − Brake Pedal, Inspection, • Item 134: Brake switch
Stop Lamp Switch Check . • Item 135: Stop lamp switch
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 20. YES : Go to Step 23.
NO : Replace the stop lamp switch (Refer to NO : Return to Step 1.
GROUP 35A − Brake Pedal ). Then go to
Step 22. STEP 23. Read the diagnosis code.
(1) Use the M.U.T.-III, erase the diagnosis code of
STEP 20. Check the data list. the cruise control system (Refer to P.17-9).
Using M.U.T.-III, check the data list (Refer to P.17-29 (2) Turn the ignition switch to the "ON" position, and
− data list reference table). push the "ON/OFF" switch to turn the cruise
• Item 134: Brake switch control system to ON (turn ON the cruise control
indicator lamp).
Q: Is the check result normal?
(3) With the cruise control switches not operated,
YES : Go to Step 21.
NO : Replace the engine-ECU (Refer to GROUP depress the brake pedal for several seconds, and
13A − Engine-ECU ). Then go to Step 22. then use the M.U.T.-III to read the diagnosis code
of the cruise control system (Refer to P.17-9).
Q: Is diagnosis code No.P1571 set?
STEP 21. Read the diagnosis code.
YES : Return to Step 1.
(1) Use the M.U.T.-III, erase the diagnosis code of
NO : The procedure is complete.
the cruise control system (Refer to P.17-9).
(2) Turn the ignition switch to the "ON" position, and
17-20 ENGINE AND EMISSION CONTROL
CRUISE CONTROL
SYMPTOM PROCEDURES
Inspection Procedure 1: When the Brake Pedal is Depressed, Cruise Control is not Cancelled.
Inspection Procedure 2: When the Clutch Pedal is Depressed, Cruise Control is not Cancelled <M/T>.
CLUTCH
SWITCH
C-152
C-103 (B)
ACA01401 AB
ACA01405 AC
Connector: C-103 <RH drive vehicles>
C-103 (B)
ACA01402 AB
17-22 ENGINE AND EMISSION CONTROL
CRUISE CONTROL
Connector: C-152 <RH drive vehicles> STEP 3. Check the harness wire between engine-
ECU connector C-103 terminal No.112 and clutch
switch connector C-152 terminal No.1, and
between clutch switch connector C-152 terminal
C-152 No.2 and earth.
• Check harness wire for open/short circuit and
damage.
Q: Is the check result normal?
YES : Go to Step 4.
ACA01406 AC NO : Repair or replace the damaged harness
wire. Then go to Step 7.
OPERATION
• The engine-ECU connector C-103 terminal STEP 4. Check the clutch switch.
No.112 monitor the clutch switch state. Refer to GROUP 21A − Clutch Pedal, Inspection,
• The clutch switch turn ON/OFF when the clutch Clutch Switch Continuity Check .
pedal is depressed/released, and the input signal
to the engine-ECU change. According to this Q: Is the check result normal?
YES : Go to Step 5.
change, the engine-ECU judges the clutch switch
NO : Replace the clutch switch (Refer to GROUP
status.
21A − Clutch Pedal ). Then go to Step 7.
COMMENT ON TROUBLE SYMPTOM
The cause is probably a malfunction of the clutch STEP 5. Check the data list
switch circuit. Using M.U.T.-III, check the data list (Refer to P.17-29
− data list reference table).
POSSIBLE CAUSES
• Item 131: Clutch switch
• Damaged harness or connector.
• Malfunction of the clutch switch. Q: Is the check result normal?
• Malfunction of the engine-ECU. YES : Go to Step 6.
NO : Replace the engine-ECU (Refer to GROUP
DIAGNOSIS PROCEDURE 13A − Engine-ECU ). Then go to Step 7.
Inspection Procedure 3: When the Selector Lever is Set to "N" Position, Cruise Control is not
Cancelled <A/T>.
Inspection Procedure 4: When the "CANCEL" Switch is Pushed, Cruise Control is not Cancelled.
Inspection Procedure 5: Cruise Control cannot be Set (No Response when the "COAST/SET" Switch
and the "ACC/RES" Switch is Pushed).
Inspection Procedure 6: Hunting (Repeated Acceleration and Deceleration) Occurs at the Set Vehicle
Speed.
COMMENTS ON TROUBLE SYMPTOM STEP 2. Check the A/T system diagnosis code
The vehicle speed sensor or the diesel fuel system is <A/T>.
suspected. Using M.U.T.-III, perform A/T system diagnosis code
NOTE: When the vehicle is driven with the low- (Refer to GROUP 23A − Troubleshooting, Diagnosis
speed gear in the sport mode, hunting occurs easily, Function ).
however, this is not a failure <A/T>.
Q: Is any diagnosis code set?
PROBABLE CAUSE YES : Repair the A/T system (Refer to GROUP
• Malfunction of the vehicle speed sensor. 23A − Troubleshooting, Diagnosis Code
• Malfunction of the diesel fuel system. Chart ). Then go to Step 5.
• Malfunction of the A/T system <A/T>. NO : Go to Step 3.
• Malfunction of the engine-ECU.
STEP 3. Check the data list.
DIAGNOSIS PROCEDURE Using M.U.T.-III, check the data list (Refer to P.17-29
− data list reference table).
STEP 1. Check the diesel fuel system diagnosis • Item 04: Vehicle speed signal
code. Q: Is the check result normal?
Using M.U.T.-III, perform diesel fuel system diagno- YES : Go to Step 4.
sis code (Refer to GROUP 13A − Diagnosis Function NO : Replace the engine-ECU (Refer to GROUP
). 13A − Engine-ECU ). Then go to Step 5.
Q: Is any diagnosis code set?
YES : Repair the diesel fuel system (Refer to STEP 4. Check the symptom.
GROUP 13A − Troubleshooting, Inspection Q: Does a hunting occur?
Chart for Diagnosis Code ). Then go to Step YES : Replace the engine-ECU (Refer to GROUP
5. 13A − Engine-ECU ). Then go to Step 5.
NO : Go to Step 3 <M/T>. NO : It can be assumed that this malfunction is
NO : Go to Step 2 <A/T>.
intermittent (Refer to GROUP 00 − How to
Use Troubleshooting/Inspection Service
Points, How to Cope with Intermittent
Malfunctions ).
ENGINE AND EMISSION CONTROL
CRUISE CONTROL
17-27
YES : Return to Step 1.
STEP 5. Check the symptom.
NO : The procedure is complete.
Q: Does a hunting occur?
Inspection Procedure 7: When the "ON/OFF" Switch is Turned ON, the Cruise Control Indicator Lamp
does not Illuminate (However, the Cruise Control System is Normal).
COMBINATION
CLOCK METER
SPRING
NOTE
: LH drive vehicles
: RH drive vehicles
ENGINE-ECU
PROBABLE CAUSE
Connector: C-105 <LH drive vehicles>
• Damaged harness or connector.
• Malfunction of the combination meter.
• Malfunction of the engine-ECU.
AC809546 AE
ON-VEHICLE SERVICE
CRUISE CONTROL SWITCH CHECK
M1172001201295
"ACC/RES"
AC900932 AB switch
SPEED-REDUCTION SETTING
1. Turn the ignition switch to "ON" position.
2. Push the "ON/OFF" switch (cruise control system:
"COAST/SET" ON, cruise control indicator lamp: illuminated).
switch
3. Set to the desired speed within the range of
AC807212 AD approximately 40 − 200 km/h.
4. Press the "COAST/SET" switch.
4. Push the "COAST/SET" switch.
5. Check to be sure that deceleration continues
5. Check to be sure that when the "COAST/SET" while the "COAST/SET" switch is pushed, and
switch is released the speed is the desired that the speed at the time it was released
constant speed. becomes the constant driving speed.
17-32 ENGINE AND EMISSION CONTROL
CRUISE CONTROL
4 1 3 2
AC800937 AF
WARNING
For vehicles with SRS, before removing the air bag module assembly, refer to GROUP 52B −
Service Precautions , and Driver’s and Front Passenger’s Air Bag Module(s) and Clock
Spring .
1 2
AC801079 AB
Removal steps
1. Driver’s air bag module [Refer to
GROUP 52B − Driver’s, Front
Passenger’s Air Bag Module(s) and
Clock Spring ]
2. Cruise control switch
EMISSION CONTROL
GENERAL INFORMATION • Exhaust gas recirculation system
M1175000100484 • Diesel particulate filter (DPF) system <Euro5>
The emission control system consists of the following • Emission reduction system
subsystems:
17-34 ENGINE AND EMISSION CONTROL
EMISSION CONTROL
SERVICE SPECIFICATION(S)
M1175000300295
<Euro5>
To brake system
To fuel tank
Variable geometry
control solenoid valve
Injector
Variable geometry
actuator
Engine coolant
temperature sensor
Catalytic
converter
No. 1 exhaust
gas temperature Catalytic From fuel
sensor converter DPF tank
Exhaust differential pressure sensor
<Except Euro5>
To brake system
To fuel tank
Injector
Engine coolant
temperature sensor
Catalytic
Waste gate converter
actuator
From fuel
tank
AK500419 AB
ENGINE AND EMISSION CONTROL
EMISSION CONTROL
17-37
VACUUM CIRCUIT DIAGRAM
M1175004400380
<Euro5>
R R
Variable
geometry
control
Variable geometry solenoid valve
turbocharger
Vacuum
pump
White paint
B
Vacuum hose colour
B : Black
R : Red
AKB00241 AB
AKB00296 AB
EGR gas
temperature
sensor
Operation check
Valve open
AK500442AB
EGR GAS TEMPERATURE SENSOR 3. Remove the EGR gas temperature sensor
CHECK <Euro5>
M1175011500022 EGR gas
temperature sensor
1 2
Equipment side
connector
EGR gas
temperature
sensor
AKA00756 AB
<Except Euro5>
Pre-removal Operation Post-installation Operation
• Under Skid Plate and Engine Room Under Cover • Battery and Battery Box Installation (Refer to 54A − Bat-
Removal (Refer to GROUP 51 − Under Cover ). tery ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
cle Service, Engine Coolant Replacement ). cle Service, Engine Coolant Replacement ).
• Battery and Battery Box Removal (Refer to 54A − Battery • Under Skid Plate and Engine Room Under Cover Installa-
). tion (Refer to GROUP 51 − Under Cover ).
48 ± 6 N·m
2 (ATF)
3
22 ± 4 N·m 6N
1 (Engine oil)
5
N 4
N 8 7
13
N 14 12 50 ± 7 N·m
11 ± 1 N·m 48 ± 6 N·m
N 15 17 ± 2 N·m
18 9N
17
10
19
17 ± 2 N·m
24 ± 3 N·m 24 ± 3 N·m
11 N 17 ± 2 N·m
49 ± 6 N·m
24 ± 3 N·m 16
AC509026AC
<Euro5>
Pre-removal Operation Post-installation Operation
• Engine Cover Removal (Refer to GROUP 11A − Engine • Battery and Battery Box Installation (Refer to 54A − Bat-
Assembly ). tery ).
• Under Skid Plate and Engine Room Under Cover • Engine Coolant Refilling (Refer to GROUP 14 − On-vehi-
Removal (Refer to GROUP 51 − Under Cover ). cle Service, Engine Coolant Replacement ).
• Engine Coolant Draining (Refer to GROUP 14 − On-vehi- • Under Skid Plate and Engine Room Under Cover Installa-
cle Service, Engine Coolant Replacement ). tion (Refer to GROUP 51 − Under Cover ).
• Battery and Battery Box Removal (Refer to 54A − Battery • Engine Cover Installation (Refer to GROUP 11A − Engine
). Assembly ).
2
4
48 ± 6 N·m
1 (ATF)
5N
12
N 13 17 ± 2 N·m
10 N
15 11 6
N 14 49 ± 6 N·m
17 ± 2 N·m
17 ± 2 N·m
18 8 N
22 19 N
24 ± 3 N·m
20
21
28 ± 4 N·m
16
24 ± 3 N·m
17 ACB00714AB
Assembly )
16. Water hose <Euro5>
<<A>> 17. EGR pipe B, EGR cooler and
bracket assembly
18. EGR pipe B
>>A<< 19. EGR pipe gasket
20. EGR cooler bracket A
21. EGR cooler bracket B
22. EGR cooler
AC502840AC
Variable geometry
control solenoid valve
Injector
AKB00299 AB
ENGINE AND EMISSION CONTROL
EMISSION CONTROL
17-45
DPF LAMP
No. 2 exhaust gas
temperature sensor
(catalyst temperature)
connector
DPF lamp
AKB00242 AB
AKB00302 AB
No. 1 exhaust gas
temperature sensor
Exhaust differential
pressure sensor
AKB00300 AB
AKB00303AB
17-46 ENGINE AND EMISSION CONTROL
EMISSION CONTROL
MB991910
MB991824
MB991827 AC501413AC
1 2
Equipment side
connector
1 2
Equipment side
connector AKB00304 AB
Standard value: 120 − 560 kΩ (at 20°C) 1. Disconnect the No. 3 exhaust gas temperature
3. Remove the No. 2 exhaust gas temperature sensor (DPF temperature) connector.
sensor (catalyst temperature). 2. Measure resistance between terminals No. 1 and
No. 2.
Exhaust gas Standard value: 120 − 560 kΩ (at 20°C)
temperature sensor
3. Remove the No. 3 exhaust gas temperature
sensor (DPF temperature).
Exhaust gas
temperature sensor
AKB00243 AB
1 2
Equipment side
connector
AKB00306 AB
ENGINE AND EMISSION CONTROL
EMISSION CONTROL
17-49
DIESEL PARTICULATE FILTER (DPF)
<Euro5>
REMOVAL AND INSTALLATION
M1175007700238
Refer to GROUP 15 − Exhaust Pipe and Main Muffler .
CAUTION
• When the exhaust differential pressure sensor is replaced, use the M.U.T.-III to initialise the learn-
ing value (Refer to GROUP 00 − Precautions before Service, Initialisation Procedure for Learning
Value in DPF System ).
• When the exhaust differential pressure sensor is replaced, perform the forcible DPF regeneration
after learning value in DPF system (Refer to P.17-46).
• When the No.1, No.2 or No.3 exhaust gas temperature sensor is replaced, perform the forcible DPF
regeneration (Refer to P.17-46).
11 ± 1 N·m
2
3 30 ± 5 N·m
1 ACB00708 ACB00705
4 30 ± 5 N·m 5 30 ± 5 N·m
ACB00706 ACB00707
ACB02032 AB
17-50 ENGINE AND EMISSION CONTROL
EMISSION CONTROL
<Except Euro5>
Pre-removal Operation Post-installation Operation
• Under Skid Plate and Engine Room Under Cover • Battery and Battery Box Installation (Refer to 54A − Bat-
Removal (Refer to GROUP 51 − Under Cover ). tery ) <Vehicles with Sub Battery>.
• Battery and Battery Box Removal (Refer to 54A − Battery • Under Skid Plate and Engine Room Under Cover Installa-
) <Vehicles with Sub Battery>. tion (Refer to GROUP 51 − Under Cover ).
59 ± 5 N·m
5N
59 ± 5 N·m
2N
57 ± 7 N·m
AC502841 AD
59 ± 5 N·m 5N
3
59 ± 5 N·m
4
2N
57 ± 7 N·m
AC805698 AB
GROUP 21
CLUTCH
CONTENTS
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21A
GROUP 21A
CLUTCH
CONTENTS
GENERAL INFORMATION
M1211000100308
The clutch is a dry single-disc, diaphragm type;
hydraulic pressure is used for the clutch control.
SERVICE SPECIFICATIONS
M1211000300421
LUBRICANTS
M1211000400257
ON-VEHICLE SERVICE
CLUTCH PEDAL CHECK AND 2. Measure the clutch pedal height. If the height is
ADJUSTMENT outside the standard value, go to step 4.
M1211000900940 Standard value (A):
1. Turn back the carpet etc. under the clutch pedal. 183.5 − 186.5 mm <LHD>
Clutch pedal height Clutch pedal clevis pin play 178.5 − 181.5 mm <RHD>
3. Measure the clutch pedal clevis pin play. If the
play is outside the standard value, go to Step 5.
Standard value (B): 1 − 3 mm
4. Remove the clutch switch. (Refer to P.21A-4.)
<Vehicles with cruise control>
A B
AC001133 AD
CLUTCH
ON-VEHICLE SERVICE
21A-3
CAUTION 8. After the adjustments, confirm that the clutch
Do not push in the master cylinder pushrod at pedal free play (measured at the face of the pedal
this time, otherwise the clutch will not operate pad) and the distance between the clutch pedal
properly. (the face of the pedal pad) and the floorboard
when the clutch is disengaged are within the
standard value ranges.
Adjusting bolt
Standard value (C): 4 − 13 mm
Standard value (D):
Pushrod 91 mm or more <LHD>
86 mm or more <RHD>
Locking nut
9. If the measured free play and distance do not
Clutch pedal agree with the standard value ranges, it is
Setting nut
probably the result of either air in the hydraulic
13 ± 2 N·m
AC502646AC system or a faulty master cylinder or clutch. Bleed
the air, or disassemble and inspect the master
5. If the clutch pedal height is not within the standard cylinder or clutch.
value, loosen the setting nut and the locking nut
10.Reinstall the carpet, etc.
<Vehicles without cruise control> to adjust the
clutch pedal height to the standard value and CLUTCH BLEEDING
move the pushrod and the adjusting bolt M1211001400733
<Vehicles without cruise control>. CAUTION
6. Install the clutch switch. (Refer to P.21A-4.) Use the specified brake fluid. Do not mix brake
<Vehicles with cruise control> fluids.
7. If the clutch pedal clevis pin play is not within the Specified fluid: Brake fluid DOT 3 or DOT 4
standard value, loosen the setting nut and move
the pushrod to adjust.
Clutch damper
assembly
Clutch pedal free play
Clutch release
C
cylinder assembly AC609129 AC
CLUTCH PEDAL
REMOVAL AND INSTALLATION
M1211001601008
6
7 7
12 ± 2 N·m
13 ± 2 N·m
1 5 <Vehicles with
cruise control>
3
4 <Vehicles without
cruise control>
13 ± 2 N·m 9
13 ± 2 N·m
12 ± 2 N·m
10 N
2 8
AC900934AB
AC309757AC
Plunger
1
3 4
AC809413AD
CAUTION
Do not disassemble the piston assembly.
13 ± 2 N·m
6 7
2
1N
3N
5
1 3
3
3
Clutch fluid:
Piston repair kit Brake fluid DOT3 or DOT4 Grease: Rubber grease
AC712190 AB
120.4 122.4 mm
AC800214AB
INSPECTION
M1211002200196
• Check inside the cylinder body for rust and scars.
• Check the piston for rust and scars.
• Check the pipe connection for clogging.
CLUTCH
CLUTCH RELEASE CYLINDER
21A-7
CLUTCH RELEASE CYLINDER
REMOVAL AND INSTALLATION
M1211005500129
9 30 ± 3 N·m 23 ± 2 N·m
15 ± 2 N·m 8 10 6N
8 5
9 10 4 15 ± 2 N·m
7
15 ± 2 N·m
4
48 ± 6 N·m
30 ± 3 N·m 11 ± 2 N·m 3 11 ± 2 N·m 18 ± 2 N·m
1
23 ± 2 N·m
48 ± 6 N·m
6N 7 2N
5 35 ± 6 N·m
3 23 ± 2 N·m
1 Release fork
35 ± 6 N·m N 2 23 ± 2 N·m
Release cylinder
3 pushrod
Specified grease:
MITSUBISHI genuine grease
PART No. 0101011 or equivalent
AC903922AB
GROUP 21B
CLUTCH
OVERHAUL
CONTENTS
GENERAL SPECIFICATIONS
M1212000201356
SERVICE SPECIFICATIONS
M1212000300286
Item Limit
Diaphragm spring end height difference mm 0.5
Facing rivet sink mm 0.3
Release cylinder I.D. to piston O.D. clearance mm 0.15
TORQUE SPECIFICATIONS
M1212001800347
Item N⋅m
Fulcrum 35 ± 6
Clutch release cylinder mounting bolt 35 ± 6
Clutch cover mounting bolt 19 ± 3
Air bleeder 8.0 ± 1.0
LUBRICANTS
M1212000400681
3
1
2 4 7
8
35 ± 6 N·m
19 ± 3 N·m
35 ± 6 N·m 6
AK403591AB
Release fork
AK403602 AB
REASSEMBLY SERVICE POINTS 3. Install the return clip to engage the clutch release
>>A<< RELEASE FORK INSTALLATION bearing with the fork.
Flywheel
Clutch disc
Fulcrum
Release fork
8 1
5 3
4 6
AK503501AB :
Dowel pin
1. Apply the specified grease to the clutch release position 2 7 AK500601AE
bearing inside, and fill grease in the groove.
3. Install the clutch cover, aligning its installation
Specified grease: Mitsubishi Part No.
position with the dowel pins, and then tighten the
0101011 or equivalent
bolts to the specified torque of 19 ± 3 N⋅m in the
2. Install the clutch release bearing on the bearing order shown in the illustration.
retainer of the transmission.
CLUTCH OVERHAUL
CLUTCH
21B-5
INSPECTION 1. Check the facing for loose rivets, uneven contact,
M1212001100252 deterioration due to seizure, adhesion of oil or
CLUTCH COVER grease. Replace the clutch disc if defective.
2. Measure the rivet sink and replace the clutch disc
Diaphragm spring if it is out of specification.
Limit: 0.3 mm
3. Check for the torsion spring play and damage. If
defective, replace the clutch disc.
4. Combine the clutch disc with the input shaft and
check sliding condition and play in the rotating
direction. If it does not slide smoothly or the play
AK403603AB
is excessive, check after cleaning and
reassembling. If the play is excessive, replace the
1. Check the diaphragm spring end for wear and clutch disc and/or the input shaft.
uneven height. Replace if wear is evident or
height difference exceeds the limit. CLUTCH RELEASE BEARING
Limit: 0.5 mm CAUTION
2. Check the pressure plate surface for wear, cracks The clutch release bearing is packed with grease.
and seizure. Do not wash it in cleaning solvent.
3. Check the strap plate rivets for looseness and 1. Check the bearing for seizure, damage, noise, or
replace the clutch cover assembly if loose. improper rotation. If defective, replace the
bearing.
CLUTCH DISC 2. Check for wear on the surface which contacts with
the diaphragm spring. If abnormally worn, replace
CAUTION
the bearing.
Don't clean the clutch disc in a cleaning solvent.
3. Check for wear on the surface which contacts with
the release fork. If abnormally worn, replace the
bearing.
Rivet sink
RELEASE FORK
Check for wear on the surface which contacts with
the bearing. If abnormally worn, replace the release
fork.
AK400613 AC
21B-6 CLUTCH OVERHAUL
CLUTCH RELEASE CYLINDER
4
7 1
8.0 ± 1.0 N·m
8 2
9 3
5
6
AK503444 AE
AK102083
INSPECTION
M1212001600246
PISTON CUP
Check the lip of piston cup for scratch. If there are
any scratches, check if there are any scores inside
the release cylinder.
RELEASE CYLINDER
AK704100AB
1. Check the inner surface of the release cylinder for
1. Apply brake fluid to the entire inner surface of the rust or scratches.
release cylinder. 2. Use a cylinder gauge to measure the inside
Specified brake fluid: Brake fluid DOT 3 or diameter of the release cylinder at three different
DOT 4 points (innermost, middle, and outermost points).
Replace the release cylinder assembly if the
clearance between the piston and cylinder
exceeds the limit at any of the measurement
points.
Limit: 0.15 mm
GROUP 22
MANUAL
TRANSMISSION
(FR)
CONTENTS
GROUP 22A
MANUAL
TRANSMISSION
(FR)
CONTENTS
GENERAL INFORMATION
M1221100100403
The R5MB1 and V5MB1 type manual transmission
has been adopted.
SPECIFICATIONS
Item Specification
Transmission mode R5MB1 V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J- V5MB1-J-
NEG PCG NE PD2 NEZ
Engine model 4D56
Transmission type 5 forward speed, one reverse, constant mesh
Gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Reverse 4.220
Drive system 2WD Easy select 4WD Super select 4WD
Centre differential - Not provided Provided
Transfer type - 2speeds, constant mesh
Transfer gear ratio High - 1.000
Low - 1.900
LUBRICANT
M1221100200154
SEALANTS
M1221102000060
Drain plug
Filler plug
Transmission oil
AC700330AL AC502641AD
Gasket
Drain plug
Filler plug
Transmission oil
AC502641AD AC700330AL
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and drain the oil.
the filler plug hole. 3. Tighten the drain plug to the specified torque.
3. Check that the oil is not noticeably dirty. Tightening torque: 37 ± 11 N⋅m
4. Install the filler plug and new gasket, then tighten 4. Fill with gear oil API classification GL-3 SAE 75W-
them to the specified torque. 85 until the level comes to the lower portion of
Tightening torque: 37 ± 11 N⋅m filler plug hole.
Quantity:
2.3 L <2WD>
3.4 L <4WD>
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 37 ± 11 N⋅m
22A-4 MANUAL TRANSMISSION (FR)
ON-VEHICLE SERVICE
AC502640AB AC502640AB
Gasket Gasket
1. Remove the filler plug and gasket. 1. Remove the filler plug and gasket.
2. Check that the oil level is up to the lower edge of 2. Remove the drain plug and gasket, and then drain
the filler plug hole. the oil.
3. Check that the oil is not noticeably dirty. 3. Install the drain plug and new gasket, then tighten
4. Install the filler plug and new gasket, then tighten them to the specified torque.
them to the specified torque. Tightening torque: 32 ± 2 N⋅m
Tightening torque: 32 ± 2 N⋅m 4. Fill with gear oil API classification GL-3 SAE 75W-
85 or API classification GL-4 SAE 75W-85 until
the level comes to the lower portion of filler plug
hole.
Quantity: 2.5 L
5. Install the filler plug and new gasket, then tighten
them to the specified torque.
Tightening torque: 32 ± 2 N⋅m
AC503108AB
MANUAL TRANSMISSION (FR)
ON-VEHICLE SERVICE
22A-5
Check the continuity between terminals of the black Transfer lever position Specified condition
connector and earth indicated in the illustration.
4HLc and 4LLc Continuity (Less than 2
Transfer lever position Specified condition Ω)
2H Open circuit 2H and 4H Open circuit
4H, 4L Continuity (Less than 2
Ω) 2WD/4WD DETECTION SWITCH
CONTINUITY CHECK <SUPER SELECT
HIGH/LOW DETECTION SWITCH 4WD>
CONTINUITY CHECK <EASY SELECT M1221103200119
4WD>
M1221102800141
AC509434AB
AC509434AD
4WD OPERATION DETECTION SWITCH Check the continuity between terminals of the white
CONTINUITY CHECK <SUPER SELECT connector and earth indicated in the illustration.
4WD> Transfer lever position Specified condition
M1221103400038
While switching between Open circuit
4HLc and 4LLc
2H, 4H, 4HLc and 4LLc Continuity (Less than 2
Ω)
AC509434AF
HIGH/LOW DETECTION SWITCH Check the continuity between terminals of the white
connector and earth indicated in the illustration.
CONTINUITY CHECK <SUPER SELECT
4WD> Transfer lever position Specified condition
M1221102800152 2H, 4H, and 4HLc Continuity (Less than 2
Ω)
4LLc Open circuit
AC509434AG
MANUAL TRANSMISSION (FR)
TRANSMISSION CONTROL
22A-7
TRANSMISSION CONTROL
REMOVAL AND INSTALLATION
M1221102200116
<2WD>
Pre-removal Operation Post-installation Operation
Move the transmission control lever to the Neutral position. Check that the transmission control lever is moved to each
position smoothly and correctly.
1
4
4
3.2 ± 0.2 N·m
2 19 ± 3 N·m
3 N 5
Semi-drying sealant:
3M ATD Part No.8660 or
equivalent
AC609267AB
<4WD>
Pre-removal Operation Post-installation Operation
Move the transmission control lever and transfer control Check that the transmission control lever and the transfer
lever to the following positions. control lever are moved to each position smoothly and
• Transmission control lever: Neutral correctly.
• Transfer control lever: 4H
5
1
2
3
Semi-drying sealant:
3M ATD Part No.8660 or equivalent
19 ± 3 N·m
19 ± 3 N·m
AC509473AB
4 6
25 ± 4 N·m 48 ± 6 N·m
5
3
48 ± 6 N·m 1
11 ± 1 N·m
9.0 ± 1.0 N·m AC807940 AC
6
4
1
25 ± 4 N·m
48 ± 6 N·m
5
3
48 ± 6 N·m
AC509527AB
Removal steps 1. Measure the voltage with the control unit and
• Glove Box Cover (Refer to GROUP harness still connected.
52A, Instrument Panel Assembly ). 2. Earth terminal (8) and then measure the terminal
1. 4WD indicator-ECU voltage.
INSPECTION
M1221101200157 EASY SELECT 4WD
4WD INDICATOR-ECU
VIEW A
A
AC504329AB
Terminal Inspection item Ignition switch Transfer shift position Terminal voltage
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD detection switch ON 2H System voltage
4H, 4L 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
6 High/low detection switch ON While switching between System voltage
4H and 4L
2H, 4H, 4L 1 V or less
22A-12 MANUAL TRANSMISSION (FR)
4WD INDICATOR-ECU
Terminal Inspection item Ignition switch Transfer shift position Terminal voltage
No.
7 Free wheel clutch changeover ON 4H, 4L 1 V or less
solenoid valve System voltage
2H*2
10 4WD indicator lamp ON 2H 1 V or less
4H, 4L System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2
: Shift the lever from 4H to 2H, and then turn the ignition switch to OFF and then back to ON.
<SUPER SELECT 4WD>
Terminal Inspection item Ignition switch Transfer shift position Terminal voltage
No.
1 Free wheel engage switch ON 2H System voltage
4H*1 1 V or less
2 4WD operation detection ON 2H System voltage
switch 4H, 4HLc, 4LLc 1 V or less
3 Ignition switch ON − System voltage
OFF − 1 V or less
4 Centre differential lock indicator ON 4H 1 V or less
lamp 4HLc System voltage
5 Rear wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc System voltage
6 High/low detection switch ON While switching between System voltage
4HLc and 4LLc
2H, 4H, 4HLc, 4LLc 1 V or less
7 Centre differential lock ON 4HLc 1 V or less
operation detection switch System voltage
4H*2
9 Centre differential lock ON 4HLc 1 V or less
detection switch System voltage
4H*2
10 Front wheel indicator lamp ON While switching between 1 V or less
4HLc and 4LLc
4H, 4HLc, 4LLc System voltage
NOTE: .
*1
: When vehicle has been moved once.
*2: Shift the lever from 4HLc to 4H, and then turn the ignition switch to OFF and then back to ON.
22B-1
GROUP 22B
MANUAL
TRANSMISSION
OVERHAUL
<R5MB1>
CONTENTS
GENERAL INFORMATION
M1222000101275
GENERAL SPECIFICATIONS
M1222000200785
Item Specifications
Transmission model R5MB1
Transmission type 5-speed transmission, floor shift
Transmission gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.789
Reverse 4.220
SERVICE SPECIFICATIONS
M1222000300492
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
Shaft snap ring (For adjustment of transmission clutch hub No.1 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
TORQUE SPECIFICATIONS
M1222013900494
Item N⋅m
Intermediate plate − reverse shift arm bracket mounting bolt 18 ± 5
Transmission case − clutch housing mounting bolt 36 ± 7
Transmission case − clutch housing mounting bolt (with seal) 34 ± 6
Transmission case − front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
MANUAL TRANSMISSION OVERHAUL <R5MB1>
SEALANTS
22B-5
Item N⋅m
Transmission case − back-up lamp switch assembly 44 ± 9
Transmission case − shift position switch assembly <R5MB1-J-NC> 34 ± 5
Transmission case − vehicle speed sensor mounting bolt 11 ± 1
Extension housing − straight screw plug with head 18.5 ± 5.5
Transmission case − extension housing sub-assembly, and intermediate plate 37 ± 11
mounting bolt
Intermediate plate − straight screw plug with head 18.5 ± 5.5
Gear shift fork No.1 mounting bolt 19.5 ± 3.9
Gear shift fork No.2 mounting bolt 19.5 ± 3.9
Intermediate plate − rear bearing output retainer mounting bolt 18 ± 5
Oil receiver pipe mounting bolt 11 ± 4
Shift lever housing mounting bolt 33 ± 3
SEALANTS
M1222000501132
LUBRICANTS
M1222000400994
SPECIAL TOOLS
M1222000600534
MB990803
MB990811
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001001765
34 ± 5 N·m 44 ± 9 N·m
2 1 18
<R5MB1-J-NC>
3
15
14
19
16 17 8
7
13
16.5 ± 5.0 N·m 7
36 ± 7 N·m
5
12
34 ± 6 N·m 4
6 11 ± 1 N·m
11
10
18.5 ± 5.5 N·m
9 37 ± 11 N·m
AK701068AD
26 29
19.5 ± 3.9 N·m
27
25
30
28
19.5 ± 3.9 N·m
33
32
31
40
38 37 41 35
34 36
39 44
42 43
AK602734 AC
47
65
18 ± 5 N·m 46
45
45
68
61 60
59
66
63
58 57
67
64
62
18 ± 5 N·m
48
Apply gear oil to
all moving parts
50
before installation. 51
53 49
56 54 55
52 AK701069AB
AK704968AD
shift position switch assembly <R5MB1-J-NC>. 5. Remove the oil receiver pipe.
AK403768
AK604896AB
2. Remove the clutch housing.
6. Remove the straight screw plug with head.
AK500816
AK604897AB
3. Remove the vehicle speed sensor.
7. Remove the slotted spring pin.
22B-12 MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
AK403781 AK403783
8. Remove the reverse restrict pin assembly. 12.Remove the shaft snap ring.
AK403774 AK403784
9. Remove the front bearing retainer. 13.Remove the transmission case sub-assembly.
AK403775AC AK500257
AK403782 AK403786AB
11.Remove the shaft snap ring. 15.Remove the straight screw plug with head (3
places).
MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
22B-13
AK403788AB AK500260
16.Remove the compression spring (3 places). 20.Remove the gear shift fork No.2.
AK403789AB AK500261
AK403792 AB AK500262AB
18.Remove the shaft snap ring of the gear shift fork 22.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of shaft No.1 and the washer based hexagon bolt of
the gearshift fork No.2. the gear shift fork No.1.
AK500259 AK500263
19.Remove the gear shift fork shaft No.2. 23.Remove the gear shift fork shaft No.1.
22B-14 MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
AK500270 AK403790AB
24.Remove the straight pin of the gear shift fork shaft 28.Remove the slotted spring pin of the gear shift
No.1. fork No.3 assembly.
Gear shift fork shaft No.3
AK500264 AK500461AB
25.Remove the roller A. 29.Remove the gear shift fork No.3 and the gear shift
fork shaft No.3.
AK500265
AK403800
26.Remove the gear shift fork No.1.
30.Remove the roller A.
AK500266AB
AK403801
27.Remove the shaft snap ring of the gear shift fork
shaft No.3. 31.Remove the ball.
MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
22B-15
AK500453AB AK403805
32.Remove the shaft snap ring of the gear shift fork 35.Remove the compression spring.
shaft No.4.
AK403806
AK403802
36.Remove the reverse shift fork and the reverse
shift arm.
AK403803
AK403804
AK403984
AK403807
Transmission
hub sleeve No.3
AK500526
AK500269AB
MB990811 MB990803
AK500456
AK403982 AC
AK500457 AK403785AB
49.Remove the synchromesh shifting key spring 53.Remove the straight pin.
No.3.
AK403986
AK500458
54.Remove the rear bearing output shaft retainer.
50.Remove the synchromesh shifting key No.3.
AK403987
AK500459
55.Remove the snap ring.
51.Remove the needle roller bearing.
Reverse idler
gear
AK403989 AC
AK403985
56.Remove the reverse idler gear.
52.Remove the 5th gear thrust washer.
22B-18 MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
Counter gear
sub-assembly
AK403990AB
AK403993
57.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
specified torque of 18 ± 5 N⋅m.
AK403991
AK403992
Cylindrical roller
bearing
Counter gear
sub-assembly
AK403993
AK403990AB
MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
22B-19
4. Insert the counter gear sub-assembly into the
intermediate plate and hold it. Insert the cylindrical
roller bearing into the intermediate plate and the
counter gear sub-assembly.
Reverse idler
gear
AK403785AB
Straight pin
AK501229AB
AK403987
AK403985
AK403986AB
AK500458
Protrusion
Key
AK500457
AK403983AB
12.Install the synchromesh shifting key spring No.3
to the counter shaft gear No.5. CAUTION
Fit the protrusions of synchronizer ring between
keys.
16.Install the synchronizer outer race No.3.
AK500456
AK500526
MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
22B-21
20.Install the ball to the rotor.
21.Install the rotor to the output shaft.
Installation 22.Remove the shaft snap ring to the output shaft (2
direction places).
Reverse shift arm
Reverse shift fork
AK500610 AB
Transmission
hub sleeve No.3
AK500454AB
AK500269AB
AK403807
Standard value: 0 − 0.1 mm 25.Install the reverse shift fork and the reverse shift
arm to the intermediate plate.
Rotor
Ball
AK500453AB
29.Install the shaft snap ring into the gear shift fork
AK403804
shaft No.4.
27.Install the ball into the reverse shift fork.
AK403801
AK403803
30.Install the ball into the reverse shift fork.
AK403802 AK403800
AK500461AB
AK500267 AK500270
33.Install the slotted spring pin to the gear shift fork 37.Install the straight pin to the gear shift fork shaft
No.3 assembly. No.1.
AK500266AB AK500263
34.Install the snap ring to the gear shift fork shaft 38.Install the gear shift fork shaft No.1 to the
No.3. intermediate plate and the gear shift fork No.1.
AK500265 AK500262AB
35.Install the gear shift fork No.1 on the reverse gear. 39.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500264
AK500260
AK403788AB
41.Install the gear shift fork No.2 on the transmission
hub sleeve No.2. 45.Install the compression spring to the intermediate
plate (3 places).
AK500259
AK403786AB
42.Install the gear shift fork shaft No.2 to the
intermediate plate, the gear shift fork No.1 and the 46.Apply sealant to the threads. Tighten the straight
gear shift fork No.2. screw plug with head to the specified torque of
18.5 ± 5.5 N⋅m (3 places).
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403792 AB
AK500257
AK403789AB
MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
22B-25
AK500527AB AK403782
48.Completely degrease the FIPG-applied surface 52.Install the snap ring to the radial ball bearing.
so that water and oil including the old sealant
cannot adhere to the surface coated with the
MB990938
sealant.
Never touch the degreased surface by hand.
49.Apply a 1.2 mm diameter bead of liquid gasket to
the intermediate plate mounting surface of the
transmission case sub-assembly.
Special sealant: Mitsubishi genuine sealant MB990929
Part No. MD974421 or equivalent
AK600320 AB
AK701366
AK403775AB
AK403774
AK604896AB
AK403777
AK500527AB
AK704968AD
AK500460AB
AK500505
CAUTION
Install the bolt and washer (with sealant) to the Check for the continuity between the connector ter-
position having the arrow as shown in the illus- minals.
tration. Switch Connector Continuity
65.Install the clutch housing into the transmission condition terminals
case sub-assembly. Tighten the bolt with washer Switch end 1−2 Conductive
to the specified torque of 36 ± 7 N⋅m (7 places). pressed
Tighten the bolt with washer (with sealant) to the
Switch end 1−2 Open
specified torque of 34 ± 6 N⋅m (2 places).
released
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
22B-28 MANUAL TRANSMISSION OVERHAUL <R5MB1>
TRANSMISSION
SHIFT POSITION SWITCH 2. Check the needle roller bearing cage for
deformation.
AK501632
RADIAL CLEARANCE
Check for the continuity between the connector ter- 1. Fix the output shaft in a vice.
minals. 2. Inspect the radial clearance of counter shaft gear
Switch Connector Continuity No.5.
condition terminals Standard value: 0.015 − 0.068 mm
Switch end 1−2 Open Limit: 0.068 mm
pressed
Switch end 1−2 Conductive INSIDE DIAMETER
released
5
2
4
3
AK500516 AB
AK500606AB
MD998801
1. Check the installation direction of the radial ball
bearing, and put it on the input shaft.
CAUTION
AK403995AC Never push on the sealing area when installing.
Using special tool Bearing remover (MD998801),
MD998812
support the radial ball bearing and remove it.
MD998814
MD998823
AK403996 AB
22B-30 MANUAL TRANSMISSION OVERHAUL <R5MB1>
INPUT SHAFT
2. Using special tools to install the radial ball SYNCHRONIZER RING No.2
bearing.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
AK500676AB
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
AK500677AB
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002100160
21
20
18
15
17 16
26
25 6
24
12 1
2
13 5 3
7
8
4
10 9
14 11
AK500517AB
AK404004AB
AK404006AB
AK404014 AB
AK404020AB
Installation
direction
AK404019
MD998812
MD998813
MD998823
AK404029AC
22B-34 MANUAL TRANSMISSION OVERHAUL <R5MB1>
OUTPUT SHAFT
Installation
direction
AK404031
MD998814
MD998823 Installation
direction
AK404030AC
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
• Installer cap (MD998812)
Standard value: 0.10 − 0.25 mm
Limit: 0.25 mm • Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
MANUAL TRANSMISSION OVERHAUL <R5MB1>
OUTPUT SHAFT
22B-35
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
Standard value: 0 − 0.1 mm
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
M1222002300261
Installation SYNCHRONIZER RING
direction
CAUTION
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
AK500609AB
MD998812
MD998814 AK500672AB
AK404039AB
AK500603
SYNCHRONIZER KEYS
AK404022
AK500680AB
HUB SLEEVE AND SHIFT FORK
Check the synchronizer hub contact surfaces of each
CAUTION
synchronizer key for damage and excessive wear.
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
No.1 0.15 − 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 − 0.35 0.35 the needle roller bearing race.
No.3 0.26 − 0.84 0.84 Measurement Standard value mm Limit mm
part
AK404025
AK404026
COUNTERSHAFT
DISASSEMBLY AND REASSEMBLY
M1222007300158
AK500518AB
22B-38 MANUAL TRANSMISSION OVERHAUL <R5MB1>
COUNTERSHAFT
MD998801
AK404042
AK404043 AB
Using special tool Bearing remover (MD998801), 1. Select a snap ring to secure clearance of standard
support the cylindrical roller bearing and remove it. value between the cylinder roller bearing and
counter shaft.
REASSEMBLY SERVICE POINTS Standard value: 0 − 0.1 mm
>>A<< CYLINDRICAL ROLLER BEARING 2. Install the selected snap ring.
INSTALLATION
INSPECTION
M1222007400025
COUNTER GEAR
Installation
direction
D E
AK500644 AB
AK404046AB
MANUAL TRANSMISSION OVERHAUL <R5MB1>
REVERSE IDLER GEAR
22B-39
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
M1222012500233
1
AK500519AB
AK500525AB
EXTENSION HOUSING
DISASSEMBLY AND REASSEMBLY
M1222004300074
33 ± 3 N·m
5 2
4 3
11 ± 4 N·m
AK500815AB
GROUP 22C
MANUAL
TRANSMISSION
OVERHAUL
<V5MB1>
CONTENTS
COUNTERSHAFT. . . . . . . . . . . . . . . . 22C-63
OUTPUT SHAFT . . . . . . . . . . . . . . . . 22C-39
COUNTERSHAFT DISASSEMBLY AND
22C-2
GENERAL SPECIFICATIONS
M1222000201261
Item Specifications
Transmission model V5MB1
Applicable engine 4D56
Transmission type 5-speed transmission, floor shift
Transmission gear ratio 1st 4.313
2nd 2.330
3rd 1.436
4th 1.000
5th 0.788
Reverse 4.220
Transfer type Constant mesh
Transfer gear ratio High 1.000
Low 1.900
SERVICE SPECIFICATIONS
M1222000300975
Counter shaft outer shape of the needle roller D 34.000 − 34.105 34.000
bearing race mm E 29.984 − 30.000 29.984
Reverse idler gear
Reverse idler gear radial clearance mm 0.040 − 0.082 0.082
Transfer
Item Standard value Limit
Countershaft gear end play mm 0 − 0.15 −
H-L clutch hub end play mm 0 − 0.08 −
Differential lock hub end play mm <V5MB1-J-ND2, NEZ, PD2> 0 − 0.08 −
MANUAL TRANSMISSION OVERHAUL <V5MB1>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22C-5
Item Standard value Limit
Rear output shaft bearing to rear cover <V5MB1-J-NEG, JER> 0 − 0.1 −
clearance mm <V5MB1-J-ND2, NEZ, 0.025 − 0.150 −
PD2>
Input gear bearing end play mm 0 − 0.06 −
Counter shaft gear bearing end play mm 0 − 0.08 −
2-4WD synchronizer hub end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
2-4WD synchronizer ring and gear mm <V5MB1-J-ND2, NEZ, − 0.3
PD2>
Rear output shaft bearing end play mm <V5MB1-J-ND2, NEZ, 0 − 0.08 −
PD2>
Drive sprocket and synchronizer ring mm <V5MB1-J-NEG> − 0.3
Transmission
Shaft snap ring (For adjustment of gear spline piece No.5 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.80 − 2.85 A 3.00 − 3.05 E
2.85 − 2.90 B 3.05 − 3.10 F
2.90 − 2.95 C 3.10 − 3.15 G
2.95 − 3.00 D
Shaft snap ring (For adjustment of input shaft radial ball bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.10 − 2.15 A 2.30 − 2.35 E
2.15 − 2.20 B 2.35 − 2.40 F
2.20 − 2.25 C 2.40 − 2.45 G
2.25 − 2.30 D
Shaft snap ring (For adjustment of transmission clutch hub No.2 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.80 − 1.85 A 2.00 − 2.05 E
1.85 − 1.90 B 2.05 − 2.10 F
1.90 − 1.95 C 2.10 − 2.15 G
1.95 − 2.00 D
22C-6 MANUAL TRANSMISSION OVERHAUL <V5MB1>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
Shaft snap ring (For adjustment of transmission clutch hub No.1 end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.30 − 2.35 A 2.50 − 2.55 E
2.35 − 2.40 B 2.55 − 2.60 F
2.40 − 2.45 C 2.60 − 2.65 G
2.45 − 2.50 D
Shaft snap ring (For adjustment of 5th gear end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.75 − 2.80 C 3.05 − 3.10 J
2.80 − 2.85 D 3.10 − 3.15 K
2.85 − 2.90 E 3.15 − 3.20 L
2.90 − 2.95 F 3.20 − 3.25 M
2.95 − 3.00 G 3.25 − 3.30 N
3.00 − 3.05 H 3.30 − 3.35 P
Shaft snap ring (For adjustment of counter gear shaft cylindrical roller bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.05 − 2.10 A 2.20 − 2.25 D
2.10 − 2.15 B 2.25 − 2.30 E
2.15 − 2.20 C 2.30 − 2.35 F
Transfer
Snap ring (For adjustment input gear bearing end play)
Thickness mm Identification color Thickness mm Identification color
2.30 None 2.45 Blue
2.35 Red 2.50 Green
2.40 White
Spacer (For adjustment of countershaft gear end play)
Thickness mm Identification color Thickness mm Identification color
1.77 None 2.19 White
1.91 Blue 2.33 Red
2.05 Brown
Snap ring (For adjustment of countershaft gear bearing end play)
Thickness mm Identification color Thickness mm Identification color
1.48 Blue 1.62 None
Spacer (For adjustment of rear output shaft to rear cover clearance)
<V5MB1-J-NEG, JER>
Thickness mm Identification symbol Thickness mm Identification symbol
2.75 B75 2.95 B95
2.79 B79 2.99 B99
MANUAL TRANSMISSION OVERHAUL <V5MB1>
SNAP RING, SPACER AND THRUST PLATE FOR ADJUSTMENT
22C-7
Thickness mm Identification symbol Thickness mm Identification symbol
2.83 B83 3.03 C03
2.87 B87 3.07 C07
2.91 B91 3.11 C11
<V5MB1-J-ND2, NEZ, PD2>
Thickness mm Identification symbol Thickness mm Identification symbol
0.84 84 1.47 47
0.93 93 1.56 56
1.02 02 1.65 65
1.11 11 1.74 74
1.20 20 1.83 83
1.29 29 1.92 92
1.38 38 2.01 01
Snap ring (For adjustment of H-L clutch hub end play)
Thickness mm Identification color Thickness mm Identification color
2.18 − 2.32 −
2.25 − 2.39 −
Snap ring (For adjustment of differential lock hub end play) <V5MB1-J-ND2, NEZ, PD2>
Thickness mm IdentificatioN color Thickness mm IdentificatioN color
2.56 None 2.84 Yellow
2.63 Red 2.91 Green
2.70 White 2.98 Purple
2.77 Blue
Snap ring (For adjustment of 2-4WD synchronizer hub end play) <V5MB1-J-ND2, NEZ, PD2>
Thickness mm IdentificatioN color Thickness mm IdentificatioN color
2.56 None 2.77 Blue
2.63 Red 2.84 Yellow
2.70 White
Snap ring (For adjustment of rear output shaft bearing end play) <V5MB1-J-ND2, NEZ, PD2>
Thickness mm IdentificatioN color Thickness mm IdentificatioN color
2.26 None 2.40 White
2.33 Red 2.47 Blue
22C-8 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
M1222013900632
Transmission
Item N⋅m
Reverse shift arm bracket mounting bolt 18 ± 5
Rear bearing output retainer mounting bolt 18 ± 5
Gear shift fork shaft mounting bolt 19.5 ± 3.9
Straight screw plug with head 18.5 ± 5.5
Front bearing retainer sub-assembly mounting bolt 16.5 ± 5.0
Wiring harness clamp bracket mounting bolt 18 ± 3
Transfer adaptor sub-assembly mounting bolt 37 ± 11
Shift lever housing mounting bolt 33 ± 3
Cover mounting bolt 18 ± 5
Reverse restrict pin assembly mounting bolt 37 ± 11
Clutch housing mounting bolt 36 ± 7
Clutch housing mounting bolt (with seal) 34 ± 6
Shift position switch assembly 34 ± 5
Back-up lamp switch assembly 44 ± 9
Transfer mounting bolt and nut 35 ± 6
Transfer
Item N⋅m
Side cover tightening bolt 9.0 ± 1.0
Chain cover tightening bolt 35 ± 6
Rear cover tightening bolt 35 ± 6
Plug <V5MB1-J-NEG, JER> 35 ± 6
Transfer case tightening bolt and nut 35 ± 6
Speedometer sleeve clamp mounting bolt 19 ± 3
Vehicle speed sensor 25 ± 4
4WD operation detection switch 34 ± 5
Center differential lock detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
2WD/4WD detection switch <V5MB1-J-ND2, NEZ, PD2> 35 ± 6
Center differential lock operation detection switch <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
High range/Low range detection switch 34 ± 5
4LLc operation detection switch <V5MB1-J-PD2> 34 ± 5
Bearing retainer mounting bolt 19 ± 3
H-L shift fork mounting bolt 9.0 ± 2.0
Rear output shaft lock nut <V5MB1-J-NEG, JER> 255 ± 10
Rear bearing retainer <V5MB1-J-ND2, NEZ, PD2> 20 ± 2
Oil pool cover <V5MB1-J-ND2, NEZ, PD2> 9.0 ± 1.0
MANUAL TRANSMISSION OVERHAUL <V5MB1>
SEALANTS
22C-9
Item N⋅m
Plug <V5MB1-J-ND2, NEZ, PD2> 34 ± 5
Plug 32 ± 2
Center differential case mounting bolt <V5MB1-J-ND2, NEZ, PD2> 69 ± 10
SEALANTS
M1222000501251
Transmission
Item Specified sealant and adhesive
Between transmission case sub-assembly and Mitsubishi genuine sealant Part No.MD974421 or
intermediate plate equivalent
Between front bearing retainer and transmission
case sub-assembly
Between intermediate plate and extension housing
sub-assembly
Between intermediate plate and transfer adaptor
sub-assembly
Between transfer adaptor sub-assembly and cover
Straight screw plug
Front bearing retainer mounting bolt
Clutch housing mounting bolt
Transfer
Item Specified sealant and adhesive
Chain cover Mitsubishi genuine sealant Part No.MD997740 or
Rear cover equivalent
Control housing
Transfer case plate
Plug 3M AAD part No.8672 or equivalent
Return spring plug 3M STUD Looking No.4170 or equivalent
Bearing retainer mounting bolt
FORM-IN-PLACE GASKET (FIPG) FIPG hardens as it reacts with the moisture in the
This transmission has several areas where the form- atmospheric air, and it is usually used for sealing
in-place gasket (FIPG) is used for sealing. To ensure metallic flange areas.
that the FIPG fully serves its purpose, it is necessary CAUTION
to observe some precautions when applying it. Bead When re-applying liquid gasket (FIPG), be sure
size, continuity and location are of paramount impor- that:
tance.
1. Residues of FIPG are cleared from all the ins
Too thin a bead could cause leaks. Too thick a bead,
and outs of parts;
on the other hand, could be squeezed out of location,
2. Use Mitsubishi genuine parts cleaner
causing blocking or narrowing of fluid passages. To
(MZ100387) or equivalent to well degrease the
prevent leaks or blocking of passages, therefore, it is
FIPG-applied surface.
absolutely necessary to apply the FIPG evenly with-
out a break, while observing the correct bead size. 3. FIPG is correctly applied in accordance with
FIPG Application.
22C-10 MANUAL TRANSMISSION OVERHAUL <V5MB1>
LUBRICANTS
LUBRICANTS
M1222000400381
SPECIAL TOOLS
M1222000601139
Transmission
Tool Tool number Name Use
MB990803 Steering wheel puller Removal of gear spline
piece No.5
MB990803
MB990811
Transfer
Tool Number Name Use
MB990938 Installer bar Installation of oil seal
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1222001001925
1 3
35 ± 6 N·m
35 ± 6 N·m
AK500694AB
44 ± 9 N·m 18 ± 3 N·m 22
34 ± 5 N·m 16
6 4
5
19
23
20 21
8 18 ± 5 N·m
18
17
16.5 ± 5.0 N·m
36 ± 7 N·m 37 ± 11 N·m
34 ± 6 N·m 7 37 ± 11 N·m
12 10
7
15
10
14 9
13 11 37 ± 11 N·m
18.5 ± 5.5 N·m
AK603025AH
32 35
19.5 ± 3.9 N·m
33
31
36
34
19.5 ± 3.9 N·m
39
38
37
46
44 43 47 41
40 42
50
45 48 49 AK603100AB
68
18 ± 5 N·m
71
64 63
62
69
66
61 60
70
67
65
18 ± 5 N·m
51
Apply gear oil to
all moving parts
53
before installation. 54
56 52
59 57 58
55 AK603036AB
3. Remove the shift position switch assembly and 7. Remove the flange bolt.
the back-up lamp switch assembly.
AK403772
AK403768
8. Remove the control shaft assembly.
4. Remove the clutch housing.
AK501350AB
AK403769
9. Remove the shift lever housing.
5. Remove the reverse restrict pin assembly (2
places).
AK403776
AK403777 AK403773
11.Remove the oil receiver pipe. 15.Remove the wiring harness clamp bracket.
AK403779 AK403774
12.Remove the straight screw plug with head. 16.Remove the front bearing retainer.
AK403780AB AK403775AC
AK403781 AK403782
14.Remove the reverse restrict pin assembly. 18.Remove the shaft snap ring.
22C-20 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
AK403783 AK403788AB
19.Remove the shaft snap ring. 23.Remove the compression spring (3 places).
AK403784 AK403789AB
AK500257 AK403792 AB
21.Remove the transmission magnet. 25.Remove the shaft snap ring of the gear shift fork
shaft No.2 and the washer based hexagon bolt of
the gearshift fork No.2.
AK403786AB
AK500260 AK500270
27.Remove the gear shift fork No.2. 31.Remove the straight pin of the gear shift fork shaft
No.1.
AK500261
AK500264
28.Remove the roller A.
32.Remove the roller A.
AK500262AB
AK500265
29.Remove the shaft snap ring of the gear shift fork
shaft No.1 and the washer based hexagon bolt of 33.Remove the gear shift fork No.1.
the gear shift fork No.1.
AK500266AB
AK500263
34.Remove the shaft snap ring of the gear shift fork
30.Remove the gear shift fork shaft No.1. shaft No.3.
22C-22 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
AK403790AB
AK500453AB
35.Remove the slotted spring pin of the gear shift
fork No.3 assembly. 39.Remove the shaft snap ring of the gear shift fork
shaft No.4.
Gear shift fork shaft No.3
AK500461AB
AK403802
36.Remove the gear shift fork No.3 assembly and
the gear shift fork shaft No.3.
AK403803
AK403800
40.Remove the gear shift fork shaft No.4.
37.Remove the roller A.
AK403804
AK403801
41.Remove the ball.
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
22C-23
AK403805 AK403807
Transmission
hub sleeve No.3
AK403806 AK500269AB
43.Remove the reverse shift fork and the reverse 47.Remove the transmission hub sleeve No.3.
shift arm.
MB990811 MB990803
AK403982 AC
AK500455
48.Use special tools to remove the gear spline piece
44.Remove the E ring. No.5.
• Steering wheel puller (MB990803)
Reverse shift arm • Side bearing puller cup (MB990811)
Reverse shift fork
AK500454AB
AK403984 AK500458
50.Remove the counter shaft gear No.5. 54.Remove the synchromesh shifting key No.3.
AK500526 AK500459
51.Remove the shaft snap ring. 55.Remove the needle roller bearing.
AK500456 AK403985
52.Remove the synchromesh shifting key spring 56.Remove the 5th gear thrust washer.
No.3.
AK403785AB
AK500457
57.Remove the straight pin.
53.Remove the synchromesh shifting key spring
No.3.
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
22C-25
AK403986 AK403991
58.Remove the rear bearing output shaft retainer. 62.Remove the input shaft sub-assembly.
AK403987 AK403992
AK403989 AB AK403993
60.Remove the reverse idler gear shaft and reverse 64.Remove the reverse shift arm bracket.
idler gear sub-assembly.
REASSEMBLY
AK403990
AK403993
61.Remove the counter gear sub-assembly and
cylindrical roller bearing. 1. Set the reverse shift arm bracket to the
intermediate plate and tighten the bolts to the
specified torque of 18 ± 5 N⋅m.
22C-26 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
AK403992
AK403991
AK403990AB
AK403989 AB
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
22C-27
Penetration
groove
Straight pin
AK501229AB AK500457
AK403985
AK500459
AK500458
Key
AK403983AB
MD998827 MD998812
MD998813
AK404049AB
Installation
direction
AK500610 AB
AK500455
AK500269AB
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
22C-29
CAUTION
Install the gear shift fork shaft No.4 carefully in
the specified direction. If the installation direc-
tion is wrong, the roller would be in the shaft
concave and the gearshift fork shaft No.4 would
not be installed.
AK403806
AK403803
AK403805
AK403804
AK500453AB
26.Install the shaft snap ring into the gear shift fork
shaft No.4.
AK403801
22C-30 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
27.Install the ball into the reverse shift fork. 31.Install the snap ring to the gear shift fork shaft
No.3.
AK403800
AK500265
28.Install the roller A to the intermediate plate.
32.Install the gear shift fork No.1 on the reverse gear.
Gear shift fork shaft No.3
AK500461AB
AK500264
29.Install the gear shift fork No.3 assembly on the
transmission hub sleeve No.3 and hold it. Insert 33.Install the roller A to the intermediate plate.
the gear shift fork shaft No.3 into the gear shift
fork No.3 assembly, the intermediate plate and
the reverse shift fork.
AK500270
AK500263
AK500262AB AK403792 AB
36.Install the shaft snap ring to the gear shift fork 40.Install the shaft snap ring to the gear shift fork
shaft No.1. Tighten the washer based hexagon shaft No.2. Tighten the washer based hexagon
bolt to the specified torque of 19.5 ± 3.9 N⋅m. bolt to the specified torque of 19.5 ± 3.9 N⋅m.
AK500261 AK403789AB
37.Install the roller A to the intermediate plate. 41.Install the ball to the intermediate plate (3 places).
AK500260 AK403788AB
38.Install the gear shift fork No.2 on the transmission 42.Install the compression spring to the intermediate
hub sleeve No.2. plate (3 places).
AK500259 AK403786AB
39.Install the gear shift fork shaft No.2 to the 43.Apply sealant to the threads. Tighten the straight
intermediate plate, the gear shift fork No.1 and the screw plug with head to the specified torque of
gear shift fork No.2. 18.5 ± 5.5 N⋅m (3 places).
22C-32 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
AK403783
AK403782
AK500527AB MB990938
AK500560
AK403775AB
47.Install the transmission case sub-assembly to the
intermediate plate.
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
22C-33
51.Completely degrease the FIPG-applied surface 54.Install the wiring harness clamp bracket to the
so that water and oil including the old sealant transmission case sub-assembly and tighten the
cannot adhere to the surface coated with the bolt to the specified torque of 18 ± 3 N⋅m.
sealant.
Never touch the degreased surface by hand.
52.Apply a 1.2 mm diameter bead of liquid gasket to
the transmission case sub-assembly mounting
surface of the front bearing retainer sub-assembly
with seal.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
AK403781
CAUTION
Do not damage to the oil seal lip during the 55.Install the reverse restrict pin assembly to the
installation. transfer adaptor sub-assembly.
AK403774 AK403780AB
53.Apply sealant to the threads. Install the front 56.Install the slotted spring pin to the reverse restrict
bearing retainer to the transmission case sub- pin assembly.
assembly and tighten the bolts to the specified
torque of 16.5 ± 5.0 N⋅m.
Special sealant: Mitsubishi genuine sealant
Part No. MD974421 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403779
CAUTION
When installing the shift lever housing, securely
fit the shift lever housing into the head of the fork
shaft.
Transfer
adaptor
AK403777
AK500527AB
AK403772
AK403776
CAUTION
Install the bolt and washer (with sealant) to the
position having the arrow as shown in the illus-
tration.
AK500528AB
AK403770
AK403769 AB
22C-36 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSMISSION
INSIDE DIAMETER
AK501632
5
2
4
3
AK500516 AB
AK500606AB
MD998801
1. Check the installation direction of the radial ball
bearing, and put it on the input shaft.
CAUTION
AK403995AC Never push on the sealing area when installing.
Using special tool Bearing remover (MD998801),
MD998812
support the radial ball bearing and remove it.
MD998814
MD998823
AK403996 AB
22C-38 MANUAL TRANSMISSION OVERHAUL <V5MB1>
INPUT SHAFT
2. Using special tools to install the radial ball SYNCHRONIZER RING No.2
bearing.
• Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
AK500676AB
INSPECTION
M1222001700222
INPUT SHAFT SUB-ASSEMBLY AK403998
AK500677AB
OUTPUT SHAFT
DISASSEMBLY AND REASSEMBLY
M1222002100160
21
20
18
15
17 16
26
25 6
24
12 1
2
13 5 3
7
8
4
10 9
14 11
AK500517AB
AK404004AB
AK404006AB
AK404014 AB
MANUAL TRANSMISSION OVERHAUL <V5MB1>
OUTPUT SHAFT
22C-41
Using special tool Bearing remover (MD998801),
support the 2nd gear sub-assembly and remove the
reverse gear, synchronizer shifting key No. 1, com- MD998812
pression spring, the transmission clutch No. 1 hub,
synchronizer ring set No. 1 and the 2nd gear sub- MD998813
assembly.
MD998823
<<D>> TRANSMISSION CLUTCH HUB No. 2 /
SYNCHRONIZER SHIFTING KEY No. 2 /
COMPRESSION SPRING / TRANSMISSION HUB AK404029AC
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY REMOVAL 2. Using special tools to install the transmission
clutch hub No. 2, synchronizer shifting key No. 2,
compression spring, the transmission hub sleeve
No. 2, synchronizer ring set No. 2 and the 3rd
MD998801 gear sub-assembly.
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (48) (MD998823)
AK404020AB
REASSEMBLY SERVICE POINTS 3. Confirm the thrust clearance of the 3rd gear sub-
>>A<< TRANSMISSION CLUTCH HUB No. 2 / assembly is within the standard value.
SYNCHRONIZER SHIFTING KEY No. 2 / COM- Standard value: 0.10 − 0.25 mm
PRESSION SPRING / TRANSMISSION HUB Limit: 0.25 mm
SLEEVE No. 2 / SYNCHRONIZER RING SET No. 2
/ 3RD GEAR SUB-ASSEMBLY INSTALLATION
>>B<< SHAFT SNAP RING INSTALLATION
Installation
direction
AK500607AB
AK404019
1. Check the installation direction of the transmission 1. Select a shaft snap ring to secure the standard
clutch hub No. 2, and put it on the output shaft. clearance between the transmission clutch hub
No.2 and the output shaft.
Standard value: 0 − 0.1 mm
2. Install the selected snap ring.
22C-42 MANUAL TRANSMISSION OVERHAUL <V5MB1>
OUTPUT SHAFT
Installation
direction
AK404031
MD998814
MD998823 Installation
direction
AK404030AC
MD998812
MD998814
MD998823
AK404032 AK404038AB
3. Confirm the thrust clearance of the 2nd gear sub- 2. Using special tools to install the radial ball bearing
assembly is within the standard value. and the 1st gear sub-assembly.
• Installer cap (MD998812)
Standard value: 0.10 − 0.25 mm
Limit: 0.25 mm • Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
MANUAL TRANSMISSION OVERHAUL <V5MB1>
OUTPUT SHAFT
22C-43
>>G<< SHAFT SNAP RING INSTALLATION
AK500513
AK404040
3. Confirm the thrust clearance of the 1st gear sub-
assembly is within the standard value. 1. Select a shaft snap ring to secure the standard
Standard value: 0.20 − 0.45 mm clearance between the 5th gear and the output
Limit: 0.45 mm shaft
Standard value: 0 − 0.1 mm
>>F<< 5TH GEAR INSTALLATION 2. Install the selected snap ring.
INSPECTION
M1222002300261
Installation SYNCHRONIZER RING
direction
AK500609AB
MD998812
CAUTION
MD998814
When any of the outer ring, inner ring or cone
has to be replaced, replace them as a set.
MD998823 1. Check to ensure that the clutch gear tooth surface
and cone surface are not damaged and broken.
AK404039AB
AK500603
SYNCHRONIZER KEYS
AK404022
AK500680AB
HUB SLEEVE AND SHIFTFORK
Check the synchronizer hub contact surfaces of each
synchronizer key for damage and excessive wear.
COMPRESSION SPRINGS
Check the compression springs for loss of tension,
deformation, and breakage.
OUTPUT SHAFT
AK404023
CAUTION
When any of the hub sleeve or shift fork has to be
replaced, replace them as a set.
Using the thickness gauge, check the clearance
between the sleeve and the shift fork.
A B C
sleeve Standard Limit mm
value mm AK404024AB
No.1 0.15 − 0.41 0.41 1. Using the micrometer, check the outer shape of
No.2 0.15 − 0.35 0.35 the needle roller bearing race.
No.3 0.26 − 0.84 0.84 Measurement Standard value mm Limit mm
part
AK404025
AK404026
COUNTERSHAFT
DISASSEMBLY AND REASSEMBLY
M1222007300158
AK500518AB
22C-46 MANUAL TRANSMISSION OVERHAUL <V5MB1>
COUNTERSHAFT
MD998801
AK404042
AK404043 AB
Using special tool Bearing remover (MD998801), 1. Select a snap ring to secure clearance of standard
support the cylindrical roller bearing and remove it. value between the cylinder roller bearing and
counter shaft.
REASSEMBLY SERVICE POINTS Standard value: 0 − 0.1 mm
>>A<< CYLINDRICAL ROLLER BEARING 2. Install the selected snap ring.
INSTALLATION
INSPECTION
M1222007400025
COUNTER GEAR
Installation
direction
D E
AK500644 AB
AK404046AB
MANUAL TRANSMISSION OVERHAUL <V5MB1>
REVERSE IDLER GEAR
22C-47
REVERSE IDLER GEAR
DISASSEMBLY AND REASSEMBLY
M1222012500233
1
AK500519AB
AK500525AB
TRANSFER
DISASSEMBLY AND REASSEMBLY
M1222008800327
<V5MB1-J-NEG, JER>
35 ± 6 N·m 34 ± 5 N·m
3
6
35 ± 6 N·m 8
7 4
9
5
32 ± 2 N·m
12
34 ± 5 N·m
13
1
16
19 ± 3 N·m
15
14
22 ± 2 N·m
AKA00412 AB
28
29
30 24
25
26
27
22
16
19 20 21
35 ± 6 N·m 15 32 ± 2 N·m
35 ± 6 N·m
18
17
35 ± 6 N·m
AK900792AB
50
49
47
Apply gear oil to
48 all moving parts
before installation.
55 49
52
35 ± 6 N·m
38
34 35
54
53 45
31 36
42 44
51
43
41
40
39
46 37
32
33 58
56 57
AK503417AF
5 34 ± 5 N·m 26
34 ± 5 N·m
4 6
35 ± 6 N·m
34 ± 5 N·m
35 ± 6 N·m
12
2 34 ± 5 N·m
34 ± 5 N·m
7 31
9
35 ± 6 N·m
<V5MB1-J-PD2>
10
1 8 13 27
11 14
<V5MB1-J-
ND2,NEZ>
32
19 ± 3 N·m
3
28
29
30 19 18
33
25 17 25 ± 4 N·m
20 24 15
16 32 ± 2 N·m
52
Apply gear oil to
all moving parts
before installation.
51
53
43
57 60
55 45 39
59 41 35 ± 6 N·m
47 44
58
38
56 34
46 37
61
54 63
50
62
64
40
65
48
35
42
49
36
AK801157AE
70
Apply gear oil to
all moving parts
before installation.
71
20 ± 2 N·m
72
69
68 75
67 74
66
73 AK503403AJ
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>D<< 66. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>C<< 67. H-L clutch hub
68. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
69. Needle bearing tion, the chain cover cannot be removed because
70. Rear bearing retainer interlock is actuated.
71. Transfer drive shaft
72. Oil pool cover <<B>> REAR OUTPUT SHAFT / CHAIN/FRONT
73. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 74. Oil seal
75. Transfer case
AK500492
AK503405 AB
22C-54 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSFER
<<C>> 2-4WD SYNCHRONIZER / CHAIN/FRONT >>B<< FRONT OUTPUT SHAFT / CHAIN / REAR
OUTPUT SHAFT REMOVAL OUTPUT SHAFT INSTALLATION
AK101119 AK500492
Remove the 2-4WD synchronizer, chain and front 1. Engage the chain precisely with the sprocket of
output shaft as a set. the rear output shaft and the front output shaft.
2. Install the 2-4WD shift fork on the 2-4WD clutch
ADJUSTMENT BEFORE REASSEMBLY sleeve. While passing them beside the 2-4WD
Spacer selection for adjustment of counter shaft end shift rail, install the front output shaft, and chain
play. (Refer to ADJUSTMENT OF TRANSFER - and rear output shaft.
SPACER SELECTION FOR ADJUSTMENT OF
COUNTER SHAFT END PLAY P.22C-59 >>C<< H-L CLUTCH HUB INSTALLATION
MB990931 MB990938
AK503408 AB
AK500493
AK101124
AK503398
3. Place the chain in tight mesh with the 2-4WD
1. Install the thickest snap ring that can be fitted in synchronizer and front output shaft sprockets.
the snap ring groove of the transfer drive shaft. 4. With both sprockets spaced the farthest apart,
2. Make sure that the differential lock hub end play install them on the transfer case simultaneously.
meets the standard value.
Standard value: 0 − 0.08 mm >>H<< CHAIN COVER INSTALLATION
CAUTION
>>F<< SPRING PIN INSTALLATION Squeeze the sealant out evenly to apply it in
an unbroken, non-excessive quantity.
2 mm Diameter
AK503410
AK403508AB
1. Align the e2-4WD shift lug with the 2-4WD shift
rail spring pin hole. 1. Completely degrease the FIPG-applied surface so
2. Hammer in the spring valve so that the spring pin that water and oil including the old sealant cannot
slit matches the center of the shift rail shaft. adhere to the surface coated with the sealant.
Never touch the degreased surface by hand.
>>G<< 2-4WD SYNCHRONIZER/CHAIN/FRONT 2. Apply sealant to the chain cover, and then install
OUTPUT SHAFT INSTALLATION the chain cover.
Specified sealant: Mitsubishi genuine seal-
ant Part No. MD997740 or equivalent
Identification groove
AK101123
Check that the H-L clutch sleeve is in the correct 1. Align the spring pin holes on the shift rail with the
direction for installation. shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
>>J<< H-L SHIFT RAIL INSTALLATION shift rail.
MB990938
MB990932
H-L shift rail
2-4WD shift rail
Interlock plunger
H-L shift rail
AK403510AQ
MB990938
MB990929
1. Tilt the transfer case with the 2-4WD shift rail AK403510AR
AK503412
MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSFER
22C-57
>>M<< SPACER INSTALLATION 2. Subtract A from B and let the answer be C. Select
a spacer so that the subtracted value will be the
<V5MB1-J-NEG, JER>
A
Rear cover standard value shown below.
Standard value:
0 − 0.1 mm <V5MB1-J-NEG, JER>
0.025 − 0.150 mm <V5MB1-J-ND2, NEZ, PD2>
B
Oil hole
Spacer
Oil cover
AK403729 AC
2 mm
Diameter
AKX00172 AC
>>Q<< COUNTER SHAFT GEAR INSTALLATION >>S<< SPEEDOMETER DRIVEN GEAR SLEEVE
Notched selection
ASSEMBLY INSTALLATION
Mating marks
Counter shaft
AK403513
Install the spring with its tapered end toward the ball.
INSPECTION
M1222008900153
4WD DETECTION SWITCH
4WD operation detection switch
AK503422
5
4
AK500691AD
MB990933
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
socket wrench
AKX00216 AD
>>C<< SEAL BOLT INSTALLATION 1. Apply the specified sealant to the threads.
Specified sealant: 3M STUD Locking No.
4170 or equivalent
NOTE: The new bolt does not require sealant
application as it is precoated with sealant.
AK403506 AB
AK800993AB
MD998801
AK601073 AC
MANUAL TRANSMISSION OVERHAUL <V5MB1>
COUNTERSHAFT
22C-63
Use special tool, Bearing remover (MD998801),
remove the ball bearing. >>B<< SNAP RING INSTALLATION
Ball bearing
REASSEMBLY SERVICE POINTS
Standard value
>>A<< BALL BEARING INSTALLATION
Snap ring
MD998812
MD998826
AK500699AB
COUNTERSHAFT
DISASSEMBLY AND REASSEMBLY
M1222007300062
AK500663 AB
DISASSEMBLY SERVICE POINTS 1. Use special tools to install the roller bearing.
<<A>> BALL BEARING REMOVAL • Installer cap (MD998812)
• Installer adapter (38) (MD998818)
2. Install the spacer.
MD998801
>>B<< SNAP RING INSTALLATION
AKX00257 AC
AKX00258 AC
AKX00259 AC
MANUAL TRANSMISSION OVERHAUL <V5MB1>
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
22C-65
2-4WD SYNCHRONIZER <V5MB1-J-ND2, NEZ, PD2>
DISASSEMBLY AND REASSEMBLY
M1222010900020
7
Apply gear oil to
all moving parts
before installation.
9
8
6 10
5
4
3
9
2
AK503423AB
AK503426AB
AK503427AB
Snap ring
AK101272AD
AK500672AB
MANUAL TRANSMISSION OVERHAUL <V5MB1>
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
22C-67
CENTRE DIFFERENTIAL CASE <V5MB1-J-ND2, NEZ, PD2>
DISASSEMBLY AND REASSEMBLY
M1222010600041
3 3
2
3
69 ± 10 N·m 4
4
1
AK503428 AB
Dowel pin
AK101274AD
2
3
4
5
1
6
AK500689AB
AK500693 AC
14
15
16
17
18
255 ± 10 N·m
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
10 before installation.
AK500645AB
AK403520 AB
MB991013
1. Place special tool Remover (MD998801) so that
the load is applied at the bearing.
2. Use a press to push at the rear end of the rear
output shaft, and then remove the clutch hub and
ball bearing.
NOTE: .
AK500495AB
The clutch hub may fit loosely on the shaft, so
that removal is possible without using a press.
2. Hold the drive sprocket in a soft-jaw vice.
3. Shift the clutch sleeve to the drive sprocket side. REASSEMBLY SERVICE POINTS
4. Use special tool Power steering lock nut special >>A<< BALL BEARING / STOPPER PLATE
spanner (MB991013) to remove the lock nut. INSTALLATION
MD998814
MD998801
MD998829
Ball bearing
MD998801
AK403521AB
1. Fit the ball bearing and stopper plate onto the rear
AK403518AB
output shaft.
1. Use special tool Remover (MD998801) to support 2. Use special tools to press in the ball bearing.
the ball bearing. • Remover (MD998801)
2. Use a press to push at a rear end of the rear • Installer cap (MD998812)
output shaft, and then remove the radial ball • Installer-100 (MD998813)
bearing. • Installer-200 (MD998814)
• Installer adapter (60) (MD998829)
MANUAL TRANSMISSION OVERHAUL <V5MB1>
REAR OUTPUT SHAFT <V5MB1-J-NEG, JER>
22C-71
>>B<< CLUTCH HUB INSTALLATION • Installer cap (MD998812)
• Installer-200 (MD998814)
MD998812
• Installer adapter (44) (MD998821)
MD998813
MD998814
NOTE: .
The ball bearing may be fitted loosely on the
MD998821
shaft, so that installation is possible without using a
Installation
direction 2-4WD clutch hub press
AK500686 AB
MB991013
1. Confirm the clutch hub installation direction, and
fit onto the rear output shaft.
2. Use special tools press in the clutch hub.
• Remover (MD998801)
• Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer-200 (MD998814) AK500495AB
• Installer adapter (44) (MD998821)
NOTE: . 1. Hold the drive sprocket in a soft-jaws vice.
The clutch hub may fit loosely on the shaft, so that 2. Shift the clutch sleeve to the drive sprocket side.
installation is possible without using a press. 3. Using special tool Power steering lock nut special
spanner (MB991013) tighten the lock nut to the
>>C<< CLUTCH SLEEVE INSTALLTION specified torque of 255 ± 10 N⋅m.
Installation
direction
AK500685AB AK403516
Check that the clutch sleeve is in the correct direc- 4. Stake the two places of the lock nut as shown in
tion for installation. illustration.
MD998814
Ball bearing
MD998821
MD998801
AK403526AD
1
4
AK101106 AC
Disassembly steps
>>B<< 1. Snap ring
<<A>> >>A<< 2. Ball bearing
3. Viscous coupling
4. Rear output shaft
MANUAL TRANSMISSION OVERHAUL <V5MB1>
REAR OUTPUT SHAFT <V5MB1-J-ND2, NEZ, PD2>
22C-73
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.
<<A>> BALL BEARING REMOVAL • Installer cap (MD998812)
• Installer-200 (MD998814)
• Installer adapter (48) (MD998823)
AK101110 AF
MD998823
AK101111 AC
22C-74 MANUAL TRANSMISSION OVERHAUL <V5MB1>
TRANSFER DRIVE SHAFT <V5MB1-J-ND2, NEZ, PD2>
AK503431AB
DIsassembly steps
<<A>> >>A<< 1. Ball bearing REASSEMBLY SERVICE POINT
2. Transfer drive shaft
>>A<< BALL BEARING INSTALLATION
MD998830
MD998192
MD998801
AK503430 AB
1
2
AKX00425 AC
MD998801
MD998801
AK403462 AB
MD998818
MD998801
AK403523 AB
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
M1222003400175
3
2
AKX00429 AC
Slit
Spring pin
AK403524 AB
23-1
GROUP 23
AUTOMATIC
TRANSMISSION
CONTENTS
GROUP 23A
AUTOMATIC
TRANSMISSION
CONTENTS
GENERAL
M1231100100675
OUTLINE OF CHANGE
V5A5A type automatic transmission (5A/T) has been
newly adopted as well as the R4A5A/V4A5A type
automatic transmission (4A/T). The items for 5A/T
vehicles that differ from 4A/T vehicles are as follows:
SPECIFICATIONS
Item Specification
Transmission model R4A5A V4A5A-J-LEEP V4A5A-J-LEEL V5A5A
V4A5A-J-LEEY
Engine model 4D5 (Except high power) 4D5 (High
power)
Torque Type 3-element, 1-stage, 2-phase type
converter Lock-up Provided
Stall torque 1.62
ratio
Transmission type 4 forward speeds, 1 reverse speed, fully automatic 5 forward
speeds, 1
reverse speed,
fully automatic
Transmission 1st 2.842 3.789
gear ratio 2nd 1.495 2.057
3rd 1.000 1.421
4th 0.731 1.000
5th − 0.731
Reverse 2.720 3.865
Drive system 2WD Easy select 4WD Super select 4WD
Transfer type - 2-speed, constant mesh
Transfer gear High - 1.000
ratio Low - 1.900
Clutch Multi-disk type × 3 sets Multi-disc type 4
sets
Brake Multi-disk type × 2 sets Multi-disc type 2
sets, band type 1
set
Manual control system P-R-N-D-2-L + Overdrive (6 positions) P-R-N-D (4
positions) +
Sport mode (up,
down)
Shift pattern control Electronic control
Hydraulic control during shifting Electronic control (Each clutch hydraulically independently controlled)
Lock-up clutch control Electronic control
AUTOMATIC TRANSMISSION
GENERAL
23A-5
SECTIONAL VIEW
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
34 33 32 31 30 29
AC608404 AB
One-way clutch
AC603606AB
When the 1st gear is selected, the underdrive clutch, locked by the one-way clutch, the direct planetary
the one-way clutch (OWC-L), the low-reverse brake*, carrier rotates anti-clockwise with the fashion that the
the reduction brake and the one-way clutch (OWC- direct pinion revolves around the direct sun gear to
D) are participating. The driving force from the input obtain reduction ratio of the first gear. Since the out-
shaft is transmitted to the underdrive sun gear via the put planetary carrier is connected to the output annu-
underdrive clutch. The driving force transmitted to lus gear, the overdrive pinion gear is driven at the
the underdrive sun gear via the output pinion turns same time. However, since the overdrive planetary
the low reverse annulus gear clockwise and at the carrier is locked by the one-way clutch (OWC-L) and
same time turns the output planetary carrier anti- the reverse sun gear is free to rotate, it runs idle and
clockwise with the fashion that the output pinion has no effect on the rotation of the output planetary
revolves around the underdrive sun gear. However, carrier.
since the one-way clutch (OWC-L) and the low- NOTE: *: The low-reverse brake is activated only
reverse brake* are engaged at this time, the low- when the vehicle is stationary (10 km/h or less) and
reverse annulus gear is locked and the output plane- in the sport mode.
tary carrier only rotates anti-clockwise. This driving
force turns the direct pinion anti-clockwise via the
direct annulus gear. Since the direct sun gear is
2ND GEAR
Output planetary Direct annulus gear
Low-reverse carrier
Second brake annulus gear Underdrive Reduction brake
clutch
One-way clutch
Direct planetary
Input shaft
carrier
When the 2nd gear is selected, the underdrive reverse annulus gear also rotates anti-clockwise.
clutch, the second brake, the reduction brake and the This rotation of the low-reverse annulus gear is
one-way clutch (OWC-D) are participating. The sec- transmitted to the direct annulus gear via the output
ond brake is operated under the first gear condition, pinion, however, since the elements of the direct
the reverse sun gear is locked and the driving force planetary gear are the same as that of the first gear,
from the output annulus gear turns the overdrive rotation amount of the low-reverse annulus gear is
planetary carrier anti-clockwise with the fashion that added to the rotation of the output planetary carrier to
the overdrive pinion revolves around the reverse sun obtain the reduction ratio of the second gear.
gear. Since the overdrive planetary carrier is con-
nected with the low-reverse annulus gear, the low-
3RD GEAR
Direct planetary Direct annulus gear
Low-reverse carrier
annulus gear Underdrive Reduction brake
Overdrive clutch
clutch
One-way clutch
Direct planetary
Input shaft carrier
AC603608AB
When the 3rd gear is selected, the underdrive clutch, dition, the planetary gear set is locked and rotates as
the overdrive clutch, the reduction brake and the one body to transmit the driving force to the direct
one-way clutch (OWC-D) are participating. Since the annulus gear. The operation of the direct planetary
overdrive clutch connects the input shaft with the carrier elements is the same as the first gear, there-
overdrive planetary carrier and the low reverse annu- fore, the reduction ratio of the third gear is obtained
lus gear, the rotation speed of the underdrive sun by the configuration that the planetary gear set
gear that is connected with the input shaft by the rotates as one body under locked condition.
underdrive clutch and the rotation speed of the low-
reverse annulus gear become equal. Under this con-
4TH GEAR
Output planetary
Second brake carrier Underdrive clutch
Overdrive clutch
Direct annulus gear
Direct planetary
Input shaft carrier
AC603609AB
AUTOMATIC TRANSMISSION
GENERAL
23A-9
When the 4th gear is selected, the underdrive clutch, nected with the output planetary carrier, via the direct
the overdrive clutch and the direct clutch are partici- pinion, to the direct sun gear and turns it clockwise.
pating. The operating condition of input shaft ele- On the other hand, since the direct sun gear is con-
ments is the same as that of the third gear, where the nected with the direct planetary carrier by the direct
planetary gear set is locked to rotate as one body. clutch, they rotate anti-clockwise as one body to
The driving force input to the output planetary carrier obtain the reduction ratio of the fourth gear.
is transmitted from the direct annulus gear con-
5TH GEAR
Reverse clutch Direct planetary
Second
carrier
brake
Overdrive clutch
Direct annulus gear
Direct planetary
Input shaft carrier
Direct clutch
Overdrive planetary Overdrive
Output annulus gear
carrier pinion
AC603610AB
When the 5th gear is selected, the overdrive clutch, mitted to the output annulus gear. This driving force
the direct clutch and the second brake are participat- is then transmitted to the output planetary carrier that
ing. The driving force of the input shaft is transmitted is connected to the overdrive planetary carrier and
to the overdrive planetary carrier via the reverse the direct annulus gear. Since the operating ele-
clutch. On the other hand, since the reverse sun gear ments of the direct planetary carrier are the same as
is locked by the second brake, rotation amount of the that of the fourth gear, the reduction ratio of the fifth
overdrive pinion that revolves around the reverse gear is obtained by the revolution of the overdrive
sun gear is added to the rotation of the overdrive pinion.
planetary carrier and the resultant rotation is trans-
REVERSE
Direct annulus gear
Overdrive planetary carrier
Direct planetary
Input shaft
carrier
When the reverse gear is selected, the reverse sun gear is locked by the reduction brake, rotation
clutch, the low-reverse brake and the reduction amount of the direct pinion that revolves around the
brake are participation. The driving force of the input direct sun gear is added to rotate the direct planetary
shaft is transmitted to the reverse sun gear via the carrier clockwise. Thus the reduction ratio of reverse
reverse clutch. On the other hand, since the over- gear is obtained. At this time, the output pinion is
drive planetary carrier is locked by the low-reverse driven by the output planetary carrier, however, since
brake, the driving force of the reverse sun gear is the underdrive sun gear is free to rotate, it runs idle
transmitted to the output annulus gear via the over- and has no effect on the rotation of the output plane-
drive pinion as the clockwise rotating force. This driv- tary carrier.
ing force is then transmitted to the direct annulus
gear via the output planetary carrier. Since the direct
PARKING and NEUTRAL
Overdrive clutch
Low-reverse brake
Reduction brake
Second brake
Underdrive clutch
Input shaft
Direct clutch
AC603612AB
Inhibitor switch
Underdrive (UD) solenoid valve
Select switch
Reduction (RED) solenoid valve
Up shift switch
A/T fluid temperature warning lamp
CAN communication
M.U.T.-III
AC903575 AD
Item Function
Actuator A/T control relay Turns solenoid valve power supply circuit ON/OFF
DCC solenoid valve Regulates hydraulic pressure to damper clutch control
valve
LR/DIR solenoid valve Regulates hydraulic pressure to pressure control valve
2ND solenoid valve (for gear shift control)
UD solenoid valve
OD solenoid valve
RED solenoid valve
N range lamp Indicates that fail-safe is active and shows a diagnosis
code
Shift indicator lamp Indicates present shift stage by lamp in combination
meter
A/T fluid temperature warning lamp Gives a warning about A/T fluid temperature
SERVICE SPECIFICATIONS
M1231100300259
LUBRICANTS
M1231100400171
SEALANTS
M1231100500145
SPECIAL TOOLS
M1231100600368
MB991825
MB991826
MB991955
MB992006
AUTOMATIC TRANSMISSION
SPECIAL TOOLS
23A-15
Tool Number Name Use
MD998330 Oil pressure gauge (3.0 Hydraulic pressure measurement
(including MPa)
MD998331)
AC103525
MD998900 Joint
23A-16 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
TROUBLESHOOTING
DIAGNOSIS TROUBLESHOOTING FLOW
M1231104000153
NG
Check the A/T fluid Replace the A/T fluid
OK
Perform switch,
Inhibitor the repair
TPS check
AC212495AD
DIAGNOSTIC FUNCTION If there is a problem with any of the A/T system, the
M1231103300151 selector lever position indicator lamp will flash at a
SELECTOR LEVER POSITION INDICATOR rate of approximately once per second.
LAMP SYSTEM If the selector lever position indicator lamp is flashing
at a rate of approximately once per second, check
the diagnosis output.
Selector lever position indicator lamp flashing
item
• Input shaft speed sensor system
• Output shaft speed sensor system
• Solenoid valves system
• Non-synchronization at various shift ranges
• A/T control relay system
AC504108AB
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-17
NOTE: If the A/T fluid temperature warning lamp is METHOD OF ERASING THE DIAGNOSIS
illuminating, the A/T fluid temperature is high. (It illu- CODE
minates when the fluid is approximately 135°C or
Use the M.U.T.-III to erase the diagnosis code.
more and goes off when the fluid is approximately
(Refer to GROUP 00 − How to Use Troubleshooting/
115°C or less.)
Inspection Service Points .)
METHOD OF READING THE DIAGNOSIS ROAD TEST
CODE M1231100800500
SHIFT PATTERN
M1231126500714
Throttle
opening (%)
100
1 2 2 3 3 4
80
60
40
20
Throttle
opening (%)
100
1 2 2 3 3 4 4 5
80
60
40
20
Throttle
opening (%)
100
1 2 2 3 3 4
80
60
40
2 3 (L, 2) 3 4 (L, 2, D (OD-OFF))
1 2 (L)
20
Throttle
opening (%)
100
1 2 2 3 3 4 4 5
80
1 2 4 5
60 3 4
(Sport mode)
(Sport mode) (Sport mode)
40 2 3
(Sport mode)
20
Throttle
opening (%)
100
Throttle
opening (%)
100
40 Deceleration
lock-up zone
20
Throttle
opening (%)
100
Damper clutch Damper clutch engaged
80 disengaged
60
Partial lock-up
zone Deceleration
40
lock-up zone
20
Throttle
opening (%)
100
60
40 Deceleration
lock-up zone
20
A/T CONTROL
A/T SOLENOID
FLUID VALVE ASSEMBLY
TEMPERATURE
SENSOR
A/T-ECU
AC903903
Connector: B-10
Connector: B-15
Harness side Harness side
B-15 (B)
B-10 (B)
AC510056AD
AC510056AB
Connector: B-11
Harness side
B-11 (B)
AC510056AC
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-33
STEP 7. M.U.T.-III data list connector C-12 terminal No.44 and earth.
Item 07: A/T fluid temperature sensor (Refer to Data OK:
List Table P.23A-103.) • 3.8 − 4.0 V (at 20°C)
• 3.2 − 3.4 V (at 40°C)
Q: Is the check result normal?
• 1.7 − 1.9 V (at 80°C)
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent Q: Is the check result normal?
Malfunction ). YES : Go to Step 12.
NO : Replace the A/T-ECU. NO : Go to Step 11.
STEP 8. Connector check: B-11 intermediate STEP 11. Connector check: C-12 A/T-ECU
connector, C-12 A/T-ECU connector connector
Check for the contact with terminals. Check for the contact with terminals.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 14. YES : Go to Step 7.
NO : Repair the defective connector. NO : Repair the defective connector.
STEP 9. Measure the voltage at A/T control STEP 12. Connector check: B-10 intermediate
solenoid valve assembly connector B-15. connector, C-12 A/T-ECU connector
(1) Disconnect the connector, and measure the Check for the contact with terminals.
voltage between terminal 1 and earth at the Q: Is the check result normal?
wiring harness side. YES : Go to Step 13.
(2) Turn the ignition switch to the ON position. NO : Repair the defective connector.
OK: 4.5 − 4.9 V
Q: Is the check result normal? STEP 13. Check the harness between A/T control
YES : Go to Step 7. solenoid valve assembly connector B-15 terminal
NO : Go to Step 10. No.1 and A/T-ECU connector C-12 terminal No.44.
Check the output line for short-circuited or open cir-
STEP 10. Measure the voltage at A/T-ECU cuit.
connector C-12. Q: Is the check result normal?
(1) Connect A/T control solenoid valve assembly YES : Go to Step 7.
connector B-15. NO : Repair the wiring harness.
(2) Turn the ignition switch to the ON position.
(3) Measure the voltage between A/T-ECU STEP 14. Check the harness between A/T control
solenoid valve assembly connector B-15 terminal
No.2 and A/T-ECU connector C-12 terminal No.43.
Check the earth line for open circuit.
Q: Is the check result normal?
YES : Go to Step 7.
NO : Repair the wiring harness.
STEP 3. Measure the voltage at A/T control Q: Is the check result normal?
YES : Go to Step 5.
solenoid valve assembly connector B-15.
NO : Go to Step 7.
(1) Disconnect the connector, and measure the
voltage between terminal 1 and earth at the
wiring harness side. STEP 7. Connector check: B-10 intermediate
(2) Turn the ignition switch to the ON position. connector, C-12 A/T-ECU connector
OK: 4.5 − 4.9 V Check for the contact with terminals.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4. YES : Go to Step 8.
NO : Go to Step 6. NO : Repair the defective connector.
STEP 4. Measure the resistance at A/T control STEP 8. Check the harness between A/T control
solenoid valve assembly connector B-15. solenoid valve assembly connector B-15 terminal
Disconnect the connector, and measure the resist- No.1 and A/T-ECU connector C-12 terminal No.44.
ance between terminal 1 and 2 at the sensor side. Check the output line for short-circuited or open cir-
cuit.
OK:
• 16.7 − 20.5 kΩ (at 0°C) Q: Is the check result normal?
• 7.3 − 8.9 kΩ (at 20°C) YES : Go to Step 5.
• 3.4 − 4.2 kΩ (at 40°C) NO : Repair the wiring harness.
• 1.9 − 2.2 kΩ (at 60°C)
• 1.0 − 1.2 kΩ (at 80°C)
• 0.57 − 0.69 kΩ (at 100°C)
Q: Is the check result normal?
23A-36 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
IGNITION
SWITCH (IG1)
<4A/T, 5A/T-LHD>
<5A/T-RHD>
INPUT SHAFT
SPEED SENSOR
A/T-ECU
AC903904
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-37
Connector: B-10
Connector: C-34 <RHD>
Harness side
Harness side
C-34
B-10 (B)
AC510056AD
AC509930AG
Connector: B-11
Connector: C-52 <LHD>
Harness side
C-52
Harness side
B-11 (B)
AC510056AC
AC509613AG
Connector: B-17
Harness side Connectors: C-207, C-208 <LHD>
Junction block (Front view) Harness side
C-208
AC510056AE
AC509934 CX
Connector: C-12 <LHD>
Connectors: C-207, C-208 <RHD>
Junction block
A/T-ECU Harness side (Front view)
<RHD>
C-207
C-208
A/T-ECU AC509936 BZ
OPERATION
C-12 The input shaft speed sensor detects the speed of
Harness side the underdrive clutch retainer, and sends the infor-
mation to the A/T-ECU as a pulse signal.
AC510057AB
23A-38 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
DIAGNOSIS CODE SET CONDITIONS (3) Measure the voltage between A/T-ECU
The diagnosis code No.P1766 (P0715) is set if the connector C-12 terminal No.43 and earth.
input shaft speed sensor does not send a pulse sig- OK: 0.5 V or less
nal for one second or more while the 3rd gears are
engaged and the vehicle speed is 40 km/h or more Q: Is the check result normal?
YES : Go to Step 7.
(the output shaft speed sensor speed is 1,000 r/min
NO : Go to Step 5.
or more).
If the code No.P1766 (P0715) is set four times, the
transmission will be fixed in 3rd gear as a fail-safe STEP 5. Connector check: C-12 A/T-ECU
measure. However, the transmission can be down- connector
shifted to 2nd gear by operating the selector lever. Check for the contact with terminals.
Q: Is the check result normal?
PROBABLE CAUSES
YES : Go to Step 6.
• Malfunction of input shaft speed sensor
NO : Repair the defective connector.
• Malfunction of underdrive clutch retainer
• Damaged harness wires and connectors
• Malfunction of the A/T-ECU STEP 6. M.U.T.-III data list
Item 05: Input shaft speed sensor (Refer to data list
DIAGNOSIS PROCEDURE reference table P.23A-103).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
STEP 1. M.U.T.-III data list
Item 05: Input shaft speed sensor (Refer to data list 00 − How to Cope with Intermittent
reference table P.23A-103). Malfunction ).
NO : Replace the A/T-ECU.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent STEP 7. Connector check: B-11 intermediate
Malfunction ). connector, C-12 A/T-ECU connector
NO : Go to Step 2. Check for the contact with terminals.
Q: Is the check result normal?
YES : Go to Step 8.
STEP 2. Connector check: B-17 input shaft speed
NO : Repair the defective connector.
sensor connector
Check for the contact with terminals.
STEP 8. Check the harness between input shaft
Q: Is the check result normal?
YES : Go to Step 3. speed sensor connector B-17 terminal No.1 and
NO : Repair the defective connector. A/T-ECU connector C-12 terminal No.43.
Check the earth line for open circuit.
STEP 3. Measure the resistance at input shaft Q: Is the check result normal?
speed sensor connector B-17. YES : Go to Step 6.
NO : Repair the wiring harness.
Disconnect the connector, and measure the resist-
ance between terminal 1 and earth at the wiring har-
ness side. STEP 9. Measure the voltage at input shaft speed
OK: Continuity (Less than 2 Ω) sensor connector B-17.
(1) Disconnect the connector, and measure the
Q: Is the check result normal? voltage between terminal 3 and earth at the
YES : Go to Step 9.
wiring harness side.
NO : Go to Step 4.
(2) Turn the ignition switch to the ON position.
OK: System voltage
STEP 4. Measure the voltage at A/T-ECU
connector C-12. Q: Is the check result normal?
YES : Go to Step 12.
(1) Connect input shaft speed sensor connector B-
NO : Go to Step 10.
17.
(2) Turn the ignition switch to the ON position.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-39
STEP 10. Connectors check: C-208 J/B STEP 15. Check the harness between input shaft
connector, B-10 and C-52 <4A/T, 5A/T-LHD>or C- speed sensor connector B-17 terminal No.2 and
34 <5A/T-RHD> intermediate connector A/T-ECU connector C-12 terminal No.31.
Check for the contact with terminals. Check the output line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 11. YES : Go to Step 6.
NO : Repair the defective connector. NO : Repair the wiring harness.
STEP 11. Check the harness between input shaft STEP 16. Connector check: B-11 intermediate
speed sensor connector B-17 terminal No.3 and connector, C-12 A/T-ECU connector
junction block connector C-208 terminal No.2. Check for the contact with terminals.
Check the power supply line for short or open circuit. Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 17.
YES : Go to Step 6. NO : Repair the defective connector.
NO : Repair the wiring harness.
STEP 17. Check the harness between input shaft
STEP 12. Measure the voltage at input shaft speed sensor connector B-17 terminal No.2 and
speed sensor connector B-17. A/T-ECU connector C-12 terminal No.31.
(1) Disconnect the connector, and measure the Check the output line for open circuit.
voltage between terminal 2 and earth at the Q: Is the check result normal?
wiring harness side. YES : Go to Step 6.
(2) Turn the ignition switch to the ON position. NO : Repair the wiring harness.
OK: 4.5 − 4.9 V
Q: Is the check result normal? STEP 18. Measure the output wave pattern of the
YES : Go to Step 18. input shaft speed sensor at A/T-ECU connector
NO : Go to Step 13. C-12 (using an oscilloscope).
(1) Shift the selector lever to the D range.
STEP 13. Measure the voltage at A/T-ECU (2) Accelerate the vehicle to approximately 50 km/h
connector C-12. (shift range; 3rd).
(1) Disconnect input shaft speed sensor connector (3) Connect an oscilloscope, and measure the
B-17. voltage between A/T-ECU connector C-12
(2) Turn the ignition switch to the ON position. terminal No.31 and earth.
(3) Measure the voltage between A/T-ECU OK: A wave pattern such as the one
connector C-12 terminal No.31 and earth. shown on P.23A-110 (Check Procedure
OK: 4.5 − 4.9 V Using an Oscilloscope) should be output,
and the maximum value should be 4.8 V
Q: Is the check result normal? or more and the minimum value should
YES : Go to Step 16.
be 0.8 V or less. There should be no noise
NO : Go to Step 14.
in the output wave pattern.
Q: Is the check result normal?
STEP 14. Connector check: B-11 intermediate YES : Go to Step 6.
connector, C-12 A/T-ECU connector NO : Go to Step 19.
Check for the contact with terminals.
Q: Is the check result normal? STEP 19. Connector check: C-12 A/T-ECU
YES : Go to Step 15.
connector
NO : Repair the defective connector.
Check for the contact with terminals.
Q: Is the check result normal?
YES : Go to Step 20.
NO : Repair the defective connector.
23A-40 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
STEP 20. Replace the input shaft speed sensor STEP 21. Underdrive clutch retainer inspection
and then recheck the diagnosis code. Visually check the underdrive clutch retainer for dam-
(1) Replace the input shaft speed sensor. age.
(2) Test drive the vehicle. Q: Is the check result normal?
(3) Check if the diagnosis code is set. YES : Eliminate the cause of the noise.
Q: Is diagnosis code P1766 set? NO : Replace the underdrive clutch retainer.
YES : Go to Step 21.
NO : The inspection is complete.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-41
<4A/T, 5A/T-LHD>
<5A/T-RHD>
OUTPUT SHAFT
SPEED SENSOR
A/T-ECU
AC903905
23A-42 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
Connector: B-10
Connector: C-34 <RHD>
Harness side
Harness side
C-34
B-10 (B)
AC503225AE
AC509930AG
Connector: B-11
Connector: C-52 <LHD>
Harness side
C-52
Harness side
B-11 (B)
AC503225AD
AC509613AG
Connector: B-16
Connectors: C-207, C-208 <LHD>
B-16 (GR) Junction block (Front view)
Harness side Harness side
C-208
C-207
AC510056AF
AC509934 CX
Connector: C-12 <LHD>
Connectors: C-207, C-208 <RHD>
Junction block
A/T-ECU Harness side (Front view)
<RHD>
C-207
C-208
A/T-ECU AC509936 BZ
OPERATION
C-12 The output shaft speed sensor detects the speed of
Harness side the transfer drive gear, and sends the information to
the A/T-ECU as a pulse signal.
AC510057AB
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-43
DIAGNOSIS CODE SET CONDITIONS (2) Turn the ignition switch to the "ON" position.
If the output pulse from the output shaft speed sen- (3) Measure the voltage between A/T-ECU
sor has been lost for one second or more while the connector C-12 terminal No.43 and earth.
vehicle is being driven, it is judged that there is an OK: 0.5 V or less
open circuit or short circuit in the output shaft speed
sensor, and diagnosis code No.P1767 (P0720) is Q: Is the check result normal?
YES : Go to Step 7.
set.
NO : Go to Step 5.
If the code No.P1767 (P0720) is set four times, the
transmission will be fixed in 3rd gear as a fail-safe
measure. However, the transmission can be down- STEP 5. Connector check: C-12 A/T-ECU
shifted to 2nd gear by operating the selector lever. connector
Check for the contact with terminals.
PROBABLE CAUSES
Q: Is the check result normal?
• Malfunction of output shaft speed sensor
YES : Go to Step 6.
• Malfunction of output shaft <4A/T>
NO : Repair the defective connector.
• Malfunction of direct planetary carrier <5A/T>
• Damaged harness wires and connectors
• Malfunction of the A/T-ECU STEP 6. M.U.T.-III data list
Item 06: Output shaft speed sensor (Refer to data list
DIAGNOSIS PROCEDURE reference table P.23A-103).
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
STEP 1. M.U.T.-III data list
Item 06: Output shaft speed sensor (Refer to data list 00 − How to Cope with Intermittent
reference table P.23A-103). Malfunction ).
NO : Replace the A/T-ECU.
Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent STEP 7. Connector check: B-11 intermediate
Malfunction ). connector, C-12 A/T-ECU connector
NO : Go to Step 2. Check for the contact with terminals.
Q: Is the check result normal?
YES : Go to Step 8.
STEP 2. Connector check: B-16 output shaft
NO : Repair the defective connector.
speed sensor connector
Check for the contact with terminals.
STEP 8. Check the harness between output shaft
Q: Is the check result normal?
YES : Go to Step 3. speed sensor connector B-16 terminal No.1 and
NO : Repair the defective connector. A/T-ECU connector C-12 terminal No.43.
Check the earth line for open circuit.
STEP 3. Measure the resistance at output shaft Q: Is the check result normal?
YES : Go to Step 6.
speed sensor connector B-16.
NO : Repair the wiring harness.
Disconnect the connector, and measure the resist-
ance between terminal 1 and earth at the wiring har-
ness side. STEP 9. Measure the voltage at output shaft
OK: Continuity (Less than 2 Ω) speed sensor connector B-16.
(1) Disconnect the connector, and measure the
Q: Is the check result normal? voltage between terminal 3 and earth at the
YES : Go to Step 9.
wiring harness side.
NO : Go to Step 4.
(2) Turn the ignition switch to the ON position.
OK: System voltage
STEP 4. Measure the voltage at A/T-ECU
connector C-12. Q: Is the check result normal?
YES : Go to Step 12.
(1) Connect output shaft speed sensor connector B-
NO : Go to Step 10.
16.
23A-44 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
STEP 10. Connectors check: C-208 J/B STEP 15. Check the harness between output
connector, B-10 and C-52 <LHD>or C-34 <RHD> shaft speed sensor connector B-16 terminal No.2
intermediate connector and A/T-ECU connector C-12 terminal No.32.
Check for the contact with terminals. Check the output line for short circuit.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 11. YES : Go to Step 6.
NO : Repair the defective connector. NO : Repair the wiring harness.
STEP 11. Check the harness between output STEP 16. Connector check: B-11 intermediate
shaft speed sensor connector B-16 terminal No.3 connector, C-12 A/T-ECU connector
and junction block connector C-208 terminal Check for the contact with terminals.
No.2. Q: Is the check result normal?
Check the power supply line for short or open circuit. YES : Go to Step 17.
Q: Is the check result normal? NO : Repair the defective connector.
YES : Go to Step 6.
NO : Repair the wiring harness.
STEP 17. Check the harness between output
shaft speed sensor connector B-16 terminal No.2
STEP 12. Measure the voltage at output shaft and A/T-ECU connector C-12 terminal No.32.
speed sensor connector B-16. Check the output line for open circuit.
(1) Disconnect the connector, and measure the Q: Is the check result normal?
voltage between terminal 2 and earth at the YES : Go to Step 6.
wiring harness side. NO : Repair the wiring harness.
(2) Turn the ignition switch to the ON position.
OK: 4.5 − 4.9 V
STEP 18. Measure the output wave pattern of the
Q: Is the check result normal? output shaft speed sensor at A/T-ECU connector
YES : Go to Step 18. C-12 (using an oscilloscope).
NO : Go to Step 13. (1) Shift the selector lever to the D range.
(2) Accelerate the vehicle to approximately 50 km/h
STEP 13. Measure the voltage at A/T-ECU (shift range; 3rd.)
connector C-12. (3) Connect an oscilloscope, and measure the
(1) Disconnect output shaft speed sensor connector voltage between A/T-ECU connector C-12
B-16. terminal No.32 and earth.
(2) Turn the ignition switch to the "ON" position. OK: A wave pattern such as the one
(3) Measure the voltage between A/T-ECU shown on P.23A-110 (Check Procedure
connector C-12 terminal No.32 and earth. Using an Oscilloscope) should be output,
OK: 4.5 − 4.9 V and the maximum value should be 4.8 V
or more and the minimum value should
Q: Is the check result normal? be 0.8 V or less. There should be no noise
YES : Go to Step 16.
in the output wave pattern.
NO : Go to Step 14.
Q: Is the check result normal?
YES : Go to Step 6.
STEP 14. Connector check: B-11 intermediate NO : Go to Step 19.
connector, C-12 A/T-ECU connector
Check for the contact with terminals.
STEP 19. Connector check: C-12 A/T-ECU
Q: Is the check result normal? connector
YES : Go to Step 15.
Check for the contact with terminals.
NO : Repair the defective connector.
Q: Is the check result normal?
YES : Go to Step 20.
NO : Repair the defective connector.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-45
STEP 20. Replace the output shaft speed sensor STEP 21. Check the output shaft <4A/T> or direct
and then recheck the diagnosis code. planetary carrier <5A/T>.
(1) Replace the output shaft speed sensor. Visually check the output shaft <4A/T> or direct plan-
(2) Test drive the vehicle. etary carrier <5A/T> for damage.
(3) Check if the diagnosis code is set. Q: Is the check result normal?
Q: Is diagnosis code P1767 set? YES : Eliminate the cause of the noise.
YES : Go to Step 21. NO : Replace the output shaft <4A/T> or direct
NO : The inspection is complete. planetary carrier <5A/T>.
23A-46 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
INHIBITOR
SWITCH
A/T-ECU
C-207
B-10 (B)
AC510056AD
AC509934 CX
Connector: B-14
Harness side Connectors: C-207, C-208 <RHD>
Junction block
Harness side (Front view)
C-207
B-14 (B)
C-208
AC510056AG
AC509936 BZ
PROBABLE CAUSES
• Malfunction of the inhibitor switch
C-20 • Damaged harness wires and connectors
• Malfunction of the A/T-ECU
Harness side
DIAGNOSIS PROCEDURE
IGNITION
SWITCH (IG1)
<LHD>
<RHD>
INHIBITOR
SWITCH
A/T-ECU
B-14 (B)
B-10 (B)
AC510056AD AC510056AG
23A-50 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
C-208
A/T-ECU AC509936 BZ
OPERATION
C-20
The inhibitor switch detects the selector lever posi-
Harness side tion (P, R, N, D) which the driver has selected, and
sends the information to the ECU.
DIAGNOSIS PROCEDURE
AC509930AG
AC509934 CX
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-51
STEP 3. Connector check: B-14 Inhibitor switch STEP 6. Check the inhibitor switch.
connector, C-208 J/B connector, C-52 <LHD> or Refer to P.23A-118.
C-34 <RHD> and B-10 intermediate connector Q: Is the check result normal?
Check for the contact with terminals. YES : Go to Step 7.
Q: Is the check result normal? NO : Replace the inhibitor switch.
YES : Go to Step 4.
NO : Repair the defective connector.
STEP 7. Connector check: B-14 inhibitor switch
connector, C-20 A/T-ECU connector, B-10
STEP 4. Check the harness between inhibitor intermediate connector.
switch connector B-14 terminal No.7 and J/B Check for the contact with terminals.
connector C-208 terminal No 2. Q: Is the check result normal?
Check the power supply line for open circuit. YES : Go to Step 8.
Q: Is the check result normal? NO : Repair the defective connector.
YES : Go to Step 5.
NO : Repair the wiring harness.
STEP 8. Check the harness between inhibitor
switch connector B-14 terminal No.3, 2, 8, 1 A/T-
STEP 5. M.U.T.-III data list ECU connector C-20 terminal No.67, 56, 66, 55.
Item 34: Inhibitor switch (Refer to Data List Refer- Check the output line for open circuit.
ence Table P.23A-103). Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 5.
YES : Intermittent malfunction (Refer to GROUP NO : Repair the wiring harness.
00 − How to Cope with Intermittent
Malfunction ).
NO : Replace the A/T-ECU.
INHIBITOR SWITCH SYSTEM CIRCUIT STEP 2. Connector check: B-14 Inhibitor switch
Refer to P.23A-46. connector, B-10 intermediate connector, C-20 A/
OPERATION T-ECU connector
Refer to P.23A-46. Check for the contact with terminals.
Q: Is the check result normal?
DIAGNOSIS CODE SET CONDITIONS YES : Go to Step 3.
If the inhibitor switch has been sending multiple sig- NO : Repair the defective connector.
nals for at least 30 seconds, the circuit may be open
and diagnosis code No.P1771 (P0705) is set.
STEP 3. Check the harness between inhibitor
PROBABLE CAUSES switch connector B-14 terminal No.1, 8, 2, 3, 4, 5
• Malfunction of the inhibitor switch and A/T-ECU connector C-20 terminal No.55, 66,
• Damaged harness wires and connectors 56, 67, 68, 58.
• Malfunction of the A/T-ECU Check the output line for open circuit or short circuit.
Q: Is the check result normal?
DIAGNOSIS PROCEDURE YES : Go to Step 4.
NO : Repair the wiring harness.
STEP 1. Check the inhibitor switch.
Refer to P.23A-113. STEP 4. M.U.T.-III data list
Item 34: Inhibitor switch P.23A-103 (Refer to data list
Q: Is the check result normal?
YES : Go to Step 2.
reference table).
NO : Replace the inhibitor switch. Q: Is the check result normal?
23A-52 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
INHIBITOR SWITCH SYSTEM CIRCUIT STEP 2. Connector check: B-14 Inhibitor switch
Refer to P.23A-49. connector, B-10 intermediate connector C-20 A/T-
OPERATION ECU connector
Refer to P.23A-49. Check for the contact with terminals.
Q: Is the check result normal?
DIAGNOSIS CODE SET CONDITIONS YES : Go to Step 3.
If the inhibitor switch has been sending multiple sig- NO : Repair the defective connector.
nals for at least 30 seconds, the circuit may be open
and diagnosis code No.P1771 (P0705) is set.
STEP 3. Check the harness between inhibitor
PROBABLE CAUSES switch connector B-14 terminal No.3, 2, 8, 1 and
• Malfunction of the inhibitor switch A/T-ECU connector C-20 terminal No.67, 56, 66,
• Damaged harness wires and connectors 55.
• Malfunction of the A/T-ECU Check the output line for open circuit or short circuit.
Q: Is the check result normal?
DIAGNOSIS PROCEDURE YES : Go to Step 4.
NO : Repair the wiring harness.
STEP 1. Check the inhibitor switch.
Refer to P.23A-118. STEP 4. M.U.T.-III data list
Item 34: Inhibitor switch (Refer to Data List Refer-
Q: Is the check result normal?
YES : Go to Step 2.
ence Table P.23A-103).
NO : Replace the inhibitor switch. Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP
00 − How to Cope with Intermittent
Malfunction ).
NO : Replace the A/T-ECU.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-53
FUSIBLE
LINK 23
NOTE
RELAY : UNDERDRIVE
SOLENOID VALVE
BOX : SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL SOLENOID
VALVE
: LOW AND REVERSE
SOLENOID VALVE
A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
A/T-ECU
FUSIBLE
LINK 23
NOTE
RELAY : UNDERDRIVE
SOLENOID VALVE
BOX : SECOND
SOLENOID VALVE
: OVERDRIVE
SOLENOID VALVE
: DAMPER CLUTCH
CONTROL SOLENOID
VALVE
: LOW AND REVERSE
SOLENOID VALVE
: REDUCTION
SOLENOID VALVE
A/T
CONTROL
RELAY
A/T CONTROL
SOLENOID
VALVE ASSEMBLY
A/T-ECU
Wire colour code
B : Black LG : Light green G : Green L : Blue W : White Y : Yellow SB : Sky blue
BR : Brown O : Orange GR : Grey R : Red P : Pink V : Violet PU : Purple
AC903909
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-55
AC509975AO AC510056AB
A-19X
A/T-ECU
<RHD>
AC510163AG
A/T-ECU
Connector: B-10
Harness side
AC510057AD
B-10 (B)
AC510056AD
Connector: C-20 <LHD>
Connector: B-11
B-11 (B)
AC510056AC A/T-ECU
C-20
Harness side
AC510057AC
23A-56 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
STEP 3. Connector check: B-15 A/T control STEP 8. M.U.T.-III actuator test
solenoid valve assembly connector Item 01: Low-reverse solenoid valve
Check for the contact with terminals. OK: Operating sound can be heard.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 4. YES : Intermittent malfunction (Refer to GROUP
NO : Repair the defective connector. 00 − How to Cope with Intermittent
Malfunction .)
NO : Replace the A/T-ECU.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-57
STEP 9. Connector check: B-15 A/T control STEP 11. Connector check: A-19X A/T control
solenoid valve assembly connector relay connector, B-10 intermediate connector
Check for the contact with terminals. Check for the contact with terminals.
Q: Is the check result normal? Q: Is the check result normal?
YES : Go to Step 10. YES : Go to Step 12.
NO : Repair the defective connector. NO : Repair the defective connector.
STEP 10. Measure the resistance at A/T control STEP 12. Check the harness between A/T control
solenoid valve assembly connector B-15. solenoid valve assembly connector B-15 terminal
Disconnect the connector, and measure the resist- No.10 and A/T control relay connector A-19X
ance between terminal No.6 and No.10 at the sole- terminal No.3.
noid valve side. Check the power supply line for short or open circuit.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 8.
YES : Go to Step 11. NO : Repair the wiring harness.
NO : Check the solenoid valve harness.
STEP 8. M.U.T.-III actuator test STEP 12. Check the harness between A/T control
Item 02: Underdrive solenoid valve solenoid valve assembly connector B-15 terminal
OK: Operating sound can be heard. No.9 and A/T control relay connector A-19X
Q: Is the check result normal? terminal No.3.
YES : Intermittent malfunction (Refer to GROUP Check the power supply line for short or open circuit.
00 − How to Cope with Intermittent Q: Is the check result normal?
Malfunction .) YES : Go to Step 8.
NO : Replace the A/T-ECU. NO : Repair the wiring harness.
SOLENOID VALVE SYSTEM CIRCUIT STEP 4. Measure the resistance at A/T control
Refer to P.23A-53. solenoid valve assembly connector B-15.
OPERATION Disconnect the connector, and measure the resist-
Refer to P.23A-53. ance between terminal No.5 and No.9 at the solenoid
valve side.
DIAGNOSIS CODE SET CONDITIONS OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
If the drive terminal voltage of the overdrive solenoid
Q: Is the check result normal?
valve is 3.0 V or less, it is judged that there is a short
YES : Go to Step 5.
circuit or open circuit in the overdrive solenoid valve, NO : Check the overdrive solenoid valve and
and diagnosis code No.P1776 (P0765) is output. solenoid valve harness.
If diagnosis code No.P1776 (P0765) is output 4
times, the transmission is fixed in 3rd as a fail-safe
measure. STEP 5. Measure the voltage at A/T-ECU
connector C-19.
PROBABLE CAUSES (1) Connect A/T control solenoid valve assembly
• Malfunction of overdrive solenoid valve connector B-15.
• Damaged harness wires and connectors (2) Turn the ignition switch to the ON position.
• Malfunction of the A/T-ECU (3) Measure the voltage between A/T-ECU
connector C-19 terminal No.14 and earth.
DIAGNOSIS PROCEDURE OK: 6 − 9 V
Q: Is the check result normal?
STEP 1. M.U.T.-III diagnosis code YES : Go to Step 8.
NO : Go to Step 6.
Q: Are diagnosis codes P1774 (P0755) and P1775
(P0760) set?
YES : Go to Step 9. STEP 6. Connector check: B-11 intermediate
NO : Go to Step 2. connector, C-19 A/T-ECU connector
Check for the contact with terminals.
STEP 2. M.U.T.-III actuator test Q: Is the check result normal?
Item 04: Overdrive solenoid valve YES : Go to Step 7.
OK: Operating sound can be heard. NO : Repair the defective connector.
STEP 10. Measure the resistance at A/T control STEP 12. Check the harness between A/T control
solenoid valve assembly connector B-15. solenoid valve assembly connector B-15 terminal
Disconnect the connector, and measure the resist- No.9 and A/T control relay connector A-19X
ance between terminal No.5 and No.9 at the solenoid terminal No.3.
valve side. Check the power supply line for short or open circuit.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C) Q: Is the check result normal?
Q: Is the check result normal? YES : Go to Step 8.
YES : Go to Step 11. NO : Repair the wiring harness.
NO : Check the solenoid valve harness.
DIAGNOSIS CODE SET CONDITIONS STEP 3. Connector check: B-15 A/T control
If the drive terminal voltage of the reduction solenoid solenoid valve assembly connector
valve is 3.0 V or less, it is judged that there is a short Check for the contact with terminals.
circuit or open circuit in the reduction solenoid valve, Q: Is the check result normal?
and diagnosis code No.P1777 (P0770) is set. YES : Go to Step 4.
If diagnosis code No.P1777 (P0770) is set, the trans- NO : Repair the defective connector.
mission is fixed in 3rd as a fail-safe measure.
connector C-20 terminal No.51 and earth. STEP 9. Connector check: B-15 A/T control
OK: 6 − 9 V solenoid valve assembly connector
Q: Is the check result normal? Check for the contact with terminals.
YES : Go to Step 8. Q: Is the check result normal?
NO : Go to Step 6. YES : Go to Step 10.
NO : Repair the defective connector.
STEP 6. Connector check: B-11 intermediate
connector, C-20 A/T-ECU connector STEP 10. Measure the resistance at A/T control
Check for the contact with terminals. solenoid valve assembly connector B-15.
Q: Is the check result normal? Disconnect the connector, and measure the resist-
YES : Go to Step 7. ance between terminal No.8 and No.10 at the sole-
NO : Repair the defective connector. noid valve side.
OK: 2.7 − 3.4 Ω (A/T fluid temperature 20°C)
STEP 7. Check the harness between A/T control Q: Is the check result normal?
solenoid valve assembly connector B-15 terminal YES : Go to Step 11.
No.8 and A/T-ECU connector C-20 terminal No.51. NO : Check the solenoid valve harness.
Check the output line for short or open circuit.
Q: Is the check result normal? STEP 11. Connector check: A-19X A/T control
YES : Go to Step 8. relay connector, B-10 intermediate connector
NO : Repair the wiring harness. Check for the contact with terminals.
Q: Is the check result normal?
STEP 8. M.U.T.-III actuator test YES : Go to Step 12.
Item 5: Reduction solenoid valve NO : Repair the defective connector.
OK: Operating sound can be heard.
Q: Is the check result normal? STEP 12. Check the harness between A/T control
YES : Intermittent malfunction (Refer to GROUP solenoid valve assembly connector B-15 terminal
00 − How to Cope with Intermittent No.10 and A/T control relay connector A-19X
Malfunction ). terminal No.3.
NO : Replace the A/T-ECU. Check the power supply line for short or open circuit.
Q: Is the check result normal?
YES : Go to Step 8.
NO : Repair the wiring harness.
Code No.P1779 (1st), P1780 (2nd), P1781 (3rd), P1782 (4th), P1784 (reverse): Gear incorrect ratio <4A/
T>
Code No.P1779 (1st), P1780 (2nd), P1781 (3rd), P1782 (4th), P1783 (5th), P1784 (reverse): Gear
incorrect ratio <5A/T>
• Malfunction of reverse clutch system (for diagno- STEP 3. Hydraulic pressure test
sis code P1784) Each hydraulic pressure of the elements below,
• Malfunction of direct clutch system (for diagnosis which diagnosis codes indicate, should be within the
codes P1782, P1783) standard value.
• Malfunction of reduction brake system (for diag- • diagnosis code P1779: Underdrive clutch, low-
nosis codes P1779, P1780, P1781, P1784) reverse brake, reduction brake
• Malfunction of one-way clutch (OWC-L) system • diagnosis code P1780: Underdrive clutch, sec-
(for diagnosis code P1779) ond brake, reduction brake
• Malfunction of one-way clutch (OWC-D) system • diagnosis code P1781: Underdrive clutch, over-
(for diagnosis code P1779, P1780, P1781) drive clutch, reduction brake
• diagnosis code P1782: Underdrive clutch, over-
DIAGNOSIS PROCEDURE drive clutch, direct clutch
• diagnosis code P1783: Overdrive clutch, direct
STEP 1. M.U.T.-III diagnosis code clutch, second brake
Either of diagnosis codes P1779, P1780, P1781, • diagnosis code P1784: Reverse clutch, low-
P1782, P1783 or P1784 is set, the input shaft speed reverse brake, reduction brake
sensor or output shaft speed sensor is defective. OK: Refer to Hydraulic Pressure Test P.23A-
Q: Are diagnosis codes P1766 (P0715) or P1767 120.
(P0720) output? Q: Is the check result normal?
YES diagnosis code P1766 (P0715) is set : Refer to YES : Go to Step 6.
diagnosis code P1766 (P0715) input shaft NO some hydraulic pressures are abnormal : Go
speed sensor system P.23A-36. to Step 5.
YES diagnosis code P1767 (P0720) is set : Refer to NO all hydraulic pressure are abnormal : Go to
diagnosis code P1767 (P0720) output shaft Step 4.
speed sensor system P.23A-41.
NO : Go to Step 2.
STEP 4. Adjust the line pressure and recheck the
diagnosis code.
STEP 2. M.U.T.-III diagnosis code (1) Adjust the line pressure (Refer to P.23A-129).
Either of diagnosis codes P1779, P1780, P1781, (2) Test drive the vehicle.
P1782, P1783 or P1784 is set, the corresponding (3) Check the diagnosis code.
solenoid valve is defective.
Q: Is the diagnosis code set?
Q: Is either of diagnosis code P1773 (P0750), P1774 YES : Go to Step 5.
(P0755), P1775 (P0760), P1776 (P0765), P1777 NO : The inspection is complete.
(P0770) output?
YES diagnosis code P1773 (P0750) is set : Refer to
diagnosis code P1773 (P0750): Low- STEP 5. Disassemble, clean and assemble the
reverse solenoid valve system P.23A-53. valve body and recheck the diagnosis code.
YES diagnosis code P1774 (P0755) is set : Refer to (1) Check the mounting bolts for looseness, and the
diagnosis code P1774 (P0755): Underdrive O-ring, solenoid valve and valve body for
solenoid valve system P.23A-57. damage.
YES diagnosis code P1775 (P0760) is set : Refer to Replace the valve body assembly if the damages
diagnosis code P1775 (P0760): Second are thought to be irreparable.
solenoid valve system P.23A-58. (2) Test drive the vehicle.
YES diagnosis code P1776 (P0765) is set : Refer to (3) Check the diagnosis code.
diagnosis code P1776 (P0765): Overdrive Q: Is the diagnosis code set?
solenoid valve system P.23A-60. YES : Go to Step 7.
YES diagnosis code P1777 (P0770) is set : Refer to NO : The inspection is complete.
diagnosis code P1777 (P0770): Reduction
solenoid valve system P.23A-61 .
NO : Go to Step 3. STEP 6. Replace the A/T-ECU and then recheck
the diagnosis code.
(1) Replace the A/T-ECU.
(2) Test drive the vehicle.
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-67
(3) Check the diagnosis code. necessary.
Q: Is the diagnosis code set?
• If diagnosis code P1779, P1780, P1781,
YES : Go to Step 7. P1782 are set individually or in a group,
NO : The inspection is complete. replace the underdrive clutch.
• If diagnosis code P1781, P1782, P1783 are
set individually or in a group, replace the over-
STEP 7. Check the A/T internal clutch and brake, drive clutch.
and then recheck the diagnosis code. • If diagnosis code P1784 is set, replace the
(1) Check the following clutches or brakes according reverse clutch.
to the output diagnosis codes, replace if • If diagnosis code P1779, P1784 are set indi-
vidually or in a group, replace the low-reverse
brake.
• If diagnosis code P1780, P1783 are set indi-
vidually or in a group, replace the second
brake.
• If diagnosis code P1782, P1783 are set indi-
vidually or in a group, replace the direct
clutch.
• If diagnosis code P1779, P1780, P1781,
P1784 are set individually or in a group,
replace the reduction brake.
• If diagnosis code P1779 is set, replace the
one-way clutch (OWC-L).
• If diagnosis code P1779, P1780, P1781 are
set individually or in a group, replace the one-
way clutch (OWC-D).
(2) Test drive the vehicle.
(3) Check the diagnosis code.
Q: Is the diagnosis code set?
YES : Eliminate the cause of the noise.
NO : The inspection is complete.
YES : Refer to diagnosis code P1778 (P0740): (3) Check the diagnosis code.
Damper clutch solenoid valve system
Q: Is the diagnosis code set?
P.23A-62. YES : Go to Step 7.
NO : Go to Step 3. NO : The inspection is complete.
STEP 3. M.U.T.-III data list STEP 6. Replace the A/T-ECU and then recheck
• Item 17: Damper clutch solenoid valve duty ratio the diagnosis code.
(Refer to data list reference table P.23A-103). (1) Replace the A/T-ECU.
• Item 10: Damper clutch slip amount (Refer to (2) Test drive the vehicle.
data list reference table P.23A-103). (3) Check the diagnosis code.
Q: Is the check result normal? Q: Is the diagnosis code set?
YES : Go to Step 6. YES : Go to Step 7.
NO : Go to Step 4. NO : The inspection is complete.
STEP 4. Hydraulic pressure test STEP 7. Disassemble, clean and assemble the
Measure the torque converter hydraulic pressure. valve body and recheck the diagnosis code.
(Refer to P.23A-120.) (1) Check the mounting bolts for looseness, and the
OK: Refer to Hydraulic Pressure Test P.23A- O-ring, solenoid valve and valve body for
120. damage.
Q: Is the check result normal? Replace the valve body assembly if the damages
YES : Go to Step 6. are thought to be irreparable.
NO : Go to Step 5. (2) Test drive the vehicle.
(3) Check the diagnosis code.
STEP 5. Adjust the line pressure and recheck the Q: Is the diagnosis code set?
diagnosis code. YES : Check the torque converter and replace it if
(1) Adjust the line pressure (Refer to P.23A-129). necessary.
(2) Test drive the vehicle. NO : The inspection is complete.
IGNITION FUSIBLE
SWITCH (IG1) LINK 23
RELAY
BOX
<4A/T, 5A/T-LHD>
<5A/T-RHD>
A/T
CONTROL
RELAY
A/T-ECU
SOLENOID
VALVE
POWER SOURCE
A-19X
A/T-ECU
<RHD>
AC510163AG
A/T-ECU
Connector: A-115
C-20
Harness side
A-115 Harness side
AC510057AC
AC509975AO
A/T-ECU
<RHD>
C-34
AC509930AG
C-19 C-52
Harness side
Harness side
AC510057AD AC509613AG
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-71
Connectors: C-207, C-208 <LHD> STEP 2. Check the A/T control relay connector
Junction block (Front view) Harness side
Refer to P.23A-118.
C-208
Q: Is the check result normal?
YES : Go to Step 3.
C-207 NO : Replace the A/T control relay.
RELAY
BOX
AC510282 AB
A/T-ECU
Harness side
<RHD>
A-115
AC509975AO
A/T-ECU
C-12
Harness side
AC510057AB
23A-74 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
STEP 3. Check whether the diagnosis code is (4) Turn the ignition switch to the ON position.
reset. (5) Check if the diagnosis code is set.
Check again if the diagnosis code is set. (6) Turn the ignition switch to the LOCK (OFF)
(1) Turn the ignition switch to the ON position. position.
(2) Erase the diagnosis code. Q: Is code No.U1073 set?
(3) Turn the ignition switch to the LOCK (OFF) YES : Go to Step 1.
position. NO : The procedure is complete.
YES : Go to Step 4.
STEP 4. Replace the ASTC-ECU
NO : Intermittent malfunction in CAN busline
After replacing the ASTC-ECU, re-check the A/T
between ASTC-ECU and A/T-ECU (Refer to
diagnosis code output.
GROUP 00 − How to Use Troubleshooting/
Inspection Service Points − How to Cope Q: Is the diagnosis code output?
with Intermittent Malfunction ). YES : Replace the A/T-ECU.
NO : The check is end.
SYMPTOM PROCEDURES
A/T-ECU
DIAGNOSIS
CONNECTOR
AC509577AD
23A-82 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
Harness side
(Front side)
C-119 (GR)
AC509930AM
AC509613AN
A/T-ECU
<RHD>
C-119 (GR)
A/T-ECU AC509932AU
C-20
CAUTION
Harness side If there is any problem in the CAN bus lines, an
incorrect diagnosis code may be set. Diagnose
the CAN bus lines before the diagnosis codes
(Refer to GROUP 54C, CAN bus-line diagnostic
AC510057AC
flow ).
TECHNICAL DESCRIPTION (COMMENT)
Connector: C-22 <LHD> If the M.U.T.-III can not communicate with the A/T
system, the CAN bus lines may be defective. If the A/
T system does not work, the A/T-ECU or its power
supply circuit may be defective.
PROBABLE CAUSES
Harness side
(Front side)
• Damaged wiring harness or connector
• Malfunction of the A/T-ECU
C-22 (B)
AC509611AJ
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-83
DIAGNOSIS PROCEDURE (2) Turn the ignition switch to the ON position.
(3) Diagnose the CAN bus line.
STEP 1. M.U.T.-III CAN bus diagnostics Q: Is the check result normal?
Use M.U.T.-III to diagnose the CAN bus lines. YES : Check and repair the A/T system.
(1) Connect M.U.T.-III to the 16-pin diagnosis NO : Repair the CAN bus lines (Refer to GROUP
connector. 54C, CAN bus line Diagnostic flow ).
Inspection Procedure 7: Shift Shock when Shifting from N to D and Long Delay
Inspection Procedure 8: Shift Shock when Shifting from N to R and Long Delay
COMMENTS ON TROUBLE SYMPTOM YES <diagnosis code P1770 (P0705) is set> : Refer
If abnormal shock or delay of two seconds or more to diagnosis code P1770 (P0705): Inhibitor
occurs when the selector lever is shifted from N to R switch system P.23A-46 <4A/T>, P.23A-49
range while the engine is idling, the cause is proba- <5A/T>.
bly abnormal pressure in reverse clutch and low- YES <diagnosis code P1771 (P0705) is set> : Refer
reverse clutch or a malfunction of the reverse clutch, to diagnosis code P1771 (P0705): Inhibitor
low-reverse brake, valve body or throttle position switch system P.23A-51 <4A/T>, P.23A-52
sensor. <5A/T>.
NO : Go to Step 4.
PROBABLE CAUSES
• Malfunction of low-reverse solenoid valve
STEP 4. M.U.T.-III data list
• Malfunction of input shaft speed sensor
Item 12: Low-reverse solenoid valve duty ratio (Refer
• Malfunction of the inhibitor switch
to data list reference table P.23A-103).
• Abnormal reverse clutch pressure
• Abnormal low-reverse brake pressure Q: Is the check result normal?
• Malfunction of accelerator pedal position sensor YES : Go to Step 5.
• Malfunction of the reverse clutch NO : Replace the A/T-ECU.
• Malfunction of low-reverse brake
• Malfunction of valve body STEP 5. Check when shift shock occurs.
• Malfunction of the A/T-ECU
Q: Does the shift shock occur when the vehicle starts
moving?
DIAGNOSIS PROCEDURE YES : Go to Step 7.
NO : Go to Step 6.
STEP 1. M.U.T.-III actuator test
Item 01: Low-reverse solenoid valve STEP 6. Hydraulic pressure test
OK: Operating sound can be heard. Measure the hydraulic pressure for reverse clutch
Q: Is the check result normal?
and low-reverse clutch when the selector lever is
YES : Go to Step 2. shifted from N to R range.
NO : Replace the low-reverse solenoid valve. OK: Refer to P.23A-120.
Q: Is the check result normal?
STEP 2. M.U.T.-III data list YES : Go to Step 10.
Item 05: Input shaft speed sensor (Refer to data list NO : Go to Step 9.
reference table P.23A-103).
Q: Is the check result normal? STEP 7. Check when shift shock occurs.
YES : Go to Step 3. Q: Does the shift shock always occur?
NO : Refer to diagnosis code P1766: Input shaft YES : Go to Step 9.
speed sensor system P.23A-36. NO : Go to Step 8.
Inspection Procedure 9: Shift Shock when Shifting from N to D, N to R and Long Delay
IGNITION
SWITCH (IG1)
OVERDRIVE
SWITCH Wire colour code
B : Black
LG : Light green
G : Green
L: Blue
W : White
Y: Yellow
SB : Sky blue
BR : Brown
O : Orange
GR : Grey
R : Red
P : Pink
V : Violet
PU: Purple
A/T-ECU
AC903911
23A-94 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
A/T-ECU
<RHD> Harness side
C-129
AC509932DE
A/T-ECU
C-207
AC510057AC
AC509930AG C-208
AC509936 BZ
OPERATION
During driving with 4th gear, when the overdrive
switch is turned ON, A/T-ECU performs a downshift
C-52
control to 3rd gear.
Harness side
COMMENTS ON TROUBLE SYMPTOM
If downshifting does not occur when overdrive switch
is turned on while driving in 4th gear, or upshifting
AC509613AG
does not occur when overdrive switch is turned off
Connector: C-129 <LHD>
while driving in 3rd gear, the cause is probably a
problem in the overdrive switch system.
PROBABLE CAUSES
Harness side • Malfunction of the overdrive switch
• Damaged harness wires and connectors
• Malfunction of the A/T-ECU
C-129
AC509611CX
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-95
DIAGNOSIS PROCEDURE YES : Go to Step 6.
NO : Repair the wiring harness.
A/T-ECU
4LLc
OPERATION
DETECTION
SWITCH
AC903912
Connector: A-115
Connector: C-19 <LHD>
Harness side
A-115 A/T-ECU
<RHD>
AC509975AO
Harness side
C-19
Harness side
B-05
AC510056AH AC510057AD
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-97
Connector: C-29 <LHD> STEP 2. Check the 4LLc operation detection
switch.
Refer to P.23A-119.
Harness side Q: Is the check result normal?
YES : Go to Step 3.
NO : Replace the 4LLc operation detection
switch.
C-29
AC509611CW
STEP 3. Measure the voltage at 4LLc operation
detection switch connector B-05.
(1) Disconnect the connector, and measure the
Connector: C-29 <RHD> resistance between terminal 1 and earth at the
wiring harness side.
(2) Turn the ignition switch to the ON position.
OK: System voltage
Harness side Q: Is the check result normal?
YES : Go to Step 4.
NO : Go to Step 5.
C-29
AC509930BI STEP 4. M.U.T.-III data list
Item 31: 4LLc operation detection switch (Refer to
data list reference table P.23A-103).
OPERATION
• A battery voltage is applied to the 4LLc operation Q: Is the check result normal?
detection switch output terminal (terminal 1) from YES : Intermittent malfunction (Refer to GROUP
the A/T-ECU (terminal 9) via the resistance in the 00 − How to Cope with Intermittent
unit. Malfunction ).
• The 4LLc operation detection switch is grounded NO : Replace the A/T-ECU.
through the transfer case to the vehicle body.
STEP 5. Measure the voltage at A/T-ECU
COMMENTS ON TROUBLE SYMPTOM connector C-19.
If the transmission shifts to 4th gear when the trans- (1) Disconnect 4LLc operation detection switch
fer lever is in the 4L position, the cause is probably a connector B-05.
malfunction of the 4LLc operation detection switch. (2) Turn the ignition switch to the ON position.
(3) Measure the voltage between A/T-ECU
PROBABLE CAUSES
connector C-19 terminal No.9 and earth.
• Malfunction of the 4LLc operation detection
switch OK: System voltage
• Damaged harness wires and connectors Q: Is the check result normal?
• Malfunction of the A/T-ECU YES : Go to Step 6.
NO : Go to Step 8.
DIAGNOSIS PROCEDURE
STEP 6. Connector check: B-05 4LLc operation
STEP 1. M.U.T.-III data list detection switch connector, A-115 and C-29
Item 31: 4LLc operation detection switch (Refer to intermediate connector, C-19 A/T-ECU connector
data list reference table P.23A-103). Check for the contact with terminals.
Q: Is the check result normal? Q: Is the check result normal?
YES : Intermittent malfunction (Refer to GROUP YES : Go to Step 7.
00 − How to Cope with Intermittent NO : Repair the defective connector.
Malfunction ).
NO : Go to Step 2.
23A-98 AUTOMATIC TRANSMISSION
TROUBLESHOOTING
YES : Go to Step 9.
STEP 7. Check the harness between 4LLc
NO : Repair the defective connector.
operation detection switch connector B-05
terminal No.1 and A/T-ECU connector C-19
terminal No.9. STEP 9. Check the harness between 4LLc
Check the power supply line for open circuit. operation detection switch connector B-05
terminal No.1 and A/T-ECU connector C-19
Q: Is the check result normal?
terminal No.9.
YES : Go to Step 4.
NO : Repair the wiring harness.
Check the power supply line for short circuit.
Q: Is the check result normal?
YES : Go to Step 4.
STEP 8. Connector check: B-05 4LLc operation
NO : Repair the wiring harness.
detection switch connector, A-115 and C-29
intermediate connector, C-19 A/T-ECU connector
Check for the contact with terminals.
Q: Is the check result normal?
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-99
IGNITION
SWITCH (IG1)
<LHD>
<RHD>
INHIBITOR
SWITCH
<LHD>
<RHD>
SHIFT
SWITCH
SELECT SHIFT ASSEMBLY
SWITCH SWITCH
<LHD> <LHD>
<RHD> <RHD>
A/T-ECU
Connector: B-10
Connector: C-52 <LHD>
Harness side
C-52
Harness side
B-10 (B)
AC510056AD
AC509613AG
Connector: B-14
Harness side Connector: C-172 <RHD>
B-14 (B)
AC510056AG C-172
AC903865AM
A/T-ECU
<RHD>
C-172
A/T-ECU AC903853BF
AC510057AC
Harness side
OPERATION
The shift switch assembly detects the shift range
C-34 (sport mode) which the driver has selected, and
sends the information to the A/T-ECU.
YES : Go to Step 4.
STEP 11. Connector check: C-172 shift switch
NO : Repair the wiring harness.
assembly connector
Check for the contact with terminals.
STEP 17. Check the shift switch assembly.
Q: Is the check result normal?
Refer to P.23A-134.
YES : Go to Step 12.
NO : Repair the defective connector. Q: Is the check result normal?
YES : Go to Step 18.
NO : Replace the shift switch assembly.
STEP 12. Measure the voltage at shift switch
assembly connector C-172
(1) Disconnect the connector, and measure the STEP 18. Connectors check: C-172 shift switch
voltage between terminal 1 and earth at the assembly connector, C-20 A/T-ECU connector
wiring harness side. and C-34 <RHD> or C-52 <LHD> intermediate
(2) Selector lever position: D connector
(3) Ignition switch: ON Check for the contact with terminals.
OK: System voltage Q: Is the check result normal?
YES : Go to Step 19.
Q: Is the check result normal?
YES : Go to Step 13. NO : Repair the defective connector.
NO : Go to Step 15.
STEP 19. Check the harness between shift switch
STEP 13. Connectors check: C-20 A/T-ECU assembly connector C-172 terminal No.6 and A/T-
connector, C-34 <RHD> or C-52 <LHD> ECU connector C-20 terminal No.58.
intermediate connector Check the output line for short-circuited or open cir-
Check for the contact with terminals. cuit.
STEP 14. Check the harness between shift switch STEP 20. Check the shift switch assembly.
assembly connector C-172 terminal No.4 and A/T- Refer to P.23A-134.
ECU connector C-20 terminal No.57. Q: Is the check result normal?
Check the output line for short-circuited or open cir- YES : Go to Step 21.
cuit. NO : Replace the shift switch assembly.
Q: Is the check result normal?
YES : Go to Step 15. STEP 21. Connectors check: C-172 shift switch
NO : Repair the wiring harness. assembly connector, C-20 A/T-ECU connector
and C-34 <RHD> or C-52 <LHD> intermediate
STEP 15. Connector check: B-10, C-34 <RHD> or connector
C-52 <LHD> intermediate connector Check for the contact with terminals.
Check for the contact with terminals. Q: Is the check result normal?
YES : Go to Step 22.
Q: Is the check result normal?
NO : Repair the defective connector.
YES : Go to Step 16.
NO : Repair the defective connector.
STEP 22. Check the harness between shift switch
STEP 16. Check the harness between shift switch assembly connector C-172 terminal No.5 and A/T-
assembly connector C-172 terminal No.1 and ECU connector C-20 terminal No.68.
inhibitor switch connector B-14 terminal No.3. Check the output line for short-circuited or open cir-
Check the power supply line for short or open circuit. cuit.
Item No. Inspection item Test description Inspection condition Normal status
1 Low-reverse solenoid • Actuate solenoid • Ignition switch: ON When solenoid valve
valve valve indicated by • Selector lever is actuated, operating
2 Underdrive solenoid M.U.T.-III for 5 position: P sound is audible.
valve seconds at duty • Engine: Stopped
ratio of 50%. • Accelerator pedal:
3 Second solenoid valve • Other remaining Released
4 Overdrive solenoid valve solenoid valve are
5 Reduction solenoid not ON.
valve <5A/T>
6 Damper clutch control
solenoid valve
7 1st indicator lamp <5A/ Illuminate each Shift indicator lamp
T> indicator lamp for 3 illuminates.
8 2nd indicator lamp <5A/ seconds to the signal
T> from the M.U.T.-III.
9 3rd indicator lamp <5A/
T>
10 4th indicator lamp <5A/
T>
11 5th indicator lamp <5A/
T> <5A/T>
12 A/T control relay A/T control relay is • Data list No.8
OFF for three • During test: 0 V
seconds. • Normal: System
voltage (V)
AC501291AB
AUTOMATIC TRANSMISSION
TROUBLESHOOTING
23A-107
NOTE: *: Using M.U.T.-III actuator function, check that the terminal voltage when the shift indicator is illumi-
nated is as follows.
Terminal No. 5 17 4
Check item Shift indicator A Shift indicator B Shift indicator C
Shift 1 9V 0V 0V
indicator 2 0V 9V 0V
3 9V 9V 0V
4 0V 0V 9V
5 9V 0V 9V
40
20
0 0
(ms) (ms)
AC001874AH AC001875AJ
ON-VEHICLE SERVICE
ESSENTIAL SERVICE NOTE: If the A/T fluid has a burnt smell, or if it has
become very contaminated or dirty, it means that
A/T FLUID CHECK the A/T fluid has become contaminated by minute
M1231103700212 particles form bushings (metal) or worn parts. In
CAUTION such a case, the transmission needs to be over-
When replacing the transmission with a new one, hauled and the A/T fluid cooler line needs to be
overhauling the existing transmission, or driving flushed out.
in a harsh condition, the A/T fluid cooler line
should always be flushed out and A/T fluid
should be replaced with a new one.
1. Drive the vehicle until the A/T fluid temperature
reaches the normal temperature (70 − 80°C)
NOTE: Measure A/T fluid temperature using
M.U.T.III.
NOTE:
Fluid level
[mm] 10 AC000846AB
0
HOT
-10
5. Check that the A/T fluid level is between the HOT
-20
marks on the oil level gauge. If the A/T fluid level
is too low, add more A/T fluid until the level
-30 Gauge reaches between the HOT marks.
-40
40 60 80 Automatic transmission fluid: DIA QUEEN
A/T fluid temperature [ ] ATF SP III
AC503813AB NOTE: If the A/T fluid level is too low, the oil pump
Check the fluid level referring to the characteris- draws air into the system along with the A/T fluid,
tics chart shown at left if it takes some time to and air bubbles will thus from in the fluid circuit.
reach the normal operation temperature of A/T This will cause a drop in fluid pressure and cause
fluid (70 − 80°C). the shift points to change and the clutches and
brakes to slip.
2. Park the vehicle on a level surface.
If the A/T fluid level is too high, the gear will churn
3. Move the selector lever to all positions to fully the A/T fluid and cause bubbles to develop, which
charge the torque converter and the fluid lines can then cause the same problems as when the
with A/T fluid, and then move the selector lever to A/T fluid is too low.
the P position. In either case, the air bubbles can cause over-
4. After wiping away any dirt from around the oil heating and oxidation of the A/T fluid, and also
level gauge, pull out the oil level gauge and check
the level of A/T fluid.
23A-112 AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
prevent the valves, clutches and brakes from Discharge amount: Approx. 2.0 L
operating normally. In addition, if bubbles develop 4. Install the drain plug with a gasket in between,
in the A/T fluid, the A/T fluid can overflow from the and tighten it to the specified torque.
transmission vent holes and be mistaken for
Tightening torque: 32 ± 2 N⋅m
leaks.
6. Securely re-insert the oil level gauge. CAUTION
Stop pouring in the A/T fluid once 5.5 L has been
A/T FLUID CHANGE poured in.
M1231104100279
5. Pour the new A/T fluid in through the oil filler tube.
CAUTION
Before replacing the transmission with a new Amount to add: Approx. 5.5 L
one, overhauling the existing transmission, or 6. Repeat the operation in step 2.
connecting the cooler pipe to the transmission, 7. Pour in new A/T fluid through the oil filler tube.
the A/T fluid cooler line should always be flushed
Amount to add: Approx. 3.5 L
out.
In you have an A/T fluid changer, use the A/T fluid NOTE: Carry out steps 2 and 7 so that at least 8.0
changer to flush the A/T fluid. If you do not have an L has been discharged from the cooler hose. After
A/T fluid changer, follow the procedure given below. this, discharge a small quantity of A/T fluid and
check for contamination. If the A/T fluid is contam-
inated, repeat steps 6 and 7.
AC503850AB
AC000846AB
Drain plug 11.Check that the A/T fluid level on the oil level
gauge is at the COLD mark. if it is not up to this
AC503264AB
mark, add more A/T fluid.
3. Remove the drain plug at the bottom of the 12.Drive the vehicle until the A/T fluid temperature
transmission case to drain out the remaining A/T reaches the normal temperature (70 − 80°C), and
fluid. then re check the A/T fluid level.
AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
23A-113
NOTE: The COLD mark is for reference only; the Driving conditions: N range, idling
HOT marks should be used as the standard for Discharge amount: Approx. 3.5 L
judgment.
NOTE: A/T fluid temperature using M.U.T.-III. CAUTION
Stop pouring in the A/T fluid once 3.5 L has been
NOTE: poured in.
Fluid level
[mm] 10 3. Pour in new A/T fluid through the oil filler tube.
0 Amount to add: Approx. 3.5 L
HOT
-10
4. Repeat the operation in step 2 and 3.
-20
-30
NOTE: Carry out steps 2 and 3 so that at least 8.0
Gauge
L has been discharged from the cooler hose. After
-40
40 60 80 this, discharge a small quantity of A/T fluid and
A/T fluid temperature [ ] check for contamination. If the A/T fluid is contam-
AC503813AB
inated, repeat steps 2 and 3.
5. Carry out the procedure in "A/T Fluid Change"
Check the fluid level referring to the characteris-
from step 2 onwards.
tics chart shown at left if it takes some time until
reaching the normal operation temperature of A/T
INHIBITOR SWITCH CONTINUITY CHECK
fluid (70 − 80°C.) M1231101900328
13.When A/T fluid is under the specified level, top up
A/T fluid. When A/T fluid is over the specified
level, drain the excessive A/T fluid from the drain
plug to adjust A/T fluid level to the specified level.
14.Securely insert the oil level gauge into the oil filler
tube.
AC503910AE
<4A/T>
AC503850AB
Manual 23 ± 4 N·m
TRANSFER OIL CHECK <4WD>
M1231112400305
control
lever lower
Mounting bolts 11 ± 1 N·m
AC502640AB
AC503967AB
Filler plug
Transfer oil
AC700330AM
AC509434AC AC509434AD
Check the continuity between terminal of the brown Check the continuity between terminal of the black
connector and earth indicated in the illustration. connector and earth indicated in the illustration.
Transfer lever position Specified condition Transfer lever position Specified condition
4HLc and 4LLc Continuity (Less than 2 2H and 4H Open circuit
Ω) 4HLc and 4LLc Continuity (Less than 2
2H and 4H Open circuit Ω)
AC509434AB
AC509434AG
A B
C D E F
<LHD> <RHD>
I H G G H I
K J J K
AC509780 AB
1 2 3 4 5 6
7 8 9 10
AC501840 AC
AC509434AE
A/T
ATFfluid
AC103441AD
23A-120 AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
<5A/T>
Measurement condition Standard hydraulic pressure MPa
Selector Shift Engine Underd Revers Overdri Direct Low- Second Reducti Torque
lever position speed rive e ve clutch reverse brake on convert
position (r/min) clutch clutch clutch pressur brake pressu brake er
pressur pressur pressur e [DC] pressur re [2B] pressur pressur
e [UC] e [RC] e [OC] e [LB] e [RB] e [TR]
P − 2,500 − − − − 0.26 − − 0.26 − 0.22 −
0.36 0.36 0.36
R Reverse 2,500 − 1.27 − − − 1.27 − − 1.27 − 0.50 −
1.77 1.77 1.77 0.73
N − 2,500 − − − − 0.26 − − 0.26 − 0.22 −
0.36 0.36 0.36
Sport 1st gear 2,500 0.98 − − − − 0.98 − − 0.98 − 0.50 −
mode 1.05 1.05 1.05 0.73
2nd gear 2,500 0.98 − − − − − 0.98 − 0.98 − 0.50 −
1.05 1.05 1.05 0.73
3rd gear 2,500 0.78 − − 0.78 − − − − 0.78 − 0.45 −
0.90 0.90 0.88 0.72
4th gear 2,500 0.78 − − 0.78 − 0.78 − − − − 0.45 −
0.90 0.90 0.88 0.72
5th gear 2,500 − − 0.78 − 0.78 − − 0.78 − − 0.45 −
0.90 0.88 0.88 0.72
NOTE: When the torque converter pressure is measured, the engine speed should be 1,500 r/min or less.
NA BCD EF G H I J K L M Q
O P
AC904046AB
AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
23A-127
<5A/T>
NA BCD EF G H I J K L M T S R Q
O P
Section a - a
U
AC904047 AB
23A-128 AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
HYDRAULIC CIRCUIT
M1231103900250
<4A/T> (Neutral)
1 2 3 4 5
7
6 6 6 6
8
9 10
11
12
13
14 15 16 17 18
19 20 21 22 23
24
25 26
R ND
P2
L
29
28
27 30
31 ACX01967AE
8 8 8 8 8 8
9
12
10 11
13
14
15
16 17 18 19 20
21 22 23 24 25 26
28
27
29
RP D
N
33
31
30 32
34
AC603759AB
Standard value: 1.01 − 1.05 MPa (Change in 1. Apply the parking brake, and check that the
pressure for a single full of the adjusting selector lever moves smoothly and accurately to
screw: 0.035 MPa) each position.
4. Install the valve body cover, and then pour in the 2. Check that the engine starts when the selector
specified amount of A/T fluid. lever is in the N or P position, and that it does not
5. Repeat the hydraulic pressure test (Refer to start when the selector lever is in any other
P.23A-120.) Readjust the line pressure if position.
necessary. 3. Start the engine, release the parking brake, and
check that the vehicle moves forward when the
SELECTOR LEVER OPERATION CHECK selector lever is moved from N position to the D,
M1231101300274 2, L position or sport mode, and that the vehicle
<5A/T> reverses when the selector lever is moved to the
P R position.
R
4. Stop the engine.
N 5. Turn the ignition switch to ON position. Check that
D the backup lamp illuminates and the buzzer
sounds when the selector lever is moved from P
position to R position.
: Operation when the pushbutton is kept pressed.
: Operation when the pushbutton is not pressed.
AC801688 AD
<4A/T>
P
R
N
D
2
L
2 4
11 ± 2 N·m 19 ± 3 N·m
19 ± 3 N·m
1 5
6 5
Semi-drying sealant:
3M ATD Part No.8660 or
23 ± 4 N·m
equivalent
11 ± 2 N·m
11 ± 2 N·m
8
11 ± 2 N·m
AC509716AB
2
1
2.2 ± 0.4 N·m
4
3
AC900376AB
1 6
2.2 ± 0.4 N·m
2
11 ± 2 N·m
3 7 19 ± 3 N·m
5
19 ± 3 N·m
8
4
9 8
10
11 ± 2 N·m
AC800082 AB
<2WD>
Pre-removal Operation Post-installation Operation
• Under Skid Plate and Engine Room Under Cover • No.2 Crossmember Assembly Installation (Refer to
Removal (Refer to GROUP 51 − Under Cover .) GROUP 32 − Rear Engine Mounting .)
• A/T Fluid Draining (Refer to P.23A-112.) • Starter Assembly Installation (Refer to GROUP 16 −
• Propeller Shaft Removal (Refer to GROUP 25 − Propeller Starter Motor Assembly ).
Shaft .) • Pipe Assembly Installation (Refer to P.23A-141.)
• Front Exhaust Pipe Removal (Refer to GROUP 15 − Front • Transmission Control Cable Connection Installation
Exhaust Pipe Main Muffler .) (Refer to P.23A-131.)
• Transmission Control Cable Connection Removal (Refer • Front Exhaust Pipe Installation (Refer to GROUP 15 −
to P.23A-131.) Front Exhaust Pipe Main Muffler .)
• Pipe Assembly Removal (Refer to P.23A-141.) • Propeller Shaft Installation (Refer to GROUP 25 − Propel-
• Starter Assembly Removal (Refer to GROUP 16 − Starter ler Shaft .)
Motor Assembly ). • A/T Fluid Supplying (Refer to P.23A-112.)
• No.2 Crossmember Assembly Removal (Refer to GROUP • Under Skid Plate and Engine Room Under Cover Installa-
32 − Rear Engine Mounting .) tion (Refer to GROUP 51 − Under Cover .)
3
48 ± 6 N·m
9
7
6 6 8
25 ± 4 N·m
24 ± 3 N·m
49 ± 3 N·m
8
4 48 ± 6 N·m
22 ± 4 N·m
11 ± 1 N·m
2N
8.9 ± 0.9 N·m
50 ± 7 N·m
AC904029 AB
11 6
48 ± 6 N·m
9 3
8 8 10
25 ± 4 N·m
24 ± 3 N·m
49 ± 3 N·m
4
7
8
5 48 ± 6 N·m
22 ± 4 N·m
11 ± 1 N·m
2N
8.9 ± 0.9 N·m
50 ± 7 N·m
AC904030 AB
AC004836AG
10
6
48 ± 6 N·m
8 9 3
8
48 ± 6 N·m
49 ± 3 N·m
7
4
7
48 ± 6 N·m
5
1
11 ± 1 N·m 22 ± 4 N·m
2N
9.0 ± 1.0 N·m
50 ± 7 N·m AC903384 AD
INSTALLATION SERVICE POINT Press the torque converter into the transmission
>>A<< TRANSMISSION ASSEMBLY INSTALLA- properly, and then assembly into the engine.
TION
Approx. 21.0 mm
AC004836AI
AUTOMATIC TRANSMISSION
A/T FLUID COOLER
23A-141
A/T FLUID COOLER
REMOVAL AND INSTALLATION
M1231128700372
10
11
1
5 48 ± 7 N·m
2N
7
6
2 N
3
12 ± 2 N·m 4 9
AC509593 AE
11 ± 2 N·m
5 11 ± 2 N·m 48 ± 7 N·m
5.0 ± 1.0 N·m
4 2N
5.0 ± 1.0 N·m
N2
5.0 ± 1.0 N·m 1
3
6
AC807090 AC
<LHD>
12 ± 2 N·m
4
5
2
1
AC509596AB
4WD INDICATOR-ECU
REMOVAL AND INSTALLATION
M1231119100015
Refer to GROUP 22A .
23B-1
GROUP 23B
AUTOMATIC
TRANSMISSION
OVERHAUL <R4A5>
CONTENTS
GENERAL INFORMATION
M1233000101848
TRANSMISSION MODEL
Transmission model Engine model Vehicle model
R4A5A-J-LH 4D56 DI-D DOHC KA4T
SECTIONAL VIEW
70NT
68NT 17NT
21NT
38NT
25NT
AK801605
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
GENERAL INFORMATION
23B-3
HYDRAULIC CIRCUIT
1 2 3 4 5
7 8
9 10
11
12 13 14 15
16 17 18 19 20
21
22 23
R ND
P
26
24 27
25
AK600223AB
GENERAL SPECIFICATIONS
M1233000201191
Item Specifications
Transmission model R4A5A
Torque converter Type 3-element, 1-stage, 2-phase type
Stall torque ratio 1.62
Lock-up Present
Transmission type Electronically controlled 4-speed full-automatic
Gear ratio 1st 2.842
2nd 1.495
3rd 1.000
4th 0.731
Reverse 2.720
SERVICE SPECIFICATIONS
M1233000300979
TORQUE SPECIFICATIONS
M1233023101623
Item N⋅m
Transmission case to extension housing mounting bolt 48 ± 6
Cable end bracket mounting bolt 48 ± 6
Clip mounting bolt 11 ± 1
Air breather hose bracket mounting bolt 11 ± 1
Harness clamp bracket mounting bolt 26 ± 5
Oil filler tube mounting bolt 44 ± 8
Output shaft support mounting bolt 23 ± 3
Oil pump mounting bolt 23 ± 3
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
VALVE BODY SPRING IDENTIFICATION
23B-5
Item N⋅m
Converter housing to transmission case mounting bolt 48 ± 6
Valve body mounting bolt 11 ± 1
Oil temperature sensor mounting bolt 11 ± 1
Detent spring mounting bolt 6.0 ± 1.0
Oil filter mounting bolt 6.0 ± 1.0
Oil pan mounting bolt 11 ± 1
Manual control lever mounting nut 21.5 ± 3.5
Output shaft speed sensor mounting bolt 11 ± 1
Input shaft speed sensor mounting bolt 11 ± 1
Inhibitor switch mounting bolt 11 ± 1
Cover mounting bolt 11 ± 1
Solenoid support mounting bolt 6.0 ± 1.0
Separating plate mounting bolt 6.0 ± 1.0
Lower valve body mounting bolt 11 ± 1
Upper valve body mounting bolt 11 ± 1
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
Thickness mm Identification color Thickness mm Identification color
1.6 Brown 2.4 Blue
1.7 None 2.5 Brown
1.8 Blue 2.6 None
1.9 Brown 2.7 Blue
2.0 None 2.8 Brown
2.1 Blue 2.9 None
2.2 Brown 3.0 Blue
2.3 None
Thrust race (For adjustment of input shaft end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.4 None 2.2 None
1.6 None 2.4 None
1.8 None 2.6 None
2.0 None
Snap ring (For adjustment of overdrive clutch return spring retainer end play)
Thickness mm Identification color Thickness mm Identification color
1.48 Brown 1.58 None
1.53 Black 1.63 Brown
Pressure plate (For adjustment of second brake end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Snap ring (For adjustment of center support and brake reaction plate end play)
Thickness mm Identification color Thickness mm Identification color
2.2 None 2.4 Brown
2.3 Blue 2.5 None
Snap ring (For adjustment of reverse clutch end play)
Thickness mm Identification color Thickness mm Identification color
1.6 None 2.3 Blue
1.7 Blue 2.4 Brown
1.8 Brown 2.5 None
1.9 None 2.6 Blue
2.0 Blue 2.7 Brown
2.1 Brown 2.8 None
2.2 None
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
SEALANTS
23B-7
Pressure plate (For adjustment low/reverse brake end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
SEALANTS
M1233000501114
LUBRICANT(S)
M1233000400415
SPECIAL TOOLS
M1233000600743
D998727
8
48 ± 6 N·m
7
10
48 ± 6 N·m
1 6
2
5
4
3
44 ± 8 N·m 11 ± 1 N·m
26 ± 5 N·m
AK800428 AB
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION AND EXTENSION HOUSING
23B-11
Disassembly steps CAUTION
1. Oil level gauge • Completely degrease the FIPG-applied sur-
2. Oil filler tube face so that water and oil including the old
3. Harness clamp bracket sealant cannot adhere to the surface coated
4. Air breather hose bracket
with the sealant. Never touch the degreased
5. Clip
6. Cable end bracket
surface by hand.
7. Harness bracket • Make sure the starting point and the ending
8. Harness bracket point are about the middle between the bolts.
>>A<< 9. Extension housing
10. Transmission
AKX00006 AD
EXTENSION HOUSING
DISASSEMBLY AND REASSEMBLY
M1233007600120
2 8
1
5
4
AK602526AB
MB990938
Sealing cap
MB990929
1.5 mm 1.5 mm
A K 6 0 2 5 3 1AB A K 6 0 2 5 3 2AB
A K 6 0 2 5 3 3A B
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1233101200013
6
11 ± 1 N·m
3 7
1 5
11 ± 1 N·m
4
2 21.5 ± 3.5 N·m
16
11 ± 1 N·m
14 15
11 ± 1 N·m 13
11 ± 1 N·m
11 ± 1 N·m
11 12
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m 10
8
11 ± 1 N·m
9 AK800429AB
Apply automatic
transmission fluid
to all moving parts
before installation.
38
37
28 32 34
35
31
25 27 33
30
22 24 26
29 36
21 23 20 20
20 20
18
17
19
AK503511AD
41
40
23 ± 3 N·m
39
48 ± 6 N·m
46 51
50
44 49
47 48
Apply automatic
transmission fluid
45 to all moving parts
42 before installation.
43 AK503512 AE
54 58
56 57
52
55
53 62
60
63
59
Apply automatic
transmission fluid
to all moving parts
before installation.
61
AKX00019 AG
70
68
66 80
23 ± 3 N·m
65
64
71
69
67
79
77
74
81
76
73
78
Apply automatic
transmission fluid
to all moving parts
before installation.
75
72 AK800433 AB
Snap ring
AK603561
AK403341
AK403345AB
AK701362AB
6. Remove the twenty oil pan mounting bolts and
then use the special tool Oil pan FIPG cutter
O-ring
(MD998727) to remove the oil pan.
AK403349AB
AK403347
AK403350AB
AK700990AB
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
23B-21
Oil seals
Detent lever
Pin
Manual control
shaft
Parking roller
Oil strainer
AK403351AB rod AK403353AB
12.Remove the oil strainer and two oil seals. 15.Remove the pin, and then remove the manual
control shaft, two O-rings, detent lever and
parking roller rod.
4 3 2 1
AK403352AB
AK403355AB
Spring pin
17.Remove the ten oil pump mounting bolts.
18.Install special tool Oil pump remover (MD998333)
into the bolt hole shown in the illustration.
AK403378AB
MD998333
AK403356AB
23B-22 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
AK403361
AK403358
AK403362
Overdrive
26.Remove the snap ring.
clutch hub
Second brake
AK403359AD
AK403363AB
AK403365
AK403369
29.Remove the pressure plate, brake plates and
brake discs. 33.Remove the snap ring.
AK403366AD AK403370
30.Remove the thrust bearing No.7. 34.Remove the brake plates, brake discs, and
NOTE: The thrust bearing No.7 may be attached pressure plate.
to the low/reverse annulus gear.
AK403371
AK403367
35.Remove the wave spring.
23B-24 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
Snap ring
NOTE: The thrust bearing No.11 may be attached
to the underdrive clutch hub.
Thrust
Bearing
bearing
retainer
No.11
AK403380AD
39.Remove the thrust bearing No.11 and underdrive
clutch.
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
23B-25
43.Remove the thrust bearing No.13 and bearing 1. Install a new gasket and output shaft support.
retainer. 2. Tighten the eight output shaft support mounting
NOTE: The thrust bearing No.13 may be attached bolts to the specified torque of 23 ± 3 N⋅m.
to the output shaft support.
CAUTION
Bearing retainer
Output shaft
support AK403379AB
AKX00062 AG
44.Remove the eight output shaft support mounting
bolts, and then remove the output shaft support Make sure the thrust bearing is mounted in the
and gasket. correct direction.
Thrust bearing
REASSEMBLY No.13
CAUTION
• Never reuse any gasket, O-ring, and oil seal. Bearing
retainer
Always replace them with new ones.
• Never use any product other than blue petro-
latum jelly or white vaseline to lubricate or
hold parts during assembly.
• Apply ATF to friction elements, rotating parts,
AK403380AD
and sliding parts before installation.Soak new
clutch discs or brake discs in ATF for at least 3. Install the bearing retainer and thrust bearing
two hours before installing them. No.13 onto the output shaft.
• Never apply sealant or adhesive to gaskets.
• When a bushing requires replacement,
replace the assembly of which the bushing
forms a part.
• Never use any cloth gloves or any rags during
reassembly. Use only nylon cloth or paper
towels if necessary.
• Change also the ATF in the cooler circuit.
CAUTION
Never reuse a gasket.
Output shaft
support AK403379AB
23B-26 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13
AKX00061AE
AK403443
AKX00066AE
AK403445
CAUTION CAUTION
Output flange
Underdrive clutch
hub
AKX00069AE AKX00072 AG
Make sure thrust bearing No.10 is mounted in the Make sure thrust bearing No.9 is mounted in the
correct direction. correct direction.
10.Apply vaseline or petroleum jelly on the thrust 12.Apply vaseline or petroleum jelly on the thrust
bearing No.10, and then install it on the bearing No.9, and then install on the output
underdrive clutch hub. flange.
CAUTION
Measure and record the thickness of the thrust
race No.8 to be assembled.
AK403447
AK403449AD
AK403451 AB
AK800431AB
Thrust race No.8 End play
15.Remove the two output shaft support mounting AKX00078AD
(1) Install the snap ring used for fixing the center
support used.
MB991603
AK403371
AK403453AB
end play of center support. (2) Install special tool Clearance dummy plate
NOTE: When pushing the output shaft in, be (MB991632) onto the position shown in the
sure to push them in to the point where the illustration instead of the pressure plate for the
center support touches the snap ring. low/reverse brake. Install the six brake disc,
five brake plate and snap ring.
Standard value
Center support
Snap ring
Low/Reverse
brake piston AKX00081AC
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
23B-31
CAUTION CAUTION
Pay close attention to the assembly direction of Pay close attention to the shape and assembly
the reaction plate. direction of the brake plate A installation.
MB991632
AKX00083 AC AKX00084 AD
(3) Install the reaction plate and snap ring that (7) Next, install special tool Clearance dummy
was used. plate (MB991632) instead of the pressure
(4) Install a dial gauge onto special tool Dial plate for the second brake. Install the four
gauge extension (MD998913) so that the end brake discs and three brake plates.
contacts the brake reaction plate. Measure the (8) Install the return spring, second brake and
end play by moving special tool Clearance snap ring.
dummy plate (MB991632).
(5) Select the snap ring installed in step 19 (3) so
MD998913
that the end play is within the standard value.
Then, reassemble. Moving
amount
Standard value: 0 − 0.16 mm
(For brake reaction plate end play) MB991632
AKX00085 AC
(11)Install the pressure plate selected in step (9), (12)Install a dial gauge onto special tool Dial
and install the return spring, second brake and gauge extension (MD998913) so the end
snap ring again. contacts the special tool. Move special tool
Clearance dummy plate (MB991632) and
MD998913 measure the moving amount. Select a
pressure plate with a thickness that
corresponds to the measured moving amount
from the following table.
Standard value (reference): 1.65 − 2.11 mm
(For low/reverse brake end play)
A
MB991632
AKX00086AC
less than 2.1 Make sure thrust bearing No.7 is mounted in the
2.1 or more − 2.4 B correct direction.
less than 2.3
2.3 or more − 2.6 A
less than 2.5
2.5 or more − 2.8 0
less than 2.7
2.7 or more − 3.0 1
less than 2.9
Thrust bearing No.7
(13)Remove the parts installed in steps 19 (1) to
(12). AK403366AD
AK403396
AK403361
AK403394
AK403395
23B-34 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
Reaction
plate
AK403362
CAUTION
Thrust
bearing No.4
AKX00099 AD
Return spring
Thrust bearing No.4
AK403360AD
Thrust
bearing No.3
Make sure thrust bearing No.3 is mounted in the Make sure thrust bearing No.2 is mounted in the
correct direction. correct direction.
Thrust bearing No.3
Overdrive
clutch hub
AK403359AD AK403404
32.Apply vaseline or petroleum jelly on the thrust 34.Install the reverse and overdrive clutch.
bearing No.3, and then install on the overdrive Thrust bearing No.2
clutch hub.
33.Install the overdrive clutch hub.
AK403405AD
AK403566AD
CAUTION
CAUTION • Completely degrease the FIPG-applied sur-
Never reuse a gasket. face so that water and oil including the old
sealant cannot adhere to the surface coated
MD998412
with the sealant. Never touch the degreased
surface by hand.
• Evenly squeeze out the sealant so that it is
not insufficient or excessive.
L1
AK403406AB
AK403407AB
Parking
roller rod
Detent
lever
AK403455AB
Outer spring
4 3 2 1
Inner spring
O-ring
AK403408AB AKA00051AB
Pin
4 3 2 1
AK403352AB
CAUTION
Pay close attention to the installation direction of
the oil seal.
Detent lever
Oil seals
Control shaft
AK503726AD
50.Install the oil strainer and two new oil seals. Install
the oil seals so that the notched section is
oriented as shown in the illustration.
Snap ring
AK602028AC
AK403350AB
AK403416AE
AK403347
AK403456
AK403346AB
23B-40 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
TRANSMISSION
Transmission
side
AK403457AB
• Heat the parking gear to 160 − 180 °C and 69.Install the output shaft speed sensor.
shrink fit up to the stepped section of the out-
70.Tighten the output shaft speed sensor mounting
put shaft. Do not heat for longer than neces-
bolt to the specified torque 11 ± 1 N⋅m.
sary at this time.
Snap ring
AK403341
Parking gear AK800430AB
71.Install the input shaft speed sensor.
65.Install the parking gear and snap ring.
72.Tighten the input shaft speed sensor mounting
bolt to the specified torque 11 ± 1 N⋅m.
CAUTION
Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful not to
damage the oil seal lip when installing the torque
converter.
Inhibitor switch
AK601368AC
AK503859AB
Apply automatic 14
transmission fluid
to all moving parts
before installation. 17
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB
AK700994AB
Snap ring
AK403382AB Align the two return spring holes with the two projec-
tions on the overdrive clutch piston, and then assem-
1. Set special tools as shown in the illustration. ble.
• Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
>>D<< SNAP RING INSTALLATION
2. Compress the return spring, and remove the snap
ring. MD999590
MD998924
>>B<< REVERSE CLUTCH PISTON 1. Set special tools as shown in the illustration.
INSTALLATION • Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
2. Tighten the special tool nut, and press the spring
retainer against the reverse clutch retainer.
A 3. Install the thickest snap ring that can be fitted in
the snap ring groove of reverse clutch retainer.
AK705065AB
AK403386
B
A
Clutch discs
AKX00126 AE
>>F<< SNAP RING INSTALLATION 1. Alternately assemble the clutch plate and clutch
1. Install the snap ring in the reverse clutch piston disc in the reverse clutch retainer. Align and
groove. assemble both clutch plates (where there are no
MD998924 teeth) (A in the illustration) with the reverse clutch
retainer hole (B in the illustration).
MB991629 R stamp
AK403634AB
2. Set special tools as shown in the illustration, and Clutch discs AKX00131 AC
compress the clutch element
• Spring compressor (MB991629) 2. Install the reaction plate so that it is oriented as
• Spring compressor retainer (MD998924) shown in the illustration. Assemble in the same
manner as the clutch plate so the section with no
teeth (A in the illustration) matches the retainer
hole (B in the illustration).
Reaction plate
AKX00129 AC
1. Install the snap ring in the reverse clutch retainer 3. Check that the clearance between the snap ring
groove. and the clutch reaction plate is within the standard
2. Set special tools as shown in the illustration, and valus.if not within the standard value, select a
compress the clutch element. snap ring to adjust.
• Spring compressor (MB991789) Standard value: 1.5 − 1.7 mm
• Spring compressor retainer (MD998924) (For reverse clutch end play)
SECOND BRAKE
DISASSEMBLY AND REASSEMBLY
M1233021800258
4
1
2
3
AKX00134 AB
Apply automatic
transmission fluid
to all moving parts
before installation.
7
8
4
9
2 3
1
10
5 6
AKX00135 AC
Disassembly steps Install the one-way clutch so that the arrow stamp is
1. Snap ring oriented as shown in the illustration.
2. Overdrive planetary carrier
>>D<< 3. Thrust bearing No.5 >>B<< STOPPER PLATE INSTALLATION
4. Underdrive sun gear
>>C<< 5. Thrust bearing No.6 Claw
6. Output planetary carrier
>>B<< 7. Stopper plate
>>A<< 8. One-way clutch
9. Snap ring
10. Low/reverse annulus gear
Arrow
AK403387AB
23B-46 AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
CENTRE SUPPORT
>>C<< THRUST BEARING No.6 INSTALLATION >>D<< THRUST BEARING No.5 INSTALLATION
CAUTION CAUTION
Make sure thrust bearing No.6 is mounted in the Make sure thrust bearing No.5 is mounted in the
correct direction. correct direction.
Output planetary
Overdrive planetary
carrier side
carrier side
AKX00138 AC AKX00139 AC
Apply vaseline or petroleum jelly on the thrust bear- Apply vaseline or petroleum jelly on the thrust bear-
ing No.6, and then install onto the output planetary ing No.5, and then install on the overdrive planetary
carrier. carrier.
CENTRE SUPPORT
DISASSEMBLY AND REASSEMBLY
M1233010000184
Apply automatic
transmission fluid
to all moving parts
before installation.
5
10
9
4
3 8
2
7
1
6
AKX00140 AC
Snap ring
AK403389AB
UNDERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY
M1233027300273
4
Apply automatic
transmission fluid
to all moving parts
before installation.
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
UNDERDRIVE CLUTCH
23B-49
Disassembly steps
>>E<< 1. Snap ring >>C<< SNAP RING INSTALLATION
>>D<< 2. Reaction plate
>>D<< 3. Clutch disc MD998924
MD998907
>>D<< 4. Clutch plate
<<A>> >>C<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring
>>B<< 8. Return spring
9. Underdrive clutch piston
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring Snap ring
AK403391AB
13. Underdrive clutch retainer
Use the special tools to install the snap ring.
DISASSEMBLY SERVICE POINT • Spring compressor (MD998924)
<<A>> SNAP RING REMOVAL • Spring compressor retainer (MD998907)
Snap ring
AK403391AB
W
stamp
Reaction plate
Reaction plate
AKX00149 AC
2 1
11 ± 1 N·m
2
11 ± 1 N·m
6
Apply automatic
transmission fluid 8
to all moving parts 7
before installation.
5
3
9 4
10
11
15
14
12
13 14
11 ± 1 N·m
2
16
15
AKX00150AC
19 17
20
21 18
38
6.0 ± 1.0 N·m
22 24
25
23
Apply automatic 30 27
transmission fluid 32 29
to all moving parts
before installation. 28
33
35
37 26
36 31
34
AKX00151AC
40 42
45 43
44 46 41 39
48 47
52 51
49
53 50
54
55 60
67
59
Apply automatic 64 58
transmission fluid 56
63
to all moving parts
before installation.
62
61
57
66
11 ± 1 N·m
65
11 ± 1 N·m
AKX00152AC
2. Following the marks made when removing, install Install the knock bushing onto the lower valve body
each solenoid valve in its proper position. position shown in the illustration.
Dowel pin
6 mm
4.5 mm
AK403430AB AK403428AB
Install the dowel pin at the specified position on the Install the knock bushing onto the lower valve body
lower valve body. position shown in the illustration.
>>C<< KNOCK BUSHING INSTALLATION >>E<< SPRING / STEEL BALL (LINE RELIEF)
INSTALLATION
Steel ball
Spring
AK403429AB
AK403427AB
AUTOMATIC TRANSMISSION OVERHAUL <R4A5>
VALVE BODY
23B-55
>>F<< SPRING / STEEL BALL (ORIFICE CHECK 1. Install the spring (4.5 mm diameter, 15.4 mm
BALL) / BALL (ORIFICE CHECK BALL) / length) and the steel ball (6.4 mm diameter) onto
DAMPING VALVE SPRING / SEAL RING / the upper valve body position shown in the
DAMPING VALVE INSTALLATION illustration.
Steel ball Seal ring 2. Install the ball (rubber) (6.4 mm diameter) onto the
upper valve body position shown in the
illustration.
3. After installing the seal ring onto the damping
valve, install together with the damping valve
Damping Damping spring (7.7 mm diameter, 35.8 mm length) onto
Spring valve spring the upper valve body position shown in the
illustration.
Manual valve
Pin
Control shaft
Ball (Rubber) AK403393AB
AK403431AB
Insert the control shaft into the valve body, putting
the pin of the control shaft into the groove of the
manual valve.
23C-1
GROUP 23C
AUTOMATIC
TRANSMISSION
OVERHAUL <V4A5>
CONTENTS
TRANSMISSION MODELS
Transmission model Engine model Vehicle model
V4A5A-J-LE 4D56 DI-D DOHC KB4T
V4A5A-J-LH 4D56 DI-D DOHC KB4T
70NT
68NT 17NT
21NT
38NT
25NT
AK605052
23C-4 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
GENERAL INFORMATION
AK603727
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
GENERAL INFORMATION
23C-5
<Super select 4WD>
AK403433
23C-6 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
GENERAL INFORMATION
HYDRAULIC CIRCUIT
1 2 3 4 5
7 8
9 10
11
12 13 14 15
16 17 18 19 20
21
22 23
R ND
P
26
24 27
25
AK600223AB
Item Specifications
Transmission model V4A5A-J-LEEL V4A5A-J-LEEP
Torque converter Type 3-element, 1-stage, 2-phase type
Stall torque ratio 1.62
Lock-up Present
Transmission type Electronically controlled 4-speed full-automatic
Transmission gear ratio 1st 2.842
2nd 1.495
3rd 1.000
4th 0.731
Reverse 2.720
Transfer type Easy select 4WD Super select 4WD
Transfer gear ratio High 1.000
Low 1.900
Speedometer gear ratio (driven/drive) 25/9
SERVICE SPECIFICATION(S)
M1233000301013
Transmission
Item Standard value
Output shaft end play mm 0.25 − 0.71
Center support end play mm 0 − 0.16
Brake reaction plate end play mm 0 − 0.16
Second brake end play mm 1.49 − 1.95
Low/reverse brake end play mm 1.65 − 2.11
Input shaft end play mm 0.25 − 0.81
Overdrive clutch return spring retainer end play mm 0 − 0.09
Overdrive clutch end play mm 2.0 − 2.2
Reverse clutch end play mm 1.5 − 1.7
Underdrive clutch end play mm 1.6 − 1.8
Transfer
Standard Limit
Item
value
H-L clutch hub end play mm 0 − 0.08 −
Differential lock hub end play mm <Super select 4WD> 0 − 0.08 −
Rear output shaft bearing to rear cover clearance mm Easy select 4WD 0 − 0.1 −
Super select 4WD 0.025 − 0.150 −
Countershaft gear end play mm 0 − 0.15 −
23C-8 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TORQUE SPECIFICATIONS
Standard Limit
Item
value
Input gear bearing end play mm 0 − 0.06 −
Countershaft gear bearing end play mm 0 − 0.08 −
2-4WD synchronizer hub end play mm 0 − 0.08
Synchronizer ring clearance mm − 0.3
Rear output shaft bearing end play mm 0 − 0.08 −
TORQUE SPECIFICATIONS
M1233023101689
Transmission
Item N⋅m
Harness bracket mounting bolt 26 ± 5
Air breather hose bracket mounting bolt 11 ± 1
Cable end bracket mounting bolt 48 ± 6
Transfer to transfer case adapter mounting bolt 35 ± 6
Transmission case to transfer case adapter mounting bolt 48 ± 6
Output shaft support mounting bolt 23 ± 3
Oil pump mounting bolt 23 ± 3
Converter housing to transmission case mounting bolt 48 ± 6
Valve body mounting bolt 11 ± 1
Detent spring mounting bolt 6.0 ± 1.0
Oil filter mounting bolt 6.0 ± 1.0
Oil pan mounting bolt 11 ± 1
Manual control lever mounting nut 21.5 ± 3.5
Output shaft speed sensor mounting bolt 11 ± 1
Input shaft speed sensor mounting bolt 11 ± 1
Inhibitor switch mounting bolt 11 ± 1
Lower valve body cover mounting bolt 11 ± 1
Lower valve body mounting bolt 11 ± 1
Separating plate mounting bolt 6.0 ± 1.0
Solenoid support mounting bolt 6.0 ± 1.0
Upper valve body mounting bolt 11 ± 1
Transfer
Item N⋅m
Rear bearing retainer mounting bolt <Super select 4WD> 20 ± 2
Oil pool cover mounting bolt <Super select 4WD> 9.0 ± 1.0
Transfer case − chain cover mounting bolt 35 ± 6
Rear cover − chain cover mounting bolt 35 ± 6
Drain plug 32 ± 2
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
VALVE BODY SPRING IDENTIFICATION
23C-9
Item N⋅m
Filler plug 32 ± 2
Control housing to transfer case mounting bolt 19 ± 3
Transfer case plate − transfer case mounting bolt and nut 35 ± 6
Speedometer sleeve clamp mounting bolt 19 ± 3
Plug 34 ± 5
Vehicle speed sensor 25 ± 4
4LLc detection switch <Super select 4WD> 35 ± 6
Low detection switch <Easy select 4WD> 35 ± 6
High/low detection switch 34 ± 5
4WD operation detection switch 34 ± 5
Center differential lock detection switch <Super select 4WD> 35 ± 6
2WD/4WD detection switch <Super select 4WD> 35 ± 6
Center differential lock operation detection switch <Super select 4WD> 34 ± 5
Bearing retainer mounting bolt 19 ± 3
Center differential case mounting bolt <Super select 4WD> 69 ± 10
Rear output shaft lock nut <Easy select 4WD> 255 ± 10
Transmission
Thrust race (For adjustment of output shaft end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 None 2.0 None
1.8 None 2.2 None
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 Brown 2.4 Blue
1.7 None 2.5 Brown
1.8 Blue 2.6 None
1.9 Brown 2.7 Blue
2.0 None 2.8 Brown
2.1 Blue 2.9 None
2.2 Brown 3.0 Blue
2.3 None
Thrust race (For adjustment of input shaft end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.4 None 2.2 None
1.6 None 2.4 None
1.8 None 2.6 None
2.0 None
Snap ring (For adjustment of overdrive clutch return spring retainer end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.48 Brown 1.58 None
1.53 Black 1.63 Brown
Pressure plate (For adjustment of second brake end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Snap ring (For adjustment of center support and brake reaction plate end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.2 None 2.4 Brown
2.3 Blue 2.5 None
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
SNAP RING, SPACER, THRUST RACE AND PRESSURE PLATE FOR ADJUSTMENT
23C-11
Snap ring (For adjustment of reverse clutch end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 None 2.3 Blue
1.7 Blue 2.4 Brown
1.8 Brown 2.5 None
1.9 None 2.6 Blue
2.0 Blue 2.7 Brown
2.1 Brown 2.8 None
2.2 None
Pressure plate (For adjustment low/reverse brake end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.6 F 2.4 B
1.8 E 2.6 A
2.0 D 2.8 0
2.2 C 3.0 1
Transfer
Snap ring (For adjustment input gear bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
2.30 None 2.45 Blue
2.35 Red 2.50 Green
2.40 White
Spacer (For adjustment of counter shaft gear end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.77 None 2.19 White
1.91 Blue 2.33 Red
2.05 Brown
Snap ring (For adjustment of counter shaft gear bearing end play)
Thickness mm Identification symbol Thickness mm Identification symbol
1.48 Blue 1.62 None
Spacer (For adjustment of rear output shaft to rear cover clearance) <Easy select 4WD>
Thickness mm Identification symbol Thickness mm Identification symbol
2.75 B75 2.95 B95
2.79 B79 2.99 B99
2.83 B83 3.03 C03
2.87 B87 3.07 C07
2.91 B91 3.11 C11
23C-12 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
SEALANTS AND ADHESIVES
LUBRICANTS
M1233000400448
SPECIAL TOOL(S)
M1233000601092
TRANSMISSION
Tool Number Name Use
MB990936 Installer adapter Installation of oil seal
D998727
TRANSFER
Tool Number Name Use
MB990931 Installer adapter Installation of oil seal
35 ± 6 N·m
4
5 3
7 48 ± 6 N·m
9 1
2 48 ± 6 N·m
35 ± 6 N·m
8
6 11 ± 1 N·m
26 ± 5 N·m
AK801717AB
REASSEMBLY SERVICE POINT After squeezing out and applying the sealant on the
>>A<< TRANSFER CASE ADAPTER INSTALLA- transfer case adapter at the section indicated in the
TION illustration, install onto the transmission case.
Specified sealant:
CAUTION
Mitsubishi Part No.MD997740 or equivalent
• Completely degrease the FIPG-applied sur-
face so that water and oil including the old
sealant cannot adhere to the surface coated
with the sealant. Never touch the degreased
surface by hand.
• Make sure the starting point and the ending
point are about the middle between the bolts.
1.6 mm
diameter
AK403460AD
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER CASE ADAPTER
23C-21
TRANSFER CASE ADAPTER
DISASSEMBLY AND REASSEMBLY
M1233007000292
2
8
3
5
4
1 6
AK602202 AC
MB990938
MB990936
1.5 mm
1.5 mm
AK403557 AB
3
6
11 ± 1 N·m
7
1
5
2
11 ± 1 N·m
4
21.5 ± 3.5 N·m
14 11 ± 1 N·m
16
11 ± 1 N·m 15
13
11 ± 1 N·m
11 ± 1 N·m
11 ± 1 N·m
11 12
10 Apply automatic
6.0 ± 1.0 N·m transmission fluid
6.0 ± 1.0 N·m to all moving parts
before installation.
11 ± 1 N·m
9 8 AK801718 AB
Apply automatic
transmission fluid
to all moving parts
before installation.
38
37
28 32 34
35
31
25 27 33
30
22 24 26
29 36
21 23 20 20
20 20
18
17
19
AK503511AD
41
40
23 ± 3 N·m
39
48 ± 6 N·m
46 51
50
44 49
47 48
Apply automatic
transmission fluid
45 to all moving parts
42 before installation.
43 AK503512 AE
54
58
56 57
52
55
53 62
60
63
59
Apply automatic
transmission fluid
to all moving parts
before installation.
61
AKX00019 AK
71
69
80 23 ± 3 N·m
65
66
64
70
67 68 79
77
81
76
73 78
Apply automatic
transmission fluid
to all moving parts
before installation.
74
75
72
AKX00020AH
• All removed parts must be washed clean. 3. Remove the output shaft speed sensor.
Metal parts may be washed in an ordinary sol-
vent, but they should be dried completely
Manual control lever
using compressed air.
• Clutch discs, plastic thrust plates and rubber
parts should be washed in automatic trans-
mission fluid (ATF) and keep them free of dirt
after washing.
• If the transmission has been found damaged
and repaired, also disassemble and clean the
ATF cooler system. Inhibitor switch AK403343AB
Snap ring
AK603561
AK403341
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-29
CAUTION 9. Disconnect the valve body harness connectors.
Carefully hammer the special tool so that the oil
Oil temperature sensor
pan mounting surface is not damaged.
MD998727
AK701362AB
AK403345AB O-ring
AK403349AB
AK403347
AK403350AB
AK700990AB
23C-30 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
Oil seals
Detent lever
Pin
Manual control
shaft
Parking roller
Oil strainer
AK403351AB rod AK403353AB
12.Remove the oil strainer and two oil seals. 15.Remove the pin, and then remove the manual
control shaft, two O-rings, detent lever and
parking roller rod.
4 3 2 1
AK403352AB
AK403355AB
Spring pin
17.Remove the ten oil pump mounting bolts.
18.Install special tool Oil pump remover (MD998333)
into the bolt hole shown in the illustration.
AK403378AB
MD998333
AK403356AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-31
19.While screwing in special tools Oil pump remover
(MD998333) evenly, remove the oil pump.
20.Remove the oil pump gasket.
Trust race No.1
AK403361
AK403358
AK403362
Overdrive
26.Remove the snap ring.
clutch hub
Second brake
AK403359AD
AK403363AB
AK403365
AK403369
29.Remove the pressure plate, brake plates and
brake discs. 33.Remove the snap ring.
AK403366AD AK403370
30.Remove the thrust bearing No.7. 34.Remove the brake plates, brake discs, and
NOTE: The thrust bearing No.7 may be attached pressure plate.
to the low/reverse annulus gear.
AK403371
AK403367
35.Remove the wave spring.
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-33
Snap ring
NOTE: The thrust bearing No.11 may be attached
to the underdrive clutch hub.
Thrust
Bearing
bearing
retainer
No.11
AK403380AD
39.Remove the thrust bearing No.11 and underdrive
clutch.
23C-34 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
43.Remove the thrust bearing No.13 and bearing 1. Install a new gasket and output shaft support.
retainer. 2. Tighten the eight output shaft support mounting
NOTE: The thrust bearing No.13 may be attached bolts to the specified torque 23 ± 3 N⋅m.
to the output shaft support.
CAUTION
Bearing retainer
Output shaft
support AK403379AB
AKX00062 AG
44.Remove the eight output shaft support mounting
bolts, and then remove the output shaft support Make sure the thrust bearing is mounted in the
and gasket. correct direction.
Thrust bearing
REASSEMBLY No.13
CAUTION
• Never reuse any gasket, O-ring, and oil seal. Bearing
retainer
Always replace them with new ones.
• Never use any product other than blue petro-
latum jelly or white vaseline to lubricate or
hold parts during assembly.
• Apply ATF to friction elements, rotating parts,
AK403380AD
and sliding parts before installation.Soak new
clutch discs or brake discs in ATF for at least 3. Install the bearing retainer and thrust bearing
two hours before installing them. No.13 onto the output shaft.
• Never apply sealant or adhesive to gaskets.
• When a bushing requires replacement,
replace the assembly of which the bushing
forms a part.
• Never use any cloth gloves or any rags during
reassembly. Use only nylon cloth or paper
towels if necessary.
• Change also the ATF in the cooler circuit.
CAUTION
Never reuse a gasket.
Output shaft
support AK403379AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-35
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13
AKX00061AE
CAUTION
AK403377
Underdrive clutch
retainer
5. Install the output shaft into the output shaft
support.
AKX00066AE
CAUTION
Make sure thrust bearing No.11 is mounted in the
correct direction.
Thrust bearing No.12
Output shaft
AKX00063AG
Make sure thrust bearing No.12 is mounted in the Thrust bearing No.11
AK403444AC
correct direction.
8. Apply vaseline or petroleum jelly on the thrust
bearing No.11, and then install on the front end of
the underdrive clutch retainer.
CAUTION
Output flange
AK403445
AKX00072 AG
CAUTION
Make sure thrust bearing No.9 is mounted in the
correct direction.
Underdrive clutch
hub
AKX00069AE
Make sure thrust bearing No.10 is mounted in the Thrust bearing No.9 AK403448AC
correct direction.
12.Apply vaseline or petroleum jelly on the thrust
bearing No.9, and then install on the output
flange.
CAUTION
Measure and record the thickness of the thrust
race No.8 to be assembled.
AK403449AD
AK403447
23C-38 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
AK403451 AB
AK403424AB
Thrust race No.8 End play
15.Remove the two output shaft support mounting AKX00078AD
bolts. (3) Reinstall by selecting the thrust race No.8
16.Using the two removed bolts, install special tool installed by the procedure (13) so that the end
Bearing installer stopper (MB991603) to the play of output shaft becomes the standard
specified torque 23 ± 3 N⋅m. value.
17.Select the thrust race No.8 with the following NOTE: Refer to the thickness recorded in step
procedure. 13.
Standard value: 0.25 − 0.71 mm
MB991603
(For output shaft end play)
(4) Measure the end play again, and confirm that
it is within the standard value.
NOTE: Carry this step out with special tool
Bearing installer stopper (MB991603) and dial
gauge installed.
Output shaft
AK403450AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-39
Standard value
Center support
Snap ring
Low/Reverse
AK403369 brake piston AKX00081AC
18.Using the following steps, select the snap ring for (3) Select the snap ring for fixing the center
fixing the center support. support installed in step 18 (1) so that the end
(1) Install the snap ring used for fixing the center play of the center support is at the standard
support used. value. Then, reassemble.
Standard value: 0 − 0.16 mm
MB991603 (For center support end play)
(4) Measure the end play again, and confirm that
it is within the standard value.
Output shaft
AK403450AB
Center support
AK403371
AKX00082 AC
CAUTION CAUTION
Pay close attention to the assembly direction of Pay close attention to the shape and assembly
the reaction plate. direction of the brake plate A installation.
MB991632
AKX00083 AC AKX00084 AD
(3) Install the reaction plate and snap ring that (7) Next, install special tool Clearance dummy
was used. plate (MB991632) instead of the pressure
(4) Install a dial gauge onto special tool Dial plate for the second brake. Install the four
gauge extension (MD998913) so that the end brake discs and three brake plates.
contacts the brake reaction plate. Measure the (8) Install the return spring, second brake and
end play by moving special tool Clearance snap ring.
dummy plate (MB991632).
(5) Select the snap ring installed in step 19 (3) so
MD998913
that the end play is within the standard value.
Then, reassemble. Moving
amount
Standard value: 0 − 0.16 mm
(For brake reaction plate end play) MB991632
AKX00085 AC
AKX00086AC
less than 2.1 Make sure thrust bearing No.7 is mounted in the
2.1 or more − 2.4 B correct direction.
less than 2.3
2.3 or more − 2.6 A
less than 2.5
2.5 or more − 2.8 0
less than 2.7
2.7 or more − 3.0 1
less than 2.9
Thrust bearing No.7
(13)Remove the parts installed in steps 19 (1) to
(12). AK403366AD
CAUTION 24.Install the pressure plate, six brake disc and five
Make sure that thrust bearing No.7 attached to brake plate selected in step 19 (12).
the rear side of the low/reverse annulus gear
does not fall off.
AK403396
AK403361
AK403394
AK403395
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-43
CAUTION 29.Install the return spring and second brake.
Make sure the brake plate (reaction plate side) is
installed in the proper direction.
Pressure plate
Brake plate
Reaction
plate
AK403362
CAUTION
Thrust
bearing No.4
AKX00099 AD
Return spring
Thrust bearing No.4
AK403360AD
CAUTION CAUTION
Thrust
bearing No.3
Make sure thrust bearing No.3 is mounted in the Make sure thrust bearing No.2 is mounted in the
correct direction. correct direction.
Thrust bearing No.3
Overdrive
clutch hub
AK403359AD AK403404
32.Apply vaseline or petroleum jelly on the thrust 34.Install the reverse and overdrive clutch.
bearing No.3, and then install on the overdrive Thrust bearing No.2
clutch hub.
33.Install the overdrive clutch hub.
AK403405AD
AK403566AD
AK403406AB
AK403407AB
Parking
roller rod
Detent
lever
AK403455AB
Outer spring
4 3 2 1
Inner spring
O-ring
AK403408AB AKX00112 AD
Pin
4 3 2 1
AK403352AB
CAUTION
Pay close attention to the installation direction of
the oil seal.
Detent lever
Oil seals
Control shaft
AK503726AD
50.Install the oil strainer and two new oil seals. Install
the oil seals so that the notched section is
oriented as shown in the illustration.
Snap ring
AK602028AC
AK403350AB
C
51.Install the solenoid valve harness, and then
secure the snap ring into connector groove.
NOTE: Install the harness so that it is oriented as
shown in the illustration. D A D C
D
AK701362AE
AK403416AE
AK403347
AK403456
AK403346AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSMISSION
23C-49
CAUTION 67.Install the manual control lever.
68.Tighten the manual control lever mounting bolts to
the specified torque 21.5 ± 3.5 N⋅m.
Identification
symbol A
Transmission
side
AK403457AB
• Heat the parking gear to 160 − 180 °C and 69.Install the output shaft speed sensor.
shrink fit up to the stepped section of the out-
70.Tighten the output shaft speed sensor mounting
put shaft. Do not heat for longer than neces-
bolts to the specified torque 11 ± 1 N⋅m.
sary at this time.
Snap ring
AK403341
Parking gear AK403344AB
CAUTION
Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful not to
damage the oil seal lip when installing the torque
converter.
Inhibitor switch
AK601368AC
AK403458AB
Apply automatic 14
transmission fluid
to all moving parts
before installation. 17
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB
AK700994AB
Snap ring
AK403382AB Align the two return spring holes with the two projec-
tions on the override clutch piston, and then assem-
1. Set special tools as shown in the illustration. ble.
• Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
>>D<< SNAP RING INSTALLATION
2. Compress the return spring, and remove the snap
ring. MD999590
MD998924
>>B<< REVERSE CLUTCH PISTON 1. Set special tools as shown in the illustration.
INSTALLATION • Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
2. Tighten the special tool nut, and press the spring
retainer against the reverse clutch retainer.
A 3. Install the thickest snap ring that can be fitted in
the snap ring groove of reverse clutch retainer.
AK705065AB
AK403386
B
A
Clutch discs
AKX00126 AE
>>F<< SNAP RING INSTALLATION 1. Alternately assemble the clutch plate and clutch
1. Install the snap ring in the reverse clutch piston disc in the reverse clutch retainer. Align and
groove. assemble both clutch plates (where there are no
teeth) (A in the illustration) with the reverse clutch
MD998924
retainer hole (B in the illustration).
R stamp
MB991629
AK403634AB
2. Set special tools as shown in the illustration, and Clutch discs AKX00131 AC
compress the clutch element
• Spring compressor (MB991629) 2. Install the reaction plate so that it is oriented as
• Spring compressor retainer (MD998924) shown in the illustration. Assemble in the same
manner as the clutch plate so the section with no
teeth (A in the illustration) matches the retainer
hole (B in the illustration).
Reaction plate
AKX00129 AC
SECOND BRAKE
DISASSEMBLY AND REASSEMBLY
M1233021800269
4
1
2
3
AKX00134 AB
Apply automatic
transmission fluid
to all moving parts
before installation.
7
8
4
9
2 3
1
10
5 6
AKX00135 AC
Disassembly steps Install the one-way clutch so that the arrow stamp is
1. Snap ring oriented as shown in the illustration.
2. Overdrive planetary carrier
>>D<< 3. Thrust bearing No.5 >>B<< STOPPER PLATE INSTALLATION
4. Underdrive sun gear
>>C<< 5. Thrust bearing No.6 Claw
6. Output planetary carrier
>>B<< 7. Stopper plate
>>A<< 8. One-way clutch
9. Snap ring
10. Low/reverse annulus gear
Arrow
AK403387AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
CENTRE SUPPORT
23C-55
>>C<< THRUST BEARING No.6 INSTALLATION >>D<< THRUST BEARING No.5 INSTALLATION
CAUTION CAUTION
Make sure thrust bearing No.6 is mounted in the Make sure thrust bearing No.5 is mounted in the
correct direction. correct direction.
Output planetary
Overdrive planetary
carrier side
carrier side
AKX00138 AC AKX00139 AC
Apply vaseline or petroleum jelly on the thrust bear- Apply vaseline or petroleum jelly on the thrust bear-
ing No.6, and then install onto the output planetary ing No.5, and then install on the overdrive planetary
carrier. carrier.
CENTRE SUPPORT
DISASSEMBLY AND REASSEMBLY
M1233010000195
Apply automatic
transmission fluid
to all moving parts
before installation.
5
10
9
4
3 8
2
7
1
6
AKX00140 AC
Snap ring
AK403389AB
4
Apply automatic
transmission fluid
to all moving parts
before installation.
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
23C-58 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
UNDERDRIVE CLUTCH
Disassembly steps
>>E<< 1. Snap ring >>C<< SNAP RING INSTALLATION
>>D<< 2. Reaction plate
>>D<< 3. Clutch disc MD998924
MD998907
>>D<< 4. Clutch plate
<<A>> >>C<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring
>>B<< 8. Return spring
9. Underdrive clutch piston
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring Snap ring
AK403391AB
13. Underdrive clutch retainer
Use the special tools to install the snap ring.
DISASSEMBLY SERVICE POINT • Spring compressor (MD998924)
<<A>> SNAP RING REMOVAL • Spring compressor retainer (MD998907)
Snap ring
AK403391AB
W
stamp
Reaction plate
Reaction plate
AKX00149 AC
VALVE BODY
DISASSEMBLY AND REASSEMBLY
M1233012100206
2 1
11 ± 1 N·m
2
11 ± 1 N·m
6
Apply automatic
transmission fluid 8
to all moving parts 7
before installation.
5
3
9 4
10
11
15
14
12
13 14
11 ± 1 N·m
2
16
15
AKX00150AC
19 17
20
21 18
38
6.0 ± 1.0 N·m
22 24
25
23
Apply automatic 30 27
transmission fluid 32 29
to all moving parts
before installation. 28
33
35
37 26
36 31
34
AKX00151AC
40 42
45 43
44 46 41 39
48 47
52 51
49
53 50
54
55 60
67
59
Apply automatic 64 58
transmission fluid 56
63
to all moving parts
before installation.
62
61
57
66
11 ± 1 N·m
65
11 ± 1 N·m
AKX00152AC
Dowel pin
6 mm
4.5 mm
AK403430AB AK403428AB
Install the dowel pin at the specified position on the Install the knock bushing onto the lower valve body
lower valve body. position shown in the illustration.
>>C<< KNOCK BUSHING INSTALLATION >>E<< SPRING / STEEL BALL (LINE RELIEF)
INSTALLATION
Steel ball
Spring
AK403429AB
AK403427AB
23C-64 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
VALVE BODY
>>F<< SPRING / STEEL BALL (ORIFICE CHECK 1. Install the spring (4.5 mm diameter, 15.4 mm
BALL) / BALL (ORIFICE CHECK BALL) / length) and the steel ball (6.4 mm diameter) onto
DAMPING VALVE SPRING / SEAL RING / the upper valve body position shown in the
DAMPING VALVE INSTALLATION illustration.
Steel ball Seal ring 2. Install the ball (rubber) (6.4 mm diameter) onto the
upper valve body position shown in the
illustration.
3. After installing the seal ring onto the damping
valve, install together with the damping valve
Damping Damping spring (7.7 mm diameter, 35.8 mm length) onto
Spring valve spring the upper valve body position shown in the
illustration.
Manual valve
Pin
Control shaft
Ball (Rubber) AK403393AB
AK403431AB
Insert the control shaft into the valve body, putting
the pin of the control shaft into the groove of the
manual valve.
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER
23C-65
TRANSFER
DISASSEMBLY AND REASSEMBLY
M1233013300333
34 ± 5 N·m
3
35 ± 6 N·m
9 35 ± 6 N·m
10 35 ± 6 N·m 4
11
6 5
34 ± 5 N·m
14
34 ± 5 N·m 15
1 7
8 12
13
18
19 ± 3 N·m
17
16
Apply gear oil to
all moving parts 25 ± 4 N·m
before installation.
AK700638AC
19 ± 3 N·m 36
19 ± 3 N·m
25
35 ± 6 N·m 37
Apply gear oil to
all moving parts
26 31
before installation.
33
28 34
35
35 ± 6 N·m
27
32 ± 2 N·m 32
29
35 ± 6 N·m 24
23
22 30
32 ± 2 N·m
21
19 20
35 ± 6 N·m AK900188AB
56
57
58
57
63 59
60 62
61 39 35 ± 6 N·m
47 53 46
38 42
40 51
52 43
50 44
41
49
54
45
48
55
Apply gear oil to
all moving parts
before installation.
66
65
64 AK705024 AD
34 ± 5 N·m
35 ± 6 N·m
34 ± 5 N·m
21 34 ± 5 N·m 8 39
22 9 11
34 ± 5 N·m 23 12 34 ± 5 N·m 34
5 10
6 13 36
14
35 ± 6 N·m
7 15
3 16
1
35 ± 6 N·m
2 19 40
17
4 18 35
19 ± 3 N·m
37 25
41 38
20 27 26
32 ± 2 N·m
33
28 32 24
25 ± 4 N·m
29
35 ± 6 N·m AK900189 AB
51
53
70 56
46
68 66 57 50
19 ± 3 N·m 19 ± 3 N·m
58
59
75
62
42 49
73
74
43 45 76
77
52
44
60
47 54
61
48
AK800442 AC
82
Apply gear oil to
all moving parts
before installation.
83
20 ± 2 N·m
84
81
80 87
79 86
78
85 AK503403AG
Disassembly steps 1. Fix the H-L shift rail at the high position.
>>E<< 78. Snap ring 2. Shift the 2-4WD shift rail at the 4WD position.
>>D<< 79. H-L clutch hub
80. Low speed gear
NOTE: If the 2-4WD shift rail is at the 2WD posi-
81. Needle bearing tion, the chain cover cannot be removed because
82. Rear bearing retainer interlock is actuated.
83. Transfer drive shaft
84. Oil pool cover <<B>> REAR OUTPUT SHAFT / CHAIN / FRONT
85. Dust seal guard OUTPUT SHAFT REMOVAL
>>A<< 86. Oil seal
87. Transfer case
AK500492
AK503405 AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER
23C-71
<<C>> 2-4WD SYNCHRONIZER / CHAIN / FRONT >>B<< SPRING PIN INSTALLATION
OUTPUT SHAFT REMOVEAL
Spring pin
AK403503AB
AK101119
1. Align the 2-4WD shift lug with the 2-4WD shift rail
Remove the 2-4WD synchronizer, chain and front spring pin hole.
output shaft as a set.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
ADJUSTMENT BEFORE REASSEMBLY
>>C<< FRONT OUTPUT SHAFT / CHAIN / REAR
Spacer selection for adjustment of countershaft gear
OUTPUT SHAFT INSTALLATION
end play. (Refer to adjustment of transfer - spacer
selection for adjustment of countershaft gear end
play P.23C-77)
AK500492
AK503408 AB
>>E<< SNAP RING INSTALLATION 1. Align the 2-4WD shift lug with the 2-4WD shift rail
spring pin hole.
2. Hammer in the spring valve so that the spring pin
slit matches the center of the shift rail shaft.
AK500493
AK503398
AK503410
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER
23C-73
>>I<< CHAIN COVER INSTALLATION >>K<< H-L SHIFT RAIL INSTALLATION
CAUTION
• Completely degrease the FIPG-applied sur-
face so that water and oil including the old
sealant cannot adhere to the surface coated
with the sealant. Never touch the degreased
surface by hand.
• Make sure the starting point and the ending
point are about the middle between the bolts.
H-L shift rail
2 mm Diameter 2-4WD shift rail
Interlock plunger
H-L shift rail
AK403508AB
Specified sealant:
1. Tilt the transfer case with the 2-4WD shift rail
Mitsubishi Part No. MD997740 or equivalent
downward as shown in the illustration.
2. Move the 2-4WD shift rail in the direction of the
>>J<< H-L CLUTCH SLEEVE INSTALLATION arrow fully.
3. After making sure that the plunger is not exposed
Identification groove out of the H-L shift rail hole in the transfer case,
install the H-L shift rail.
AK500678AB
AK503412
1. Align the spring pin holes on the shift rail with the
shift fork. Then tap in the spring pin so that the slit
of the spring pin is facing the shaft center of the
shift rail.
23C-74 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER
MB990938
MB990932 B
AK403510 AC
Spacer
MB990938
MB990929
AK403510AH
AK403504AE
Spacer
AK503414AE
Oil hole
AK403511AB
Oil cover 1. Insert the bent section of the return spring into the
AK403729 AC
control housing as shown.
Install the oil cover so that the oil hole shown in the
illustration. CAUTION
• Completely degrease the FIPG-applied sur-
>>P<< REAR COVER INSTALLATION face so that water and oil including the old
CAUTION sealant cannot adhere to the surface coated
• Completely degrease the FIPG-applied sur- with the sealant. Never touch the degreased
face so that water and oil including the old surface by hand.
sealant cannot adhere to the surface coated • Make sure the starting point and the ending
with the sealant. Never touch the degreased point are about the middle between the bolts.
surface by hand.
• Make sure the starting point and the ending
point are about the middle between the bolts.
AK403517 AB
AK000033AD AK403617AC
Apply the sealant to the control housing. 1. Apply the sealant to the transfer case plate.
Specified sealant: Specified sealant:
Mitsubishi Part No. 997740 or equivalent Mitsubishi Part No. MD997740 or equivalent
Mating marks
Counter shaft
face so that water and oil including the old SPACER SELECTION FOR ADJUST-
sealant cannot adhere to the surface coated MENT OF COUNTERSHAFT GEAR END
with the sealant. Never touch the degreased PLAY
surface by hand.
<Measurement using a solder>
• Make sure the starting point and the ending
point are about the middle between the bolts. CAUTION
• If soft solder is not available, select the
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard
value cannot be selected using soft solder,
select the spacer in accordance with Plasti-
gage method.
AK403514AB
Plastigage
6. Measure the thickness of the crushed solder with 7. Measure the width of the crushed Plastigage at its
a micrometer and select a spacer that will provide widest part using a scale printed on the Plastigage
the standard value. package.
Spacer thickness: (T − 0) to (T − 0.15) Standard value: 0 − 0.15 mm
T: The crushed solder thickness (For countershaft gear end play)
Standard value: 0 − 0.15 mm
(For countershaft gear end play) INSPECTION
M1233013400114
Plastigage
AK403499AC
AK500505
1. Put plastigage (about 10 mm long) in the
Check for the continuity between the connector ter-
illustrated positions of the transfer case housing.
minals.
2. Install the adjusting spacer having the minimum
thickness. Switch Connector Continuity
condition terminals
3. Install the countershaft gear into the transfer case.
Switch end 1−2 Conductive
4. Install the transfer case plate and tighten the bolts
pressed
to the specified torque of 35 ± 6 N⋅m.
5. Remove the transfer case plate and the Switch end 1−2 Open
countershaft gear, and then take out crushed released
solders.
6. If the Plastigages have not crushed, replace the HIGH/LOW DETECTION SWITCH
spacer with a thicker one and repeat steps 3 to 5.
AK500510
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
TRANSFER
23C-79
Check for the continuity between the connector ter- <Super select 4WD>
minals. CENTER DIFFERENTIAL LOCK DETECTION
Switch Connector Continuity SWITCH, 2WD/4WD DETECTION SWITCH,
condition terminals CENTER DIFFERENTIAL LOCK OPERATION
Switch end 1−2 Open DETECTION SWITCH, 4WD OPERATION DETEC-
pressed TION SWITCH, HIGH/LOW DETECTION SWITCH
Switch end 1−2 Conductive
released
AK503422
AK503422
19 ± 3 N·m
Apply automatic 1
transmission fluid
to all moving parts
before installation.
AK700641AB
Disassembly steps
>>B<< 1. Bolt MB990938
2. Bearing retainer
MB990933
3. Transfer input gear
>>A<< 4. Oil seal
5. Baffle plate
6. Transfer case plate
AK403506 AB
INPUT GEAR
DISASSEMBLY AND REASSEMBLY
M1233015100249
AK700643 AB
DISASSEMBLY SERVICE POINT Use special tools to install the ball bearing.
<<A>> BALL BEARING REMOVAL • Installer cap (MD998812)
• Installer-100 (MD998813)
• Installer adapter (MD998824)
Snap ring
AKX00253AC
AK500669AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
COUNTERSHAFT GEAR
23C-83
COUNTERSHAFT GEAR
DISASSEMBLY AND REASSEMBLY
M1233024000273
AK700644AB
MD998801
AKX00258 AC
REASSEMBLY SERVICE POINTS 1. Install the thickest snap ring that can be fitted into
>>A<< ROLLER BEARING INSTALLATION the snap ring groove of the counter shaft gear.
2. Make sure that the countershaft gear roller
bearing end play meets the standard value.
MD998812
Standard value: 0 − 0.08 mm
(For countershaft gear bearing end play)
MD998818
AKX00259 AC MD998812
AKX00261AC
>>B<< SNAP RING INSTALLATION
Use special tools to install the ball bearing.
• Installer cap (MD998812)
• Installer adapter (MD998818)
AKX00260
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
2-4WD SYNCHRONIZER
23C-85
2-4WD SYNCHRONIZER
DISASSEMBLY AND REASSEMBLY
M1233014200072
7
Apply gear oil to
all moving parts
before installation.
9
8
6 10
5
4
3
9
2
AK503423AB
AK503426AB
AK503427AB
Snap ring
AK101272AD
AK500672AB
AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
CENTRE DIFFERENTIAL CASE
23C-87
CENTRE DIFFERENTIAL CASE
DISASSEMBLY AND REASSEMBLY
M1233013900056
3 3
2
3
69 ± 10 N·m 4
4
1
AK503428 AB
Dowel pin
AK101274AD
14
15
16
17
18
255 ± 10 N·m
12 9
11 3
13 4
6
8 7 Apply gear oil to
all moving parts
10 before installation.
AK500645AB
1
4
AK101106 AC
AK500495AB
AK403516
23C-90 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
REAR OUTPUT SHAFT
<<B>> BALL BEARING REMOVAL NOTE: The clutch hub may fit loosely on the
<Easy select 4WD>
shaft, so that removal is possible without using a
press.
MD998814
<Super select 4WD>
MD998829
Ball bearing
MD998917
MD998801
AK403521AD
AK403520 AB
MD998812
MD998813 AK403526AD
AK500685AB
AK403516
AK403556
1
AK700646AB
MD998812
MD998813
AK403522AB
MD998818
MD998801
1. Use special tool Bearing remover (MD998801) to
support the ball bearing.
2. Press the front output shaft with a press and
remove the ball bearings. AK403523 AB
MD998801
AK403462 AB
23C-94 AUTOMATIC TRANSMISSION OVERHAUL <V4A5>
SPEEDOMETER GEAR
SPEEDOMETER GEAR
DISASSEMBLY AND REASSEMBLY
M1233015700092
4
Apply gear oil to
all moving parts 1
before installation.
5
AK700647AB
AK403524 AB
Drive the spring pin in, while making sure that slit
does not face gear shaft.
23D-1
GROUP 23D
AUTOMATIC
TRANSMISSION
OVERHAUL <V5A5>
CONTENTS
OUTPUTSHAFT SUPPORT. . . . . . . . 23D-68 2-4 SHIFT RAIL/H-L SHIFT RAIL DISASSEMBLY AND
OUTPUTSHAFT SUPPORT DISASSEMBLY AND REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-88
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-68
TRANSFER DRIVE SHAFT . . . . . . . . 23D-89
VALVE BODY . . . . . . . . . . . . . . . . . . 23D-70 TRANSFER DRIVE SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-89
VALVE BODY DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-70
FRONT OUTPUT SHAFT . . . . . . . . . . 23D-90
TRANSFER . . . . . . . . . . . . . . . . . . . . 23D-75 FRONT OUTPUT SHAFT DISASSEMBLY AND
REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-90
TRANSFER DISASSEMBLY AND REASSEMBLY
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23D-75
ADJUSTMENT OF TRANSFER . . . . . . . . . 23D-84 REAR OUTPUT SHAFT . . . . . . . . . . . 23D-91
REAR OUTPUT SHAFT DISASSEMBLY AND
TRANSFER CASE PLATE . . . . . . . . 23D-85 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 23D-91
TRANSMISSION MODEL
Transmission model Engine model Vehicle model
V5A5A-J-LH 4D56 DI-DC I/T KB4T
AK900017
23D-4 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
GENERAL INFORMATION
AK602539
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
GENERAL INFORMATION
23D-5
HYDRAULIC CIRCUIT
1 2 3 4 5 28 29
6
7 8 30
9 10
11
13 14 15
16 12 17 18 19 20 31 32
21
22 23
24 26
27
25
AK603794AB
GENERAL SPECIFICATIONS
M1233000201287
Item Specifications
Transmission model V5A5A
Torque converter Type 3-element, 1-stage, 2-phase type
Stall torque ratio 1.62
Lock-up Present
Transmission type 5 forward speeds, 1 reverse speed, fully automatic
Gear ratio 1st 3.789
2nd 2.057
3rd 1.421
4th 1.000
5th 0.731
Reverse 3.865
Transfer type 2-speed, constant mesh
Gear ratio High 1.000
Low 1.900
SERVICE SPECIFICATIONS
M1233000301035
Transmission
Item Standard value
Direct planetary carrier end play mm 0.25 − 0.71
Center support end play mm 0 − 0.16
Brake reaction plate end play mm 0 − 0.16
Second brake end play mm 1.49 − 1.95
Low/reverse brake end play mm 1.65 − 2.11
Input shaft end play mm 0.25 − 0.81
Overdrive clutch return spring retainer end play mm 0 − 0.09
Overdrive clutch end play mm 2.0 − 2.2
Reverse clutch end play mm 1.5 − 1.7
Underdrive clutch end play mm 1.6 − 1.8
Direct clutch end play mm 1.0 − 1.2
Transfer
Item Standard value Limit
H-L clutch hub end play mm 0 − 0.08 −
Differential lock hub end play mm 0 − 0.08 −
2-4WD clutch hub end play mm 0 − 0.08 −
Clearance between outer synchronizer ring and drive sprocket mm − 0.3
Rear output shaft preload mm 0.12 − 0.24 −
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TORQUE SPECIFICATIONS
23D-7
Item Standard value Limit
Rear output shaft end play mm 0 − 0.12 −
Countershaft gear end play mm 0 − 0.15 −
Countershaft gear bearing end play mm 0 − 0.08 −
Rear output shaft bearing end play mm 0 − 0.08 −
Rear output shaft annulus gear end play mm 0 − 0.08 −
Input gear bearing end play mm 0 − 0.06 −
TORQUE SPECIFICATIONS
M1233023101407
Transmission
Item N⋅m
Transfer to transfer case adapter tightening bolt 35 ± 6
Transmission case to transfer case adapter tightening bolt 48 ± 6
Output shaft support mounting bolt 23 ± 3
Anchor plug 98 ± 15
Reduction brake piston nut 18.5 ± 3.5
Oil pump mounting bolt 23 ± 3
Converter housing to transmission case tightening bolt 48 ± 6
Valve body mounting bolt 11 ± 1
Detent spring mounting bolt 6.0 ± 1.0
Oil filter mounting bolt 6.0 ± 1.0
Oil pan mounting bolt 11 ± 1
Inhibitor switch mounting bolt 11 ± 1
Manual control lever mounting nut 21.5 ± 3.5
Output shaft speed sensor mounting bolt 11 ± 1
Input shaft speed sensor mounting bolt 11 ± 1
Cable end bracket mounting bolt 48 ± 6
Clamp 11 ± 1
Harness bracket 11 ± 1
Lower valve body mounting bolt 11 ± 1
Lower valve body cover mounting bolt 11 ± 1
Upper valve body mounting bolt 11 ± 1
Separating plate mounting bolt 6.0 ± 1.0
Solenoid support mounting bolt 6.0 ± 1.0
Transfer
Item N⋅m
Rear bearing retainer mounting bolt 19 ± 2
Transfer case plate to transfer case tightening bolt and nut 35 ± 6
Transfer case to chain cover tightening bolt 35 ± 6
23D-8 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
VALVE BODY SPRING IDENTIFICATION
Item N⋅m
Connector bracket 21 ± 4
Transmission wiring harness protector 5.0 ± 1.0
Rear cover to chain cover tightening bolt 35 ± 6
Shift actuator mounting bolt 11 ± 1
Front output sensor mounting bolt 11 ± 1
Rear output sensor mounting bolt 11 ± 1
Vehicle speed sensor mounting bolt 11 ± 1
Transfer case cover tightening bolt 19 ± 3
2WD-4WD switch 35 ± 6
4H switch 35 ± 6
Center differential lock switch 35 ± 6
2WD switch 35 ± 6
4LLC switch 35 ± 6
Transmission
Snap ring (For adjustment of underdrive clutch and overdrive clutch end play)
Thickness mm Identification symbol
1.6 Brown
1.7 None
1.8 Blue
1.9 Brown
2.0 None
2.1 Blue
2.2 Brown
2.3 None
2.4 Blue
2.5 Brown
2.6 None
2.7 Blue
2.8 Brown
2.9 None
3.0 Blue
Snap ring (For adjustment of overdrive clutch return spring retainer end play)
Thickness mm Identification symbol
1.48 Brown
1.53 Black
1.58 None
1.63 Brown
Snap ring (For adjustment of center support and brake reaction plate end play)
Thickness mm Identification symbol
2.2 None
2.3 Blue
2.4 Brown
2.5 None
Transfer
Snap ring (For adjustment of rear output shaft bearing end play)
Thickness mm Identification symbol
2.26 None
2.33 Red
2.40 White
2.47 Blue
Snap ring (For adjustment of rear output shaft annulus gear end play)
Thickness mm Identification symbol
1.90 None
1.94 None
1.98 None
2.02 None
2.06 None
2.10 None
SEALANTS
M1233000501170
Transmission
Item Specified sealant
Transfer case adapter (transmission side) Mitsubishi Part No. MR166584 or equivalent
Sealing cap 3M™ AAD part No. 8672 or equivalent
Converter housing Mitsubishi Part No. MR166584 or equivalent
Oil pan
Transfer
Item Specified sealant
Bearing retainer mounting bolt 3M™ STUD locking No. 4170 or equivalent
Transfer case Mitsubishi Part No. MD997740 or equivalent
Chain cover
Rear cover
Transfer case cover
FORM-IN-PLACE GASKET (FIPG) Disassembly
This transmission has several areas where the form- Parts sealed with a FIPG can be easily removed
in-place gasket (FIPG) is used for sealing. To ensure without need for the use of a special method. In
that the FIPG fully serves its purpose, it is necessary some cases, however, the FIPG in joints may have to
to observe some precautions when applying it. Bead be broken by tapping parts with a mallet or similar
size, continuity and location are of paramount impor- tool.
tance.
Too thin a bead could cause leaks. Too thick a bead, Surface Preparation
on the other hand, could be squeezed out of location, Thoroughly remove all substances deposited on the
causing blocking or narrowing of fluid passages. To FIPG application surface, using a gasket scraper.
prevent leaks or blocking of passages, therefore, it is Make sure that the FIPG application surfaces is flat
absolutely necessary to apply the FIPG evenly with- and smooth. Also make sure that the surface is free
out a break, while observing the correct bead size. from oils, greases and foreign substances. Do not fail
FIPG hardens as it reacts with the moisture in the to remove old FIPG that may remain in the fastener
atmospheric air, and it is usually used for sealing fitting holes.
metallic flange areas.
FIPG Application
CAUTION Applied FIPG bead should be of the specified size
When re-applying liquid gasket (FIPG), be sure and free of any break. FIPG can be wiped away
that: unless it has completely hardened. Install the mating
1. Residues of FIPG are cleared from all the ins parts in position while the FIPG is still wet. Do not
and outs of parts; allow FIPG to spread beyond the sealing areas dur-
2. Use Mitsubishi genuine parts cleaner ing installation. Avoid operating the transmission or
(MZ100387) or equivalent to well degrease the letting oils or water come in contact with the sealed
FIPG-applied surface. area before a time sufficient for FIPG to harden
3. FIPG is correctly applied in accordance with (approximately one hour) has passed.
FIPG Application. FIPG application method may vary from location to
location. Follow the instruction for each particular
case described later in this manual.
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
LUBRICANTS
23D-15
LUBRICANTS
M1233000400374
Transmission
Item Specified lubricant
Transmission oil DiaQueen ATF SP III
Vaseline application parts White vaseline or Blue petrolatum
Oil seal Mitsubishi Part No. 0101011 or equivalent
Transfer
Item Specified lubricant
Transfer oil Gear oil API classification GL-4 SAE 75W-85W
Oil seal Mitsubishi Part No. 0101011 or equivalent
O-ring
Shift fork and shift rail
SPECIAL TOOLS
M1233000601122
Transmission
Tool Number Name Use
MB990929 Installer adapter Installation of transfer case adapter oil seal
D998727
MD998334 Oil pump oil seal Installation of oil pump oil seal
installer
Transfer
Tool Number Name Use
MB990938 Installer bar Use with installer adapter
35 ± 6 N·m
4
5 3
7
9 48 ± 6 N·m
2 48 ± 6 N·m
35 ± 6 N·m
8
6 11 ± 1 N·m
26 ± 5 N·m
AK900862 AB
1.6 mm
diameter
AK403460AD
23D-22 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSFER CASE ADAPTER
7
2
1
5
6 4
A K X 0 0 0 1 4AC
AK403339AB
1.5 mm
1.5 mm
AK403557 AB
AK403340 AB
1. Press into the dimensions shown in the illustration
Attach the end of the spring to the position shown in
so that it is not slanted.
the illustration.
2. Apply the sealant as shown in the illustration.
23D-24 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
TRANSMISSION
DISASSEMBLY AND REASSEMBLY
M1233101200024
11 ± 1 N·m 6
9
Apply automatic
5
transmission fluid 10
to all moving parts
before installation.
2
1
11 ± 1 N·m
8
17
7
19
11 ± 1 N·m
11 ± 1 N·m
4 20
3 18 21.5 ± 3.5 N·m
21 16
11 ± 1 N·m
11 ± 1 N·m
14 15
6.0 ± 1.0 N·m
6.0 ± 1.0 N·m 13
12
11
11 ± 1 N·m
AK900863AB
37
39
43
38 41 Apply automatic
40 transmission fluid
to all moving parts
42 38 before installation.
40
37
39
43
50
49
44 46
33 47
36 45
30 32
35
27 29 31
34 48
26 28 25
25 25
25
24
23
22
AK900864AB
53
52
23 ± 3 N·m
51
62
60
48 ± 6 N·m 58
63
56 61
Apply automatic
transmission fluid
59 to all moving parts
54 before installation.
57
55 AK900865AB
Apply automatic 70
transmission fluid
to all moving parts 68
before installation.
66
64
69
67 74
65 72
71
75
73
AK900817AB
98 ± 15 N·m
80
78 99
97 98
76
101
81
23 ± 3 N·m
79 96
77 100
94
93
82
92
91
95 90
18.5 ± 3.5 N·m 89 87
84 88
86
Apply automatic
transmission fluid 85
to all moving parts 83
before installation.
AK900818 AB
cloth or paper towels if necessary. 4. Remove the output shaft speed sensor, and
• All removed parts must be washed clean. detach the O-ring from the output shaft speed
Metal parts may be washed in an ordinary sol- sensor.
vent, but they should be dried completely
using compressed air.
• Clutch discs, plastic thrust plates and rubber Manual control lever
parts should be washed in automatic trans-
mission fluid (ATF) and keep them free of dirt
after washing.
• If the transmission has been found damaged
and repaired, also disassemble and clean the
ATF cooler system.
AK900829AB
AK603561
Inhibitor switch
1. Remove the torque converter.
2. Remove the clamp. AK601368AC
Snap ring
AK900819
3. Remove the input shaft speed sensor, and detach Parking gear AK601369AC
the O-ring from the input shaft speed sensor.
7. Remove the snap ring, and remove the parking
gear using a puller (corresponding load
approximately 9,800 N).
23D-30 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
CAUTION
Carefully hammer the special tool so that the oil
pan mounting surface is not damaged.
AK601373AC
AK601370AC
O-ring AK601374
Oil filter
Oil temperature
sensor
AK601371AC
AK601372
O-ring
AK601376 AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
23D-31
NOTE: The O-rings are mounted on the transmis- Remove the snap ring, then remove the
sion case side as shown in the illustration. How- accumulator cover, O-ring and spring.
ever there may be cases where they will come off
No. Name
with the valve body.
1 For overdrive clutch
2 For second brake
Snap ring
3 For low/reverse brake
4 For underdrive clutch
5 For reduction brake
6 For direct clutch
NOTE: To make assembly easier, attach an iden-
tification tag on the removed accumulator piston.
AK601377AC
Oil strainer
Spring pin
AK601923AC
Manual control
shaft
6 5
AK601922 AC AK503505AB
15.Remove each accumulator piston, seal ring and 18.Remove the eight converter housing mounting
spring. bolts, and then converter housing.
23D-32 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
AK601926AC AK601929
19.Remove the ten oil pump mounting bolts. 24.Remove the reverse and overdrive clutch.
20.Install the special tool into the bolt hole shown in Thrust bearing No.3
the illustration.
MD998333
AK601930AD
AK601931
AK601932AD
AB601933 AK601937
28.Remove the reverse sun gear. 32.Remove the pressure plate, brake plates and
brake discs.
AK601934
AK601938
29.Remove the snap ring.
33.Remove the low/reverse annulus gear.
AK601935
Thrust bearing No.7 AK601939AD
30.Remove the second brake.
34.Remove the thrust bearing No.7.
NOTE: The thrust bearing No.7 may be attached
to the low/reverse annulus gear.
AK601936
AK601941 AK601945
36.Remove the reaction plate and one brake disc. 40.Remove the snap ring.
AK601942 AK601946
38.Remove the brake plates, brake discs, and 42.Remove the thrust race No.8 and thrust bearing
pressure plate. No.9.
NOTE: The thrust race No.8 may be attached to
the center support.
AK601944
Reduction brake
piston cover
AK601949 AD AK601953AC
44.Remove the thrust bearing No.12. 47.Remove the snap ring and then the reduction
NOTE: The thrust bearing No.12 may be attached brake piston cover and O-ring.
to the direct annulus gear.
Reduction brake piston
Snap ring
AK601954 AC
AK601950
48.Remove the snap ring and then the nut, reduction
45.Remove the direct planetary carrier. brake piston, seal ring, adjusting rod and spring.
Seal ring
AK601951AC AK601955
Seal ring
AK601952AC
AK601956AD
46.Remove the two large and two small seal rings
from the direct planetary carrier. 50.Remove the thrust bearing No.13.
NOTE: The thrust bearing No.13 may be attached
to the direct clutch.
23D-36 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
RESASSEMBLY
CAUTION
• Never reuse the gasket, O-ring, oil seal, etc.
Always replace with a new one when reas-
sembling.
• Never use grease other than blue petrolatum
jelly and white vaseline.
• Apply ATF to friction components, rotating
parts, and sliding parts before installation.
AK601957
Immerse a new clutch disc or brake disc in
51.Remove the reduction brake band. ATF for at least two hours before assembling
them.
• Never apply sealant or adhesive to gaskets.
• When replacing a bushing, replace the reas-
sembly which it belongs to.
• During the work, always use bare hands or
vinyl gloves. Do not use cotton gloves. Use
nylon cloth or paper towels when necessary.
Do not use shop towel.
• Change the oil in the cooler system.
AK601958
CAUTION
52.Remove the anchor plug and the O-ring. Never reuse a gasket.
Output shaft support Output shaft support
AK601959AC AK601959AC
53.Remove the eight output shaft support mounting 1. Install a new gasket and output shaft support.
bolts, and then remove the output shaft support 2. Tighten the eight output shaft support mounting
and gasket. bolts to the specified torque 23 ± 3 N⋅m.
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
23D-37
Identification of thrust bearings and thrust races
No.1 No.2 No.3 No.4 No.5 No.6 No.7 No.8 No.9 No.10 No.11 No.12 No.13
AK900857 AC
Symbol OD mm ID mm Thickness mm
No.1 48.9 37 1.4
1.6
1.8
2.0
2.2
2.4
2.6
No.2 59 37 2.8
No.3 57 38.5 4.12
No.4 57 38.5 4.12
No.5 54.4 38.5 3.31
No.6 57 38.5 4.12
No.7 70 48.8 4.0
No.8 73 60 1.6
1.8
2.0
2.2
No.9 71.45 57 2.81
No.10 72 48.25 4.6
23D-38 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
Symbol OD mm ID mm Thickness mm
No.11 53 34.7 4.01
No.12 57 38.5 4.12
No.13 58 37.5 4.8
CAUTION
AK601958 AK601963AD
3. Install a new O-ring on the anchor plug and Take care not to mistake the thrust bearing No.13
tighten the anchor plug to the specified torque 98 mounting direction.
± 15 N⋅m.
Thrust bearing No.13
AK601962AD
AK601957
5. Install the thrust bearing No.13 onto the direct
4. Install the reduction brake band. clutch retainer.
AK601961AC
MB991693
AK601964
MB991635
AK601965
AK601970
AK601967
23D-40 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
MB991634
AK601971 AD
Reduction brake
piston cover
AK601972AC
AK601951AC
AK601974AD
Seal ring
16.Apply vaseline or petrolatum jelly on the thrust
bearing No.12, and then install on the front end of
the direct planetary carrier.
AK601952AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
23D-41
CAUTION CAUTION
Confirm that the thrust bearing No.10 in the Measure and record the thickness of the thrust
direct annulus gear is still at the specified loca- race No.8 before assembling.
tion.
Thrust race No.8
AK601979 AD
AK601976
19.Apply vaseline or blue petrolatum jelly on the
17.Install the direct annulus gear. thrust race No.8 removed, and then install it on
the rear side of the center support.
CAUTION
CAUTION
• Install the center support so that the oil hole
Thrust bearing No.9 shown in the illustration faces the lower side
of the transmission case.
• Use care that the thrust race No.8 attached to
Direct annulus the rear side of the center support does not
gear
fall off.
AK601978 AD
AK601980
AK601977AD
AK601981AC
MD998304
MB991603
AK601982AC AK601984
22.Select the thrust race No.8 with the following 23.Using the following steps, select a suitable snap
procedure. ring for fixing the center support.
(1) Fix a dial gauge to the special tool Bearing (1) Install the snap ring which has been used for
installer stopper (MB991603). fixing the center support.
(2) Push the direct planetary carrier and direct
annulus gear in alternately, and measure the
end play of the direct planetary carrier. MB991603
NOTE: .
• When pushing in the direct planetary car-
rier, make sure that the center support does
not move.
• When pushing in the direct annulus gear,
use the special tool Oil seal installer
(MD998304). AK601985AC
Standard value
Thrust race No.8
End play Center support
AK601983AD
Standard value: 0.25 − 0.71 mm (3) Replace the snap ring for fixing the center
(For direct planetary carrier end play) support installed in step 23 (1) with a suitable
(4) Measure the end play again, and confirm that one so that the end play of the center support
it is within the standard value. is at the standard value. Then, reassemble.
NOTE: Carry this step out with the special tool Standard value: 0 − 0.16 mm
and dial gauge installed. (For center support end play)
(4) Measure the end play again, and confirm that
it is within the standard value.
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
23D-43
(5) Replace the snap ring installed in step 24 (3)
with a suitable one so that the end play may
fall within the standard value. Then,
reassemble.
Standard value: 0 − 0.16 mm
(For brake reaction plate end play)
(6) Measure the end play again, and confirm that
it is within the standard value.
CAUTION
AK601987
Take care to the shape and assembly direction of
24.Using the following steps, select a snap ring for the brake plates installed at section "A" shown in
adjusting the brake reaction plate end play and the illustration.
second brake end play, and a pressure plate for
adjusting the low/reverse brake end play. Second brake
Snap ring
(1) Install the wave spring onto the low/reverse
brake piston.
MB991632 Snap ring A Return spring
MB991632
AK601990 AC
A AK601993AD
MB991632
Take care not to mistake the thrust bearing No.7
AK601992AC mounting direction.
(12)Install a dial gauge onto special tool
Thrust bearing No.7
(MD998913) so that the end contacts the
special tool (MB991632). Move special tool
(MB991632) and measure the moving
amount.
Select a pressure plate with a thickness that
corresponds to the measured moving amount
from the following table.
Standard value (reference): 1.65 − 2.11 mm
(For low/reverse brake end play) AK601994AD
AK601999
AK601996
AB601997
AK601998
23D-46 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
Reaction
plate
AK602005
AK602007AD
End coil Take care not to mistake the thrust bearing No.4
installation direction.
AK602004AC
Thrust bearing No.4
Install the return spring so that the flat side faces
the back of the transmission.
Second brake
AK602006AD
Return spring
36.Apply vaseline or petrolatum jelly on the thrust
bearing No.4, and then install on the reverse sun
AK602003AC
gear.
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
23D-47
CAUTION CAUTION
Take care not to mistake the thrust bearing No.3 Take care not to mistake the thrust bearing No.2
mounting direction. mounting direction.
Overdrive clutch
hub AK602008AD AK602011AD
37.Apply vaseline or petrolatum jelly on the thrust 40.Apply vaseline or petrolatum jelly on the thrust
bearing No.3, and then install on the overdrive bearing No.2, and then install on the reverse and
clutch hub. overdrive clutch.
38.Install the overdrive clutch hub.
Thrust race No.1
AK602013AD
AK602010
41.Apply vaseline or petrolatum jelly on the thrust
39.Install the reverse and overdrive clutch. race No.1, and then install on the oil pump.
23D-48 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
CAUTION CAUTION
Never reuse the gasket. Evenly squeeze out the sealant so that it is not
insufficient or excessive.
MD998412
1.6 mm Diameter
AK602014AC
AK503506 AE
42.Install the special tool Guide (MD998412) at the
position shown in the illustration, and using this as 46.Apply sealant on the converter housing.
a guide, install the oil pump and gasket. Specified sealant:
43.Tighten the ten oil pump mounting bolts to the Mitsubishi Part No. MR166584 or equivalent
specified torque 23 ± 3 N⋅m.
MD998316
AK503505AB
AK602015AC
47.Install the converter housing.
44.Using the special tool Dial gauge support
48.Tighten the eight converter housing mounting
(MD998316), set a dial gauge as shown in the
bolts to the specified torque 48 ± 6 N⋅m.
illustration. Measure the end play of the input
shaft, and replace the thrust race installed in step
41 with a suitable one so that the end play may Parking roller rod
meet the standard value. Then, reassemble.
Standard value: 0.25 − 0.81 mm
(For input shaft end play)
45.Measure the end play again, and confirm that it is
within the standard value. Detent lever
AK602017AC
Outer spring
AK602018 AC
4 3 2 1
50.Install two new O-rings to the manual control
shaft.
Detent lever and Inner spring
parking roller rod
AKX00112 AD
Accumulator piston
spring
AK602023AC
AK602020
6 5
AK601922 AC
NOTE: .
• Install the accumulator pistons to the original Snap ring
positions following the identification tags
attached when they were removed.
• The springs are identified by paint application
position as shown below. Assemble following
this table.
No. Name Identification paint
application position
1 For overdrive None AK602025AC
CAUTION
Take care to the installation direction of the oil
seal. AK602027AC
56.Install the oil strainer and two new oil seals. Install
the oil seals so that the notched section is
oriented as shown in the illustration. AK602028AC
D
E B
O-ring
C
D
A D C D
AK602029AC AK602032 AC
61.Tighten the twenty valve body mounting bolts to 65.Install the new O-ring to the oil filter.
the specified torque 11 ± 1 N⋅m.
Bolt Length mm
A 25
B 30
C 40
D 45
E 55
AK602033
AK602030 AC
Magnet
62.Connect the connector to the valve body.
AK602034AC
CAUTION
Evenly squeeze out the sealant so that it is not
insufficient or excessive.
AK602031
69.Apply sealant on the oil pan.
63.Install the detent spring. Specified sealant:
64.Tighten the detent spring mounting bolt to the Mitsubishi Part No. MR166584 or equivalent
specified torque 6.0 ± 1.0 N⋅m.
23D-52 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSMISSION
Inhibitor switch
AK602205AC AK601368AC
CAUTION
Manual control lever
Transmission side
AK900829AB
AK602036 AC
75.Install the manual control lever.
76.Tighten the manual control lever mounting nut to
• Install the parking gear so that the side with-
the specified torque 21.5 ± 3.5 N⋅m.
out the spline cut faces the transmission side.
• Heat the parking gear to 160 − 180°C, and
shrink fit up to the stepped section of the out-
put shaft.
Snap ring
AK700820AB
AK601366
CAUTION
Apply ATF to the oil pump drive hub before
installing the torque converter. Be careful not to
damage the oil seal lip when installing the torque
converter.
AK700821AB
AK900867AB
OIL PUMP
DISASSEMBLY AND REASSEMBLY
M1233001300358
1
Apply automatic
transmission fluid
to all moving parts 2
before installation.
AK602037AC
Disassembly steps 1. Use the special tool Oil seal installer (MD998334)
>>B<< 1. Seal ring to install the oil seal.
>>B<< 2. Seal ring 2. Apply ATF to the lip of the oil seal.
>>A<< 3. Oil seal
4. Oil pump
>>B<< SEAL RING INSTALLATION
REASSEMBLY SERVICE POINTS Install four new seal rings to the outer groove of the
oil pump, and apply ATF to the seal ring.
>>A<< OIL SEAL INSTALLATION
MD998334
AK602038AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
REVERSE AND OVERDRIVE CLUTCH
23D-55
REVERSE AND OVERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY
M1233021200513
Apply automatic 14
transmission fluid
to all moving parts
before installation. 17
19
21 12
22 13
2
15
1 16 6
18
20 8
3 9
4
10 5
7
17 14 10 8
22
21
20 15 6
2
1 12
18
16 13 3
11
19 11 9 7 5 4
AK700992 AB
MD999590 MD998924
AK602042
Snap ring
AK602040AC Align the two return spring holes with the two projec-
tions on the overdrive clutch piston, and then assem-
1. Set the special tools as shown in the illustration. ble the return springs.
• Spring compressor (MD999590)
• Spring compressor retainer (MD998924)
>>D<< SNAP RING INSTALLATION
2. Compress the return spring, and remove the snap
ring. MD999590 MD998924
Clutch discs
AK602043AC
• Spring compressor (MB991789) If the clearance is not at the standard value, select
• Spring compressor retainer (MD998924) a suitable snap ring and adjust so that the
3. Check that the clearance between the snap ring clearance is within the standard value.
and reaction plate (reverse clutch end play) is the Standard value: 1.5 − 1.7 mm
standard value. (For reverse clutch end play)
SECOND BRAKE
DISASSEMBLY AND REASSEMBLY
M1233021800236
4
1
2
3
AK602178 AC
Apply automatic
transmission fluid
to all moving parts
before installation.
7
8
4
9
2 3
1
10
5 6
AK602049 AC
Disassembly steps Install the one-way clutch so that the arrow stamp is
1. Snap ring oriented as shown in the illustration.
2. Overdrive planetary carrier
>>D<< 3. Thrust bearing No.5 >>B<< STOPPER PLATE INSTALLATION
4. Underdrive sun gear
>>C<< 5. Thrust bearing No.6
6. Output planetary carrier Stopper
>>B<< 7. Stopper plate plate
>>A<< 8. One-way clutch Claw
9. Snap ring
10. Low/reverse annulus gear
AK602050 AC
23D-60 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
CENTRE SUPPORT
>>C<< THRUST BEARING No.6 INSTALLATION >>D<< THRUST BEARING No.5 INSTALLATION
CAUTION CAUTION
Take care not to mistake the thrust bearing No.6 Take care not to mistake the thrust bearing No.5
mounting direction. mounting direction.
AK602052AC AK602053AC
Apply vaseline or petrolatum jelly on the thrust bear- Apply vaseline or petrolatum jelly on the thrust bear-
ing No.6, and then install on the output planetary car- ing No.5, and then install on the overdrive planetary
rier. carrier.
CENTRE SUPPORT
DISASSEMBLY AND REASSEMBLY
M1233010000162
Apply automatic
transmission fluid
to all moving parts
before installation.
5
10
4 9
3 8
2
7
1
6
AK602054 AC
MB991630
MD998924
AK602056 AC
UNDERDRIVE CLUTCH
DISASSEMBLY AND REASSEMBLY
M1233027300314
4
Apply automatic
transmission fluid
to all moving parts
before installation.
2
1
11
12 13
10
9
8
5 7 1 3
6 7
10
11
12
9
6 13
2 4 AK700896AB
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
UNDERDRIVE CLUTCH
23D-63
Disassembly steps Align the two return spring holes with the two projec-
>>E<< 1. Snap ring tions on the underdrive clutch piston, and then
>>D<< 2. Reaction plate assemble the return springs.
>>D<< 3. Clutch disc
>>D<< 4. Clutch plate >>C<< SNAP RING INSTALLATION
<<A>> >>C<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring MD998337
>>B<< 8. Return spring
9. Underdrive clutch piston
>>A<< 10. D-ring
>>A<< 11. D-ring
>>A<< 12. D-ring
13. Underdrive clutch retainer
Assemble in the same manner as the clutch plate • Spring compressor retainer (MD998924)
so that the section with no teeth ("A" in the • Spring compressor (MB991629)
illustration) matches the retainer hole ("B" in the
illustration).
MD998924
Reaction plate
AK602063AC
Apply automatic
transmission fluid
to all moving parts
before installation.
2 3 7
1
5 6
AK602064 AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
DIRECT ANNULUS GEAR
23D-65
Disassembly steps Apply vaseline or petrolatum jelly on the thrust bear-
1. Snap ring ing No.11, and then install on the underdrive clutch.
2. Output flange
>>B<< 3. Thrust bearing No.10 >>B<< THRUST BEARING No.10 INSTALLATION
4. Underdrive clutch hub
>>A<< 5. Thrust bearing No.11 CAUTION
6. Underdrive clutch Take care not to mistake the thrust bearing No.10
7. Direct annulus gear mounting direction.
AK602065AC
23D-66 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
DIRECT CLUTCH
DIRECT CLUTCH
DISASSEMBLY AND REASSEMBLY
M1233019400167
4
Apply automatic
transmission fluid
to all moving parts
before installation.
2
1
3 7 10 11
12
11
10
9
8
5
5 7
6
12
1 2 4 6 8 9
AK602067AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
DIRECT CLUTCH
23D-67
Disassembly steps 1. Set the special tools as shown in the illustration.
>>D<< 1. Snap ring • Spring compressor (MB991630)
>>C<< 2. Reaction plate • Spring compressor retainer (MD998924)
>>C<< 3. Clutch disc 2. Compress the return spring, and install the snap
>>C<< 4. Clutch plate
ring.
<<A>> >>B<< 5. Snap ring
6. Spring retainer
>>A<< 7. D-ring >>C<< CLUTCH PLATE / CLUTCH DISC /
8. Return spring REACTION PLATE INSTALLATION
9. Direct clutch piston B
>>A<< 10. D-ring A
>>A<< 11. D-ring
12. Direct clutch retainer
MD998924
MB991630
AK602069 AC
Sanp ring
R Stamp
AK602068AC
Sanp ring
AK602068AC
23D-68 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
OUTPUTSHAFT SUPPORT
Snap ring
Standard value
Reaction plate
AK602072AC
OUTPUTSHAFT SUPPORT
DISASSEMBLY AND REASSEMBLY
M1233029000052
Apply automatic
transmission fluid
to all moving parts
before installation.
4
3
AK602073 AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
OUTPUTSHAFT SUPPORT
23D-69
Disassembly steps REASSEMBLY SERVICE POINTS
1. Snap ring >>A<< ONE-WAY CLUTCH INSTALLATION
>>A<< 2. One-way clutch
3. Seal ring
4. Output shaft support Output shaft
supoort
Identification
groove
One-way clutch
AK602074 AC
VALVE BODY
DISASSEMBLY AND REASSEMBLY
M1233005500600
1
Apply automatic 11 ± 1 N·m
11 ± 1 N·m
transmission fluid
to all moving parts
before installation.
5
7
6
4
2
8 3
10
14
13
11
12 13
11 ± 1 N·m
15
14
AK602075 AC
18
19
20 17
21
38
6.0 ± 1.0 N·m
16
22 24
25
23
32 30 27
29
28
35 33 26
Apply automatic 37 31
transmission fluid
to all moving parts 36
before installation. 34
AK602076 AC
41
40 42
48 45 43
52 47 49 44 46
51 53 50
54 39
55
59 56
57
60 58 74
61
62 67
66
71 65
63
70
69
73 68
64
72
11 ± 1 N·m
Apply automatic
transmission fluid
to all moving parts
before installation.
11 ± 1 N·m
AK602077 AC
AK602078 AC
4.5 mm
AK602080 AC
>>E<< SPRING / STEEL BALL (LINE RELIEF) 1. Install the spring (4.5 mm in diameter, 15.4 mm in
INSTALLATION length) and the steel ball (6.4 mm in diameter)
onto the upper valve body position shown in the
illustration.
Steel ball 2. Install the ball (rubber) (6.4 mm in diameter) onto
the upper valve body position shown in the
illustration.
3. After installing the seal ring onto the damping
valve, install together with the damping valve
spring (7.7 mm in diameter, 35.8 mm in length)
Spring
onto the upper valve body position shown in the
AK602081AC illustration.
Install the spring (7 mm in diameter, 17.3 mm in
length) and the steel ball (6.4 mm in diameter) onto >>G<< CONTROL SHAFT INSTALLATION
the lower valve body position shown in the illustra-
tion. Manual valve
AK602083AC
Ball (Rubber)
Seal ring Steel ball
Damping Spring
valve
Damping spring AK602082AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSFER
23D-75
TRANSFER
DISASSEMBLY AND REASSEMBLY
M1233006700674
35 ± 6 N·m 35 ± 6 N·m
8
35 ± 6 N·m 5 9 Apply gear oil to
all moving parts
2 6 10 before installation.
3 19 ± 3 N·m
7 35 ± 6 N·m
4 11 11 ± 1 N·m
18
17
12
13 35 ± 6 N·m
14
1
30
15
19 11 ± 1 N·m
32 31
16
27 26 11 ± 1 N·m 22
21 24
25
20 11 ± 1 N·m
28
29
23
35 ± 6 N·m
AK602084AC
33 34
Apply gear oil to 35 ± 6 N·m 37
all moving parts 36
before installation. 46
47
41 39
35 ± 6 N·m
35
49 38
50 40 21 ± 4 N·m
52 45
54
44
57
5.0 ± 1.0 N·m
51 48 42
58 53 43
60
62
55 69
56
59
68 61
71 65
73
66
64
63
72 70
67
AK602085AC
85
Apply gear oil to
all moving parts
before installation.
91 86
79
19 ± 2 N·m
83
84 90
35 ± 6 N·m
82
81
80
74 89
78 88
76 87
77
75
35 ± 6 N·m
AK602086 AC
5 mm
1.9 mm
AK602087
MB990938
MB990932
AK602090AC
AK602088AC
1. Use special tools to install the oil seal.
Unstake the positions shown in the illustration to • Handle (MB990938)
remove the oil pool cover. • Installer adapter (MB990932)
2. Apply the specified grease to the lip of oil seal.
ADJUSTMENT BEFORE REASSEMBLY
Specified lubricant:
Spacer selection for adjustment of countershaft gear
end play. (Refer to adjustment of transfer - spacer Mitsubishi Part No. 0101011 or equivalent
selection for adjustment of countershaft gear end
play P.23D-84) >>C<< SEAL BOLT INSTALLATION
AK602091AC
AK602095AC
AK602096AC
AK602093AC
CAUTION
If the sub gear does not readily come in mesh >>J<< 2-4WD SHIFT FORK AND 2-4WD CLUTCH
with the countershaft gear, rote the transfer drive SLEEVE INSTALLATION
shaft, etc. to securely engage it.
4. While making sure that the notched portion of the
input gear positioned in Step 2 is in alignment with
the gear portion of the countershaft, install the
transfer case palate.
AK602100AC
Select a proper snap ring so that the end play of the >>K<< SUN GEAR / 2-4WD CLUTCH HUB / SNAP
differential lock hub will have standard value, and RING INSTALLATION
install it on the transfer drive shaft.
Standard value: 0 − 0.08 mm
(For differential lock hub end play)
Steel ball
AK602101
AK602102 AK602104AC
1. Combine the synchronizer outer ring, 2. Install the drive sprocket so that its illustrated
synchronizer cone and synchronizer inner ring, holes will mach the projecting portions of the
press then against the drive sprocket, and synchronizer cone.
measure the dimension shown in the illustration.
Limit: 0.3 mm >>N<< REAR OUTPUT SHAFT INSTALLATION
(For clearance between synchronizer outer
ring and drive sprocket)
2. If the dimension is out of the limit value, replace
them with a synchronizer ring set.
3. Apply gear oil to the synchronizer outer ring and
synchronizer inner ring.
AK602105 AC
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
AK602106 AC
AK602109AC
MB990938
MB990932
AK602108 AC
AK602110AC
1. With the output shaft pressed toward the chain
Use special tools to install the oil seal in the rear
cover, measure the projection of the bearing from
cover.
the chain cover.
• Installer adapter (MB990932)
• Handle (MB990938)
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSFER
23D-83
>>T<< REAR COVER INSTALLTION 2. Apply the specified grease to the O-ring.
Specified lubricant:
Mitsubishi Part No. 0101011 or equivalent
3. Combine the main shift rail key with actuator key
and insert them in the transfer case.
AK602111AC
INSTALLATION Install the shift rail drive gear with its marked tooth in
mesh with the third gear groove of the each shift rail.
50.5mm
Rod A
extends
AK602695AB
move in the rod extending direction or retracting Apply specified sealant to the illustrated position of
direction until the amount of extension of the rod the transfer case cover.
is as indicated in the drawing. Specified sealant:
Terminal A Terminal B Rod Mitsubishi Part No. MD997740 or equivalent
movement
Power supply (+) Power supply (-) Extension >>X<< SWITCH INSTALLATION
Power supply (-) Power supply (+) Retraction C
E
A D
AK602115 AB
Mounting Switch name Tube Connecto 5. If the solders have not crushed, use thicker
position color r color solders (1.6 mm diameter, about 10 mm long) and
repeat steps 2 to 4.
A 2WD/4WD Blue Black
switch
B 4LLC switch Black Brown
C 2WD switch Black Black
D 4H switch Green White
E Center Blue Brown
differential lock
switch
M1233030900071
6. Measure the thickness of the crushed solder with
SPACER SELECTION FOR ADJUST- a micrometer and select a spacer that will provide
MENT OF COUNTERSHAFT GEAR END the standard value.
PLAY Spacer thickness: (T − 0) to (T − 0.15)
<Measurement using a solder> T: The crushed solder thickness
CAUTION Standard value: 0 − 0.15 mm
• If soft solder is not available, select the (For counter shaft gear end play)
spacer in accordance with Plastigage method.
• If the spacer appropriate for the standard <Measurement using plastigage>
value cannot be selected using soft solder,
select the spacer in accordance with Plasti- Plastigage
gage method.
Solder
AK602692 AB
Plastigage
Spacer AK602693AB
19 ± 2 N·m
Apply gear oil to
all moving parts
before installation.
6 1
4 AK602116 AC
MB990938
MB990933
AK602117 AC AK602091AC
COUNTERSHAFT GEAR
DISASSEMBLY AND REASSEMBLY
M1233024000284
2
1 3
AK602118 AC
AK602119 AC
AK602122
<<B>> SPACER / ROLLER BEARING / INNER
RACE REMOVAL 1. Install the thickest snap ring that can be fitted into
1. Remove the spacer and bearing. the snap ring groove of the counter shaft gear.
2. Make sure that the counter shaft gear roller
bearing end play meets the standard value.
MD998801 Standard value: 0 − 0.08 mm
MD998368
(For counter shaft gear bearing end play)
MD998812
AK602120 AC MD998818
MD998812
MD998818
AK602121AC
23D-88 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
2-4 SHIFT RAIL/H-L SHIFT RAIL
1
Apply gear oil to
all moving parts 7
before installation.
6
4
3
5
AK602124AC
AK603210AC
Install the spring pin with its split toward the forward
end of the transfer.
AK602125AC
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
TRANSFER DRIVE SHAFT
23D-89
TRANSFER DRIVE SHAFT
DISASSEMBLY AND REASSEMBLY
M1233014500095
AK602127AC
Disassembly steps 2. Press the transfer drive shaft with a press and
<<A>> >>A<< 1. Ball bearing remove the ball bearing.
2. Transfer drive shaft
REASSEMBLY SERVICE POINT
DISASSEMBLY SERVICE POINT
>>A<< BALL BEARING INSTALLATION
<<A>> BALL BEARING REMOVAL
MD998812
MD998814
MD998830
MD998917
MD998198
AK602129AC
AK602128AC
Use the special tools to install the ball bearing.
1. Use special tool Bearing remover (MD998917) to • Installer cap (MD998812)
support the ball bearing. • Installer-200 (MD998814)
• Installer adapter (66) (MD998830)
• Puller (MD998198)
23D-90 AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
FRONT OUTPUT SHAFT
2
1
AK602130 AC
Disassembly steps 2. Press the front output shaft with a press and
<<A>> >>B<< 1. Ball bearing remove the ball bearing with sensor rotor.
2. Sensor rotor
<<B>> >>A<< 3. Ball bearing <<B>> BALL BEARING REMOVAL
4. Front output shaft
MD998801
AK602132 AC
MD998813
MD998812
MD998821 MD998821
AK602134 AC
AK602133AC Use special tool to install the ball bearing with sensor
Use special tool to install the ball bearing. rotor.
• Installer cap (MD998812) • Installer cap (MD998812)
• Installer adapter (44) (MD998821) • Installer-100 (MD998813)
• Installer adapter (44) (MD998821)
2
AK602135 AC
MD998801
AK602138
AK602136AC Select and install a proper snap ring so that the end
Use special tool Bearing remover (MD998801), play of the rear output shaft bearing will have the
remove the ball bearing. standard value.
Standard value: 0 − 0.08 mm
REASSEMBLY SERVICE POINTS (For rear output shaft bearing end play)
>>A<< BALL BEARING INSTALLATION
>>C<< SNAP RING INSTALLATION
MD998812
MD998814
MD998824
AK602137AC
AK602139
Use special tools to install the ball bearing.
• Installer cap (MD998812) Select and install a proper snap ring so that the
• Installer-200 (MD998814) clearance between the annulus gear and rear output
• Installer adapter (50) (MD998824) shaft will have the standard value.
Standard value: 0 − 0.08 mm
(For rear output shaft annulus gear end play)
AUTOMATIC TRANSMISSION OVERHAUL <V5A5>
INPUT GEAR
23D-93
INPUT GEAR
DISASSEMBLY AND REASSEMBLY
M1233015100272
AK800993AB
MD998801
AK602142AC
>>B<< SNAP RING INSTALLATION 1. Install the thickest snap ring that can be fitted in
the snap ring groove of the transfer input gear.
2. Make sure that the transfer input gear bearing end
play meets the standard value.
Standard value: 0 − 0.06 mm
(For input gear bearing end play)
AK602143
1
Apply gear oil to
all moving parts
before installation. 2
5
6
AK602144AC
Washer
Install the shift rail drive gear such that its mark does
not face the washer.
25-1
GROUP 25
PROPELLER SHAFT
CONTENTS
GENERAL INFORMATION
M1251000100562
<2WD> • A 2-joint type propeller shaft for front propeller
• A 2 way split 3-joint type propeller shaft with cen- shaft, a 2-joint type propeller shaft for rear propel-
tre bearing is adopted. ler shaft are adopted. <Vehicles with Easy select
• A snap ring method of securing the journal bear- 4WD-A/T, Vehicles with Super select 4WD>
ing for the universal joint is adopted. • A snap ring method of securing the journal bear-
ing for the universal joint is adopted.
<4WD> • BJ is adopted for front propeller shaft. <Vehicles
• A 2-joint type propeller shaft for front propeller with Super select 4WD>
shaft, a 2 way split 3-joint type propeller shaft with
NOTE: BJ: Birfield Joint
centre bearing for rear propeller shaft are
adopted. <Vehicles with Easy select 4WD-M/T>
CONSTRUCTION DIAGRAM
<2WD (except High rider)>
Rear propeller shaft
Front propeller shaft assembly
assembly
AC407335AC
BJ
Front propeller
shaft assembly
AC510097AB
SERVICE SPECIFICATIONS
M1251000300265
LUBRICANT
M1251000400347
SPECIAL TOOLS
M1251000600266
MB990810
MB990840
MB991410 Collar
MB991410
ON-VEHICLE SERVICE
PROPELLER SHAFT UNIVERSAL JOINT <Correct state>
CHECK
M1251002400086
PROPELLER SHAFT VISUAL CHECK
1. Place the gearshift lever to the "N" (neutral Oil seal
position) <M/T> or the selector lever to the "N"
position <A/T>.
2. Then place the transfer shift lever to the "2WD"
position. <4WD>
3. Check the propeller shaft for dent, damage or AC808283AB
crack.
<Incorrect
state>
AC510591AB
AC501206AC
PROPELLER SHAFT
REMOVAL AND INSTALLATION
M1251001001118
2, 3, 4
Gear Oil:
Gear oil API classification GL-3 54 ± 5 N·m<Except High rider>
SAE 75W-85 34 ± 5 N·m
103 ± 5 N·m<High rider>
2 1N
<2WD>
103 ± 5 N·m
4
<4WD>
34 ± 5 N·m
103 ± 5 N·m
1N
54 ± 5 N·m
3
N
32 ± 2 N·m
N
7
6
5
AC003833 AG
AC505406AG
<Vehicles with
Super select Mating marks
4WD-font>
AC804574AB
AC804574AB
Oil seal
ACX00642 AC
AC003833 AG
INSPECTION
M1251001100394
• Check the sleeve yoke, centre yoke and flange
yoke for wear, damage or cracks.
• Check the propeller shaft for bends, twisting or
damage.
• Check the universal joint for smooth operation in
all directions.
• Check the centre bearing for smooth movement.
PROPELLER SHAFT
PROPELLER SHAFT
25-9
PROPELLER SHAFT RUN-OUT 2. If looseness is recognized, perform service work
or replace the propeller shaft with a new one.
ACX00643AB
Limit: 0.6 mm
Journal
PROPELLER SHAFT UNIVERSAL JOINT
PLAY CHECK
Grease nipple
<2WD>
<Except High rider>
4
3
7
9 4
AC407357
187 ± 29 N·m
4 1
2 3
8
10
2 3 1
5 4
4 3
9 1
2
Universal joint kit
2 3 1
AC611838 AB
PROPELLER SHAFT
PROPELLER SHAFT
25-11
<High rider>
4
3
7
9 2
AC407357
4
187 ± 29 N·m 4 3
1
8
2
10 3
1
4 2 4 2
5 3
9
1
3 Universal joint kit
1
AC807773AB
<4WD>
4
3
4 6
7
5 4
3 2 1
4
3 3 1
1 2
4
3
6
4
5 54 ± 5 N·m
4 3 1
2 3 1
4 3
12 AC407357
8 2
4 2
1 3 1 3
8 12 4 10 2 5
4 13 1 3 1
1 3
4 2
3
1
Universal joint kit
AC800582 AB
Mating
marks
AC003847AD
AC003863 AD
External type:
MB990840
Internal type:
MB991410
AC611946 AB Lock nut
Propeller shaft
AC407357AB
1. Use the following special tools to press in the
journal bearing on one side, and take out the 1. Set the centre bearing assembly in the direction
journal bearing on the opposite side. shown in the figure and install it to the propeller
• Universal joint remover and installer (MB990840) shaft.
• Collar (MB991410) 2. Install, lining up the mating marks on the centre
2. Insert the special tools into the other side and yoke and the propeller shaft.
press the journal to remove the first journal 3. While tightening the nut, install the centre bearing
bearing that was pushed. assembly with the centre yoke.
PROPELLER SHAFT
PROPELLER SHAFT
25-15
>>B<< JOURNAL/JOURNAL BEARING • Collar (MB991410)
INSTALLATION
CAUTION
Be careful when pressing the journal bearings. If
they are pressed at an angle, the inside of the
journal bearings will be damaged.
MB990840
AC003879 AC AC003888 AC
1. Use special tool universal joint remover and 1. Install a snap ring to one side of the journal.
installer (MB990840) to press the journal bearing External Internal
into the centre yoke, sleeve yoke or flange yoke type MB990840 type MB990840
until the snap ring groove is fully visible.
External Internal
type MB990840 type MB990840
Snap ring
Snap ring
MB991410
AC003889 AC
GROUP 26
FRONT AXLE
CONTENTS
GENERAL INFORMATION
M1261000101555
<2WD> • The wheel bearing uses a unit bearing (double
• The front hub assembly which uses a unit bearing tapered roller bearing) with strong transverse
(double tapered roller bearing) is mounted on the load bearing ability.
knuckle. • The driveshaft incorporates BJ-DOJ type con-
• ABS rotor for detecting the wheel speed is press- stant velocity joints with high transmission effi-
fitted into the front hub. <Vehicles with ABS> ciency for low vibration and noise.
• Due to the use of the inner shaft, the right and left
<4WD> driveshafts are approximately the same in length.
The front axle consists of the front hub assembly, This reduces noise, vibration and torque steer.
driveshaft, inner shaft, front differential, and it has the • ABS rotor for detecting the wheel speed is press-
following features: fitted to the BJ outer wheel. <Vehicles with ABS>
• A free-wheel mechanism that allows changeover BJ: Birfield Joint
between 2WD and 4WD while the vehicle is trav- DOJ:Double Offset Joint
elling.
SPECIFICATIONS
<2WD>
Item Specification
Wheel bearing Type Unit bearing (double taper roller bearing)
Bearing (OD × ID) mm Except High rider 75 × 40
High rider 88 × 50
<4WD>
Item Specification
Vehicles with Easy Vehicles with Super
select 4WD select 4WD
Wheel bearing Type Unit bearing (double Unit bearing (double
tapered roller bearing) tapered roller bearing)
Bearing (OD × ID) mm 88 × 50 88 × 50
Driveshaft Joint type Outer BJ BJ
Inner DOJ DOJ
Length (joint to joint) × LH 323 × 24 323 × 24
diameter mm RH 327.6 × 24 327.6 × 24
Inner shaft Length × diameter mm 342.7 × 31.5 342.7 × 31.5
Bearing (OD × ID) mm 62 × 35 62 × 35
FRONT AXLE
GENERAL INFORMATION
26-3
Item Specification
Vehicles with Easy Vehicles with Super
select 4WD select 4WD
Differential Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 3.917 4.100*1, 3.917*2
Differential gear type Side gear Straight bevel gear × 2 Straight bevel gear × 2
(Type × number of Pinion gear Straight bevel gear × 2 Straight bevel gear × 2
gears)
Number of teeth Drive gear 47 41*1, 47*2
Drive pinion 12 10*1, 12*2
Side gear 14 14
Pinion gear 10 10
Bearing (OD × ID) mm Side 80.0 × 45.2 80.0 × 45.2
Front 68.3 × 30.2 68.3 × 30.2
Rear 76.2 × 36.5 76.2 × 36.5
NOTE: . CONSTRUCTION DIAGRAM
• *1: Vehicles for Europe (4AT) and Russia
<Except High rider>
• *2: Vehicles for Europe (Except 4AT)
Knuckle
Knuckle
ABS rotor
Wheel bearing
Wheel bearing
AC407388
AC407387AC
26-4 FRONT AXLE
GENERAL INFORMATION
<High rider>
Knuckle Knuckle
Front hub
Front axle shaft
ABS rotor
Front hub
AC605517 AB
<4WD>
Driveshaft (RH)
Freewheel
clutch assembly
Inner shaft
Driveshaft (LH)
Knuckle
Actuator
Front hub
Differential
Knuckle
Driveshaft BJ
Wheel bearing
Front hub
Wheel bearing
AC407394 AB
AC805155AB
FRONT AXLE
SERVICE SPECIFICATIONS
26-5
SERVICE SPECIFICATIONS
M1261000301258
LUBRICANTS
M1261000401697
SPECIAL TOOLS
M1261000601691
B990767
MB991618
B991033
FRONT AXLE
SPECIAL TOOLS
26-7
Tool Number Name Use
MB991561 Boot band Resin boot band installation <4WD>
crimping tool
MB991561
MB990906
B MB990590 Rear axle shaft oil • Removal of differential carrier oil seal
A: MB990212 seal remover <4WD>
B: MB990211 A: Adapter • Removal and installation of inner
B: Slide hammer shaft <4WD> (Used together with
MB990906)
A MB990590
MB990955
MB991576
MB991318
MB990909
MB991116 Adapter
MB990810
MB990811
MB990339
MB990648
MB990326
MB990031
MB990890
MB990947
MB990847
MB990981
MB990802
Toolbox
ACX02372AE
FRONT AXLE
ON-VEHICLE SERVICE
26-11
ON-VEHICLE SERVICE
FRONT AXLE TOTAL BACKLASH CHECK FRONT AXLE GEAR OIL LEVEL CHECK
<4WD> <4WD>
M1261001300151 M1262000900238
1. If the vehicle vibrates and produces a booming 1. Remove the under cover and filler plug.
sound due to an imbalance in the drive system,
measure the front axle total backlash by the
following procedure to see if the differential carrier
Gear oil
assembly requires removal.
(1) Park the vehicle on a flat, level surface.
(2) Move the transmission control lever to the Upper
neutral position or the selector lever to the "N" limit
position. Then place the transfer shift lever to Lower
limit 8 mm
the "2H" position. Apply the parking brake.
Raise the vehicle on a jack. AC505405 AB
Mating marks 2. Check that gear oil level is not 8 mm below the
bottom of filler plug hole.
3. If the gear oil level is lower than the lower limit,
add the specified gear oil until the level comes to
the lower portion of the filler plug hole.
Specified gear oil:
Gear oil API classification GL-5 or higher
SAE 80W
ACX00962 AC
4. Tighten the filler plug to the specified torque
(3) Turn the companion flange clockwise as far as (Refer to P.26-43).
it will go. Make the mating mark on the dust
cover of the companion flange and on the GEAR OIL REPLACEMENT <4WD>
M1262005100196
differential carrier. 1. Remove the under cover and filler plug.
2. Remove the drain plug and drain oil.
3. Tighten the drain plug to the specified torque
(Refer to P.26-43).
4. Add the oil until the level comes to the lower
portion of the filler plug hole.
Specified gear oil:
Gear oil API classification GL-5 or higher SAE
80W
ACX00964 AB Amount to use: 1.2L
(4) Turn the companion flange anti-clockwise as 5. Tighten the filler plug to the specified torque
far as it will go, and measure the amount of (Refer to P.26-43).
distance the mating marks moved.
WHEEL BEARING AXIAL PLAY CHECK
Limit: 11 mm M1261001100544
2. If the backlash exceeds the limit, remove the 1. Remove the caliper assembly and brake disc, and
differential carrier assembly and final drive gear. retain the caliper assembly with a wire and the like
Then check the differential gear meshing to prevent from falling (Refer to P.26-14, P.26-16).
condition and the looseness of the driveshaft or
inner shaft splines.
26-12 FRONT AXLE
ON-VEHICLE SERVICE
Plain washer
MB990767
AC711178 AB
MB991618
Solenoid valve A
MB990767
Solenoid valve B
AC711177AB
AC500363 AB
2. Use the following special tools to remove the hub
bolts. 3. Connect a hand vacuum pump to solenoid valve
• Front hub and flange yoke holder (MB990767) A and carry out the following inspections.
• Hub bolt remover (MB991618) (1) Even if the hand pump is operated with no
other operation, no negative pressure
develops.
(2) Negative pressure does not develop when
battery voltage is applied to solenoid valve A.
Meanwhile, negative pressure is maintained
when the vacuum hose of solenoid valve B is
blocked by bending.
(3) When battery voltage is applied to solenoid
valves A and B, negative pressure is
maintained.
FRONT AXLE
ON-VEHICLE SERVICE
26-13
Intake manifold
(2) When battery voltage is applied to solenoid
Vacuum tank valve B, negative pressure disappears.
(3) When battery voltage is applied to solenoid
valve A, negative pressure disappears.
5. Measure the resistance of the solenoid valves.
Standard value: 36 −46 Ω
Solenoid valve A
Solenoid valve B
AC500364 AB
CAUTION
• For vehicles with ABS, do not strike the ABS rotors installed to the front hub assembly against
other parts when removing or installing the front hub assembly. Otherwise the ABS rotors will be
damaged.
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with your finger.
113 ± 9 N·m
74 ± 14 N·m
2
N 9
10 3
1
N 5
40 ± 4 N·m
11
8
4 6 N 7 147 ± 29 N·m
19 ± 3 N·m
AC500366 AB
CAUTION
• For vehicles with ABS, do not strike the ABS rotors installed to the BJ outer race of driveshaft
against other parts when removing or installing the driveshaft. Otherwise the ABS rotors will be
damaged.
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
• *:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in the unladen condition.
Post-installation Operation
• Check the dust cover for cracks or damage by pushing it
with your finger.
113 ± 9 N·m
16
88 ± 10 N·m 19 2
74 ± 14 N·m
8
15 N
105 ± 10 N·m* 10
3
N 11
190 - 210 N·m
40 ± 4 N·m
6
12
14 1 9 ± 2 N·m
9 108 ± 10 N·m 18
147 ± 29 N·m 17
13 N 7 N5 4
AC605728 AD
113 ± 9 N·m
15
88 ± 10 N·m 18 2
74 ± 14 N·m
14 N
105 ± 10 N·m* 9
3
N 10
190 - 210 N·m
40 ± 4 N·m
11 6
8 13 1 9 ± 2 N·m
108 ± 10 N·m 17
147 ± 29 N·m 16
12 N 7 N5 4
AC500367AE
<<C>> TIE ROD END/LOWER ARM BALL JOINT/ <<D>> KNUCKLE REMOVAL
UPPER ARM BALL JOINT DISCONNECTION When removing the knuckle, retain the driveshaft
CAUTION with a wire and the like to prevent from falling.
• Do not remove the nut from ball joint. Loosen
it and use the special tool to avoid possible INSTALLATION SERVICE POINT
damage to ball joint threads. >>A<< WASHER/ FRONT HUB NUT/DRIVESHAFT
• Hang the special tool with cord to prevent it NUT INSTALLATION
from falling. CAUTION
Before securely tightening the front hub nut or
Cord
driveshaft nuts, make sure there is no load on the
wheel bearings. Otherwise the wheel bearings
will be damaged.
<2WD (High Rider)>
Nut MB991897
or Washer
MB992011
Bolt
Ball joint AC208247AJ
Bolt Washer
Parallel
Knob Correct
MB990767 AC607861AC
Wrong AC106821AD
1
2
AC809410AB
MB991000
190 - 210 N·m
Tighten the nut
with the bolt
MB990326 secured
MB991017
AC711871AB
1
2
3
4
226 ± 29 N·m 5
N 7
6
9.0 ± 2.0 N·m
AC602034AB
ABS rotor
1. Crush the bearing cage by using chisel etc., and
MB990560
remove roller bearings from the wheel bearing
inner race (outside).
2. Remove the oil seal.
CAUTION
When removing the inner race (outside) from the
hub, be careful not to damage the hub.
AC500581AB
Grinder
Use special tool bearing remover (MB990560) to pull
out the ABS rotor from the hub.
Knuckle 3. Fix the hub and shave off the wheel bearing inner
MD998917
race (outside).
Chisel
Hub
Inner race
Iron piece (outside)
AC500583AB
MB990931
AC500582AB
MB990938
MB991576 AC511153AB
• Installer bar (MB990938) • Check the front hub and brake disc mounting sur-
• Base (MB991576) faces for galling and contamination.
• Check the knuckle inner surface for galling and
cracks.
FRONT AXLE
DRIVESHAFT ASSEMBLY <4WD>
26-23
DRIVESHAFT ASSEMBLY <4WD>
REMOVAL AND INSTALLATION
M1261003501723
CAUTION
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the earth in an unladen condition.
Pre-removal Operation Post-installation Operation
• Under Cover Removal (Refer to GROUP 51, Under Cover • Press the dust cover with a finger to check whether the
). dust cover is cracked or damaged.
• Gear Oil Draining (Refer to P.26-11). • Gear Oil Supplying (Refer to P.26-11).
• Under Cover Installation (Refer to GROUP 51, Under
Cover ).
• Wheel Alignment Check and Adjustment (Refer to
GROUP 33, On-vehicle Service ).
20 113 ± 9 N·m
19 15
N 21 2
88 ± 10 N·m 18 74 ± 14 N·m
14 N
105 ± 10 N·m* 9
3
N 10
190 - 210 N·m
40 ± 4 N·m
11 6
60 ± 10 N·m
AC500629
AC500411AE
Removal steps (Continued) <<C>> TIE ROD END /LOWER ARM BALL JOINT /
16. Dust cover UPPER ARM BALL JOINT DISCONNECTION
17. Front hub assembly
CAUTION
18. Knuckle
19. LH driveshaft assembly
• Do not remove the nut from the ball joint.
20. LH driveshaft Loosen it and use the special tool to avoid
21. Circlip possible damage to ball joint threads.
22. RH driveshaft assembly • Hang the special tool with a cord to prevent
from falling.
REMOVAL SERVICE POINTS
<<A>> CALIPER ASSEMBLY REMOVAL Cord
1. Remove the caliper assembly with brake hose.
2. Secure the removed caliper assembly with a wire Ball joint
or other similar material at a position where it will Bolt
not interfere with the removal and installation of
the hub assembly and knuckle. MB991897
or
MB992011
<<B>> DRIVESHAFT NUT REMOVAL Nut
AC106820 AE
CAUTION
Do not apply pressure to wheel bearing by the 1. Install special tool ball joint remover (MB991897
vehicle weight to avoid possible damage when or MB992011) as shown in the figure.
driveshaft nut is loosened.
Bolt
Parallel
Knob Correct
MB990767
Wrong AC106821AC
AC102462 AC
2. Turn the bolt and knob as necessary to make the
Use special tool front hub and flange yoke holder
jaws of special tool parallel, tighten the bolt by
(MB990767) to fix the hub and remove the driveshaft
hand and confirm that the jaws are still parallel.
nut.
NOTE: When adjusting the jaws in parallel, make
sure the knob is in the position shown in the fig-
ure.
3. Tighten the bolt with a wrench to disconnect the
tie rod end.
CAUTION
Never disassemble the BJ assembly except when replacing the BJ boot.
13
11 N
9
N 12
N 2
8 (LH)
N1 5N
7 10 N
N 6
13 N3
12 4
11
2 1
6
10
4
(RH)
3
9 8
6 4 1
2 5 3
(LH)
8 2
1
7
2 3 6
1 6
3 10 4 (RH) 10 10
BJ repair kit DOJ repair kit DOJ boot repair kit
AC501569AC
Grease:
Repair kit grease: 120 ± 10 g
Note
The grease in the repair kit should be
divided in half for use, respectively, at
AC500631 the joint and inside the boot.
AC501588 AB
CAUTION
Do not mix old and new or different types of grease, as a special grease is used in the joint.
DISASSEMBLY SERVICE POINTS 1. Remove the balls from the DOJ cage.
<<A>> DOJ ASSEMBLY REMOVAL
ACX01095 AB
ACX01094 AB
FRONT AXLE
DRIVESHAFT ASSEMBLY <4WD>
26-27
2. Remove the DOJ cage from the DOJ inner race in Specified grease: Repair kit grease 125 ± 10
the direction shown in the illustration. g
CAUTION
<<B>> DOJ BOOT REMOVAL Do not secure the boot band (large).
2. Install the circlip onto the DOJ outer race. Place
the DOJ boot over the DOJ outer race, and then
Plastic tape use a boot band (small) to secure the boot.
A
AC000437AB
Inner race
Direction of driveshaft
Cage rotation when vehicle
is moving forward.
AC004718 AB
Boot band
>>B<< DOJ OUTER RACE INSTALLATION
AC004719 AB
CAUTION
The driveshaft joint use special grease. Do not Be sure that the installation direction of the boot
mix old and new or different types of grease. bands is correct.
3. Secure the boot band (large) on DOJ boot.
INSPECTION
M1261003800271
• Check the driveshaft for damage, bending or cor-
rosion.
• Check the driveshaft spline part for wear or dam-
age.
• Check the boots for deterioration, damage or
cracking.
ACX02369 • Check the dust cover for damage or deteriora-
tion.
1. Fill the inside of the DOJ outer race and DOJ boot
with the specified grease.
26-28 FRONT AXLE
DRIVESHAFT ASSEMBLY <4WD>
BJ BOOT (RESIN BOOT) REPLACEMENT 4. Place the BJ boot band (small) against the
M1261005200662 projection at the edge of the boot, and then
secure it so that there is a clearance left as shown
by (A) in the illustration.
CAUTION
• Secure the drive shaft in an upright position
and clamp the part of the BJ boot band to be
crimped securely in the jaws of the special
tool MB991561.
• Crimp the BJ boot band until the special tool
touches the stopper.
ACX00982 AB
MB991561
Stopper
MB991561 AC606919AC
(W)
5. Use the special tool to crimp the BJ boot band
(small).
Adjusting bolt
ACX00993AB
BJ boot (W)
A
Adjusting bolt
ACX00993AB
BJ boot band
(small)
6. Check that crimping amount (B) of the BJ boot
Projection band is at the standard value.
Standard value (B): 2.4 − 2.8 mm
AC001175 AB
<If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 3 according to
the following formula, and then repeat the
operation in step 5.
FRONT AXLE
DRIVESHAFT ASSEMBLY <4WD>
26-29
W = 5.5 mm − B
Example: If B = 2.9 mm, then W = 2.6 mm.
<If the crimping amount is smaller than 2.4
mm> BJ boot Projection
Remove the BJ boot band, readjust the value of BJ boot band
(W) in step 3 according to the following for-
mula, and then repeat the operations in D
steps 4 and 5 using a new BJ boot band.
W = 5.5 mm − B
Example: If B = 2.3 mm then W = 3.2 mm. AC001177AB
C
E AC004720 AB
MB991561
Stopper
AC001176 AB
(W)
9. Install the BJ boot band (large) so that there is the
clearance (C) between it and the BJ housing is at
the standard value. Adjusting bolt
Standard value (C): 0.05 − 1.55 mm
ACX00993AB
10.Follow the same procedure as in step 3 to adjust 13.Check that the crimping amount (E) of the BJ boot
the size of the opening (W) shown on special tool band is at the standard value.
MB991561 so that it is at the standard value. Standard value (E): 2.4 − 2.8 mm
Standard value (W): 3.2 mm <If the crimping amount is larger than 2.8 mm>
Readjust the value of (W) in step 10 according
to the following formula, and then repeat the
operation in step 12.
W = 5.8 mm − E
Example: If E = 2.9 mm, then W = 2.9 mm.
<If the crimping amount is smaller than 2.4
mm>
Remove the BJ boot band, readjust the value of
(W) in step 10 according to the following for-
mula, and then repeat the operating in steps
11 and 12 using a new BJ boot band.
26-30 FRONT AXLE
INNER SHAFT ASSEMBLY <4WD>
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
Pre-removal and Post-installation Operation
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover .)
• Gear Oil Draining and Supplying (Refer to P.26-11.)
• Driveshaft <RH> Removal and Installation (Refer to P.26-
23).
• Shock absorber assembly <RH> Removal and Installation
(Refer to GROUP 33, Shock Absorber Assembly .)
12 ± 2 N·m
3N 10 12 AC500641
11
90 ± 10 N·m
90 ± 10 N·m* N4
1
8
105 ± 15 N·m 7
25 ± 5 N·m
6
N 9
17 ± 3 N·m 5 AC804444AB
differential carrier, be careful that the spline part Press-fit the new dust seal into the housing tube by
of the inner shaft does not damage the oil seal. using the following special tools, until it is flush with
the housing tube end face.
MB990906 • Installer bar (MB990938)
• Oil seal installer (MB990955)
N 2
1
AC804403AB
DISASSEMBLY SERVICE POINT 3. Press out the inner shaft from the bearing.
<<A>> BEARING REMOVAL
REASSEMBLY SERVICE POINTS
>>A<< DUST COVER INSTALLATION
Steel pipe
ACX01002AB
MB990560
>>B<< BEARING INSTALLATION
ACX01003 AB
ACX01016AB
ACX01013 AB
FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
26-33
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH
<4WD>
REMOVAL AND INSTALLATION
M1262001800201
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
Pre-removal and Post-installation Operation
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover .)
• Front Axle Gear Oil Level Check (Refer to P.26-11.)
• Driveshaft Removal and Installation (Refer to P.26-23.)
• Inner Shaft Removal and Installation (Refer to P.26-30.)
12 ± 2 N·m
7
8 18
16 54 ± 5 N·m
2N
59 ± 9 N·m 1
90 ± 10 N·m
15 19
13 9
105 ± 15 N·m
90 ± 10 N·m * 5 14 N 17
6
25 ± 5 N·m
6
105 ± 15 N·m
5
17 ± 3 N·m 12 11 10
90 ± 10 N·m * 108 ± 10 N·m
3
Housing
tube end
(Differential 3 108 ± 10 N·m
side)
AC501624
Sealant: 4
ThreeBond 1217 or equivalent
AC804263 AC
AC505406 AD
AC505406 AD
<Vehicles with
<Vehicles with Super select Mating marks
Super select Mating marks
4WD>
4WD>
AC804574AC
AC804574AC
Install the front propeller shaft so that the mating
Make mating marks on the flange yoke and the dif- marks of the flange yoke and the differential carrier
ferential carrier companion flange. Remove the front companion flange are aligned.
propeller shaft.
FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
26-35
INSPECTION Shaft (Switch) Tester Specified
M1262001900123
position connection condition
FREEWHEEL ENGAGE SWITCH CHECK
Pressed (ON) 1-2 Continuity (Less
<Except for Russia>
than 2 Ω)
Released (OFF) - Open circuit
1 2
Ball
FREE WHEEL CLUTCH DISASSEMBLY
AND REASSEMBLY <Except for Russia>
M1262002900159
OFF ON
ACX01021AB
14
13
12
11 AC500711
7 1
3
9 2
10
5
8 4
6
AC804392 AB
MB990560
AC500716 AB
MB990560
2. Using a press and special tool bearing remover
ACX01023 AB
(MB990560), hold the supports against the
1. After special tool bearing remover (MB990560) bearing inner race, and separate the clutch gear
has been installed as shown, tighten the nut of and bearing.
special tool until portion "A" of special tool touches
the bearing outer race. REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
CAUTION
Do not allow the mainshaft to drop.
2. Press out the mainshaft from the bearing. MB990799
MB991318
Oil seal
Clutch gear Rag Housing tube
AC500717 AB
Clutch gear
ACX01027AB
Spacer
AC500718 AB
Main shaft
ACX01031AB
0 – 1 mm
AC500719AB
Press-fit the bearing to the shoulder of the mainshaft.
26-38 FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
DISASSEMBLY
M1262002300146
28 21 20 N
N 29
7 34 31
22
32 24 23
26 25
6 27 30
17
N 2 16 33 N
1 4N
3
19
12 18
14 13 16 15
5 17
1811
8 10 9
AC500723AC
Wedge
AC102888 AC
AC102891 AC
MB990811 MB990767
ACX01041AC
• Differential side bearing cap (MB990811) Use special tool front hub and flange yoke holder
NOTE: There are two notches provided (at the differ- (MB990767) to hold the companion flange, and then
ential case side) for the claw part of the special tools; remove the companion flange self-locking nut.
use special tools at that position.
26-42 FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
<<G>> DRIVE PINION ASSEMBLY REMOVAL <<I>> DRIVE PINION FRONT BEARING OUTER
CAUTION RACE REMOVAL
The mating mark made on the companion flange
MB990939
must not be on the coupling surface of the flange
yoke and the front propeller shaft.
ACX01046AB
MB990339
ACX01047 AB
Use the following special tools to pull out the front MB990590
bearing inner race.
• Bearing puller (MB990339)
• Bearing remover (MB990648)
AC004791 AB
13 14 15 N
28 N 12
1 4
10
9
3 8 216 ± 29 N·m
84 ± 4 N·m 6 7
29 5 11
18 2N
N 33 19
59 ± 4 N·m
34 31 N
16 32 65 ± 5 N·m
23 17
21 22 20
19 18
30 1724
50 ± 10 N·m
27 25 26
18 ± 3 N·m
AC501704AB
23
21 22 20
18
17
17 18 5 15
20
Pinion shaft kit Differential gear set Final drive gear set
Adhesive:
LOCTITE No.271 or No.270 or equivalent
<Vehicles with
A A Easy select 4WD>
Section A-A
2 - 3 mm
AC501724 AC501723
Semi-drying sealant:
ThreeBond 1217 or equivalent
AC502341 AF
FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
26-45
REASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION >>D<< DRIVE PINION HEIGHT ADJUSTMENT
Adjust the drive pinion height as follows:
MB990938
MB990934
Oil seal
MB990819 Washer
ACX01051AB
ACX01054 AB
Use the following special tools to insert the oil seal,
and then apply a thin coat of multipurpose grease to 1. Apply multipurpose grease to the washer of
the lip of the oil seal. special tool drive pinion gauge assembly
• Installer bar (MB990938) (MB990819).
• Installer adapter (MB990934) 2. Install special tool, drive pinion front and rear
bearing inner races to the gear carrier.
>>B<< DRIVE PINION REAR BEARING OUTER
CAUTION
RACE INSTALLATION
There should be no gear oil adhered to the bear-
ing.
MB990819
MB990938
MB990936
AC004801 AB
MB990938
MB990934
ACX01056AB
Standard value:
Bearing Bearing Turning torque
division lubrication
New None (with anti- 0.83 − 1.19 N⋅m D
rust agent) Cylinder gauge
NOTE: Because special tool preload socket
(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure AC102914 AC
the turning torque.
9. Install the bearing cap, and then use a cylinder
4. Clean the side bearing seat of the differential
gauge and micrometer to measure the inside
carrier and bearing caps.
diameter (D) of the bearing cap as shown in the
Notch MB991170 illustration.
10.Calculate the thickness (E) of the required drive
pinion rear shim by the following formula, and
A then select a shim which most closely matches
this thickness.
E = A + B + C - 1/2D - 100.0 mm
Drive
pinion
Thickness gauge MB990819 ACX01057AC rear MB990802
shim
5. Place the following special tools in the side
bearing seat of the differential carrier, and position
the notch as shown in the illustration. Then install
the bearing caps. MB990802
• Cylinder gauge (MB991170)
• Drive pinion gauge assembly (MB990819) ACX01060 AC
6. Use a thickness gauge to measure the clearance
(A) between special tools. 11.Fit the selected drive pinion rear shim(s) to the
7. Remove the bearing caps and special tools. drive pinion, and press-fit the drive pinion front
bearing inner race by using special tool bearing
MB990819 installer (MB990802).
MB991170 C
>>E<< DRIVE PINION TURNING TORQUE
ADJUSTMENT
Adjust the drive pinion turning torque by using the
following procedure:
1. Insert the drive pinion into the gear carrier, and
B then install the drive pinion spacer, the drive
pinion front shim, the drive pinion front bearing
ACX01058 AE
inner race, and the companion flange in that
8. Use a micrometer to measure the shown order.
dimensions (B, C) of special tools. NOTE: Do not install the oil seal.
FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
26-47
NOTE:
MB990767
Identification
colour
AC004803 AB
ACX01063 AB
2. Tighten the companion flange self-locking nut to When selecting the drive pinion front shims, if the
the specified torque while holding the companion number of shims is large, reduce the number of
flange with special tool front hub and flange yoke shims to a minimum by selecting the drive pinion
holder (MB990767). spacers.
Tightening torque: 216 ± 29 N⋅m Select the drive pinion spacer from the following
two types.
CAUTION
There should be no gear oil adhered to the Height of drive pinion Identification colour
bearing. spacer mm
56.67 White
MB990326
MB990685 57.01 −
MB990031
or
MB990699
ACX01062AB
AC004803 AB
26-48 FRONT AXLE
DIFFERENTIAL CARRIER AND FREE WHEELING CLUTCH <4WD>
6. Install the drive pinion assembly and companion 2. Temporarily install the pinion shaft.
flange with the mating marks properly aligned. NOTE: Do not drive in the lock pin yet.
Tighten the companion flange self-locking nut to
the specified torque while holding the companion Wedge
flange with special tool.
Tightening torque: 216 ± 29 N⋅m
MB990326
MB990685
Side gear
thrust
Side gear spacer
thrust spacer ACX01035 AB
ACX01067AB
Tap ACX01068AB
AC000438 AB
ACX01074AB ACX01036 AB
6. Align the mating marks on the gear carrier and the 10.Measure the drive gear runout at the shoulder on
bearing cap, and then tighten the bearing cap. the reverse side of the drive gear.
Tightening torque: 59 ± 4 N⋅m Limit: 0.05 mm
11.If the drive gear runout exceeds the limit, reinstall
by changing the phase of the drive gear and
differential case, and remeasure.
12.If adjustment is not possible, replace the
differential case or replace the drive gear and
drive pinion as a set.
ACX01034AB
FRONT AXLE
SOLENOID VALVE AND VACUUM HOSE <4WD except for RUSSIA>
26-51
SOLENOID VALVE AND VACUUM HOSE <4WD except for
RUSSIA>
REMOVAL AND INSTALLATION
M1262004500083
8
7
10
9
11
12
12 ± 2 N·m
13
4
14
2
12
15 6 5
3
12
1
16 5.0 ± 1.0 N·m
12 ± 2 N·m 12 ± 2 N·m
AC903982 AB
INSTALLATION SERVICE POINTS 2. Install the vacuum hose assembly and the
>>A<< VACUUM HOSE ASSEMBLY/VACUUM vacuum hoses to the vacuum pipe assembly, so
PIPE ASSEMBLY/VACUUM HOSE INSTALLATION that colour mark (yellow or blue) of the vacuum
pipe assembly will match colour stripe (yellow or
blue) at the vacuum hose assembly and vacuum
Actuator hoses.
Vacuum pipe
assembly
Blue mark Yellow mark
and stripe and stripe
AC500725AB
FRONT AXLE
FRONT DIFFERENTIAL MOUNT <4WD>
26-53
FRONT DIFFERENTIAL MOUNT <4WD>
REMOVAL AND INSTALLATION
M1262001500095
CAUTION
*:Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on
the earth in the unladen condition.
Pre-removal and Post-installation Operation
• Under Cover Removal and Installation (Refer to GROUP
51, Under Cover .)
• Gear Oil Draining and Refill (Refer to P.26-11.)
• Driveshaft Removal and Installation (Refer to P.26-23.)
• Inner Shaft Removal and Installation (Refer to P.26-30.)
59 ± 9 N·m
90 ± 10 N·m* 4N
108 ± 10 N·m 5
6
44 ± 10 N·m
1
108 ± 10 N·m
105 ± 15 N·m
90 ± 10 N·m*
105 ± 15 N·m
2
90 ± 10 N·m *
AC804264 AB
1. Remove insulator with special tool transmission 2. Using the following special tools with a hydraulic
rear oil seal installer (MD999547). press, press fit each insulator to adjust until the
<Front-LH, RH>
hollow part faces as shown and the difference
MB990947
MB990847 between A and B is 0.7 mm.
• Lower Arm Bushing Arbour (MB990947)
• Rear Suspension Bushing Remover and Installer
MB990981
Base (MB990847)
A <Rear> • Mount Bushing Remover and Installer
Front
(MB990981)
3. Install the differential mount bracket (rear) as
B shown, so that the marking is located forward.
AC500727 AB
27-1
GROUP 27
REAR AXLE
CONTENTS
GENERAL INFORMATION
M1271000101426
The rear axle has the following features: • Helical limited slip differential has been adopted
• A banjo type semi-flowing type axle has been as optional. <2WD except High rider>
incorporated. • Hybrid limited slip differential has been adopted
• The wheel bearing is a double taper roller bearing as optional.
and is highly resistant to a thrust load. • Rear differential lock system has been adopted
• ABS rotor for detecting the wheel speed is press- as optional.<4WD>
fitted to the retainer. <Vehicles with ABS>
REAR AXLE
Item Specification
Axle housing Type Banjo
Axle shaft Type Semi-floating
Shaft outer diameter (bearing part × Vehicles without rear 40.0 × 34.5 × 736
centre part) × length mm differential lock
Vehicles with rear 40.0 × 34.5 × 715*2
differential lock − LH
40.0 × 34.5 × 718.5*3
Vehicles with rear 40.0 × 34.5 × 752.25*2
differential lock − RH
40.0 × 34.5 × 749.5*3
Bearing type Double taper roller
Bearing (Outside diameter × inside diameter) mm 80 × 40
DIFFERENTIAL
<2WD>
Item Except High rider High rider
Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 3.909 3.917
Differential type Standard Normal differential Normal differential
equipment
Optional Helical limited slip Hybrid (Helical gear +
equipment differential Viscous coupling unit)
limited slip differential
Differential gear type (Type × Side gear Straight bevel gear × 2 Straight bevel gear × 2
number of gears) Pinion gear Straight bevel gear × 2 Straight bevel gear × 2
Number of teeth Drive gear 43 47
Drive pinion 11 12
Side gear*1 14 19
Pinion gear*1 10 10
Bearing (Outside diameter × Side 80.0 × 45.2 80.0 × 45.2
inside diameter) mm Front 68.3 × 30.2 68.3 × 30.2
Rear 76.2 × 36.5 79.4 × 36.5
REAR AXLE
GENERAL INFORMATION
27-3
<Easy select 4WD>
Item Specification
Reduction gear type Hypoid gear
Reduction ratio 3.917
Differential type Standard Normal differential
equipment
Optional Hybrid (Helical gear + Viscous coupling unit) limited slip
equipment differential or Differential lock system
Number of teeth Drive gear 47
Drive pinion 12
Side gear*1 19
Pinion gear*1 10
Bearing (Outside diameter × Side 80.0 × 45.2
inside diameter) mm Front 68.3 × 30.2
Rear 79.4 × 36.5
<Super select 4WD>
Item Except 5A/T 5A/T
Reduction gear type Hypoid gear Hypoid gear
Reduction ratio 4.100*4, 3.917*5 3.917
Differential type Standard Normal differential Normal differential
equipment
Optional Hybrid (Helical gear + Hybrid (Helical gear +
equipment Viscous coupling unit) Viscous coupling unit)
limited slip differential or limited slip differential or
Differential lock system Differential lock system
Number of teeth Drive gear 41*4, 47*5 47
Drive pinion 10*4, 12*5 12
Pinion gear*1 10 10
Bearing (Outside diameter × Side 80.0 × 45.2*4, 90.0 × 55.0*5 80.0 × 45.2
inside diameter) mm
Front 68.3 × 30.2 68.3 × 30.2
Rear 79.4 × 36.5*4, 90.0 × 36.5*5 79.4 × 36.5
NOTE: .
• *1: This indicates vehicles with normal differential,
but there was no reference made to vehicles with
Helical LSD, Hybrid LSD or Rear differential lock
system.
*2
• :5A/T or except vehicles with High power
engine
• *3:Vehicles with High power engine except 5A/T
• *4:Vehicles for Europe (4AT) and Russia
• *5:Vehicles for Europe (Except 4AT)
27-4 REAR AXLE
SERVICE SPECIFICATIONS
SERVICE SPECIFICATIONS
M1271000301204
SPECIAL TOOLS
M1271000601186
B990767
MB991618
MB991354
MB990241
MB991522
MB990560
MB990890
REAR AXLE
SPECIAL TOOLS
27-7
Tool Number Name Use
MB991367 Special spanner Removal and adjustment of the
side bearing nut
B991367
MB991385 Pin
B991385
MB990810
MB991407
MB990850
A
C MB991171 Pinion height Measurement of the pinion
A: MB990819 gauge set height
B: MB991170 A: Pinion gauge
B
C: MB991169 B: Cylinder gauge
A
C
MB991171 C: Drive pinion
gauge
attachment
MB991534 Cylinder gauge
MB991534
27-8 REAR AXLE
ON-VEHICLE SERVICE
MB990326
MB991168
MB990802
MB990728
ON-VEHICLE SERVICE
REAR AXLE TOTAL BACKLASH CHECK 3. Turn the companion flange clockwise as far as it
M1271001200393 will go. Make the mating mark on the dust cover of
1. Park the vehicle on a flat, level surface. the companion flange and on the differential
2. Move the transmission control lever to the neutral carrier.
position or the selector lever to the "N" position.
Then place the transfer sift lever to the "2H"
position <4WD>. Apply the parking brake. Raise
the vehicle on a jack.
Mating marks
ACX00964
Inspection tool
24 mm
Bottom edge
A of the filler
Bottom edge
Gear oil plug hole
of the filler
level
Gear oil plug hole ACB00140AC
level ACB00137AH
4. Refill the gear oil until the level satisfies the
1. Insert an inspection tool as shown so that it specification.
touches the bottom of the filler plug. The Specified gear oil:
inspection tool: 6 mm-diameter L shaped bar (e.g. Gear oil API classification GL-5 or higher SAE
6 mm-diameter angled hexagon wrench). 80W
2. Pull out the wrench, and then check that the Amount to use:
dimension to the gear oil level is within 24 mm. 1.5 L <2WD (except High rider)>
27-10 REAR AXLE
ON-VEHICLE SERVICE
Pressure
Air
gauge
pressure
AXLE ASSEMBLY
REMOVAL AND INSTALLATION
M1271001700569
CAUTION
• For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed
sensor with tools during servicing work.
• *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle
on the ground in an unladen condition.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Filling and Air Bleeding (Refer to GROUP
35A, On-vehicle Service .)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service .)
17 14
7
2
1
54 ± 5 N·m 7
11
5 6N
52 ± 7 N·m *
4
16
22 ± 3 N·m *
3 12 108 ± 10 N·m
13
AC500808AG
REAR AXLE
AXLE ASSEMBLY
27-13
4 9
3 8
2
1
103 ± 5 N·m
11
7 5
15 ± 2 N·m 6N
22 ± 3 N·m *
12 108 ± 10 N·m
7 13
AC808344 AD
Inner Outer
washer washer
AA500013
AC003833 AC
CAUTION
For vehicles with ABS, be careful not to strike the pole piece at the tip of the front wheel speed sensor
with tools during servicing work.
Pre-removal Operation Post-installation Operation
• Brake Fluid Draining • Brake Fluid Filling and Bleeding (Refer to GROUP 35A,
On-vehicle Service .)
• Parking Brake Lever Stroke Adjustment (Refer to GROUP
36, On-vehicle Service .)
AC501171 AC501171
9 N
54 ± 5 N·m 1
5
<2WD (High rider),
4WD>
3
6 N
2
<2WD (Except High
rider)> 4
5 6 N
3 4
AC805319 AB
MB990211
MB990212
AC500819AB
AC500818AD
Pull the rear axle shaft from axle housing. If the rear
axle shaft is hard to remove, use the following spe-
cial tools.
• Slide hammer (MB990211) MB990938
• Puller body (MB991354) <2WD (except High
rider)> AC500820AB
• Rear axle shaft puller (MB990241) <2WD (High Drive the new oil seal into the rear axle housing end
rider), 4WD> by using the following special tools.
• Installation adapter (MB990930)
• Installer bar (MB990938)
REAR AXLE
AXLE SHAFT ASSEMBLY
27-17
DISASSEMBLY AND REASSEMBLY
M1271002700186
AC501172
Apply to entire inside diameter of oil
seal lip and bearing inner race.
N1
N 2
8
10 6
4
N 9
3
5
7
AC801655AB
Gummed
cloth tape
AC004867 AB
AC004868AB
4. Fix the axle shaft and shave off the remaining 2.0
mm on the side of the retainer bearing.
CAUTION
Be careful not to damage the axle shaft. AC500968 AB
MB990799
AC004869AB
Nut
Bearing
Bolt Washer
case
AC103785 AB
REAR AXLE
AXLE SHAFT ASSEMBLY
27-19
REASSEMBLY SERVICE POINTS 1. Apply multipurpose grease to the roller surface
>>A<< BEARING OUTER RACE INSTALLATION and ends of the bearing.
2. Pass the axle shaft through the bearing case and
the inner bearing inner race and outer bearing
inner race.
MB990890 or CAUTION
MB990891
Both the inner bearing inner race and outer bear-
ing inner race should be press-fitted together.
3. Use special tool ball joint remover and installer A
(MB990799) to press-fit the inner bearing inner
race and outer bearing inner race to the axle
AC004875AB shaft.
Use special tool rear suspension bushing base
(MB990890 or MB990891) to press-fit the bearing >>D<< RETAINER/ABS ROTOR INSTALLATION
outer race to the bearing case.
MB990938
Retainer
MB990799
MB990936
AC501192AB
Outer bearing
inner race
1. Use special tool ball joint remover and installer A
(MB990799) to press-fit the retainer with ABS
rotor to the axle shaft. Check that the press-fitting
AC004896 AB force is at the standard value.
2. Apply multipurpose grease to the outside of the oil 2. If the initial press-fitting force is less that the
seal. standard value, replace the axle shaft.
3. Use the following special tools, press-fit the oil Standard value:
seal into the bearing case until it is flush with the Initial press-fitting force 29,400 or more
face of the bearing case. N
• Installer adapter (MB990936)
• Installer bar (MB990938) Final press-fitting force N 98,000 − 107,800
4. Apply multipurpose grease to the lips of the oil
seal. >>E<< SNAP RING INSTALLATION
A
>>C<< INNER BEARING INNER RACE/OUTER
Snap ring
BEARING INNER RACE INSTALLATION
Axle shaft
Outer bearing
inner race Retainer ring
Inner bearing
AC501193 AB
inner race
Bearing case
MB990799
AC501191AB
27-20 REAR AXLE
AXLE SHAFT ASSEMBLY
4WD indicator
ECU
AC508535 AC508815
10
5 37 ± 6 N·m 11 N
7
12 ± 2 N·m
12 ± 2 N·m
8
AC510986
3
9 5.0 ± 1.0 N·m
AC511009 AC608183 AB
11. Gasket Connect the vacuum hose so that the white mark is
located upward.
27-22 REAR AXLE
REAR DIFFERENTIAL LOCK <4WD>
1 2 3 4
5 6 7 8 9 10
AC608602
REAR DIFFERENTIAL LOCK AIR PUMP 5. Measure the pressure 10 − 20 seconds after the
CHECK pump has stopped.
M1272003100038 Standard value: 24.5 − 39 kPa (-30 − 0°C),
1. Install the air hose to the differential. 24.5 − 34 kPa (0 − 100°C)
Air hose T-joint 6. If the pressure is within the standard value, the
release valve inside the pump is normal.
Differential
7. Check the pump does not begin operating for 5
minutes after it has stopped.
8. If the inspection for steps 4-7 is normal, the pump
Pressure is fully operational.
gauge
REAR DIFFERENTIAL LOCK DETECTION
SWITCH CHECK
M1272001000057
Battery (-)
OFF ON
1
2
Battery (+)
AC508812AB Rod
1 2
2. Connect a pressure gauge to the air pump
discharge outlet nozzle, via the air hose and T-
joint.
3. Apply battery voltage to the air pump connector. AC711365AB
<2WD>
Section A-A <Except High <High rider>
rider>
2.0 - 2.5 mm * 1
2.5 - 3.0 mm * 2 7 9
A A
8
AC808355
Sealant:
Sealant:
ThreeBond 1217 or equivalent
ThreeBond 1217 or equivalent
7 9
6 8
4
54 ± 5 N·m * 1
50 ± 10 N·m
103 ± 5 N·m* 2
1 5N
27 ± 2 N·m* 1
3N
47 ± 7 N·m* 2
NOTE: 60 ± 10 N·m
* 1 : Except High rider 2
* 2 : High rider
AC808347AD
1
AC808355
103 ± 5 N·m 5N
Sealant: 22 ± 4 N·m
4 60 ± 10 N·m
ThreeBond 1217 or equivalent 47 ± 7 N·m
AC900084AD
Vacuum
hose
AC508832AE
<Vehicles with
AC502392 High power
Remove the attaching nuts. Strike the lower part of engine
except 5A/T>
differential carrier assembly with a piece of wood
Vacuum
several times to loosen the assembly. Remove the hose
assembly.
Mating marks
AC808356AB
CAUTION
Do not disassemble the limited slip differential case assembly.
5
2 1 6 4
1312
9
10 11
8 7
14
6 5
29 3 11
12 13 2
10
N 25 27
17
1
28 22 23 24
20 21 <Limited slip differential>
3
N 16 26 19
18 1 5 6 4
7
2
6 5
2
15 1
AC611940AC
2
3 8 7
9
5
12
15 N 17 33 13
9 8
10 11
16
18
21 N 19
26 27 28
24 25 32 3 2
6
30 31 23
20 N 29 N
22
AC804640AB
ACX01042AB
MB990810
ACX01048AB
AC203814 AC
Use the following special tools to pull out the side MB990850
bearing inner race.
• Side bearing puller (MB990810)
• Differential support bush arbour (MB991407)
NOTE: Attach the prongs of special tools to the inner
race of the side bearing through the openings in the
ACX01043AB
differential case.
Use special tool end yoke holder (MB990850) to hold
the companion flange, and then remove the compan-
ion flange self-locking nut.
27-30 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
<<H>> DRIVE PINION ASSEMBLY/COMPANION Use special tool remover (MD998801) to pull out the
FLANGE REMOVAL front bearing inner race.
CAUTION
Do not make mating marks on the contact sur- <<J>> OIL SEAL/DRIVE PINION FRONT BEARING
faces of the companion flange and propeller INNER RACE/DRIVE PINION FRONT BEARING
shaft. OUTER RACE REMOVAL
1. Make mating marks to the drive pinion and MB990939
companion flange.
MB990810
Drive pinion rear
bearing outer
Drive pinion front race
bearing outer race
Drive pinion front
bearing inner
race
Oil seal
Companion ACX01101AB
flange
Use special tool brass bar (MB990939) to remove
AC102894 AD
the drive pinion front bearing outer race.
2. Use special tool side bearing puller (MB990810) <<K>> DRIVE PINION REAR BEARING OUTER
to pull out the companion flange. RACE REMOVAL
MD998801
ACX01102 AB
17 18 20
20 16
17
18 AC502389 AC502391
19 ± 3 N·m
32 26 27
31
25 18 ± 3 N·m
29
6.9 ± 1.0 N·m
74 ± 5 N·m 22
15 ± 2 N·m N 17 21
37 ± 6 N·m
19 24 25 26
16 23
32
18
8.9 ± 1.9 N·m
N 15
5 4
2 6 19 ± 3 N·m
10 9 152 ± 15 N·m 31
28
7 3 11
N 14 13
12 8 N 1
216 ± 29 N·m
22
4
14
21
AC502387 AC511010
Final drive gear kit Differential kit
AC804648 AB
<Conventional differential>
Adhesive:
LOCTITE No.271 or No.270 or equivalent
AC508830AC
MB990938
Drive pinion
MB990936 or
attachment MB990820
MB990937
(MB990819)
or
MB991169
MB990819
Washer ( )
AC102907AI AC004937AG
MB990938
MB990819
MB990934
ACX01056AB
ACX01107AB
3. Tighten the nut of special tool a little at a time
Use the following special tools to press-fit the drive while measuring the turning torque of the drive
pinion front bearing outer race. pinion by using the following special tools. Then
• Installer bar (MB990938) confirm that the turning torque (without oil seal) is
• Installer adapter (MB990934) at the standard value.
• Preload socket (MB990326)
>>C<< DRIVE PINION HEIGHT ADJUSTMENT • Torque wrench (MB990685)
Adjust the drive pinion height by the following proce- Standard value:
dures:
REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-35
8. Use a micrometer to measure the shown
Bearing type Bearing Turning torque
dimensions (B, C) of special tools.
lubrication
New None (with anti- 0.59 − 0.88 N⋅m
rust agent)
New or reuse Gear oil applied 0.39 − 0.49 N⋅m
NOTE: Because special tool preload socket D
Cylinder gauge
(MB990326) cannot be turned one turn, turn it
several times within the range that it can be
turned; then, after fitting to the bearing, measure
the turning torque.
AC102914 AC
MB991168
ACX01062AB
A AC201179 AB
Identifi-
cation 6. Install the drive pinion assembly and companion
colour flange with mating marks properly aligned.
ACX01063 AE
Tighten the companion flange self-locking nut to
the specified torque using special tool end yoke
4. If the drive pinion turning torque is not within the holder (MB990850).
standard value, adjust the turning torque by Tightening torque: 216 ± 29 N⋅m
replacing the drive pinion front shim(s) or the drive
pinion spacer.
REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
27-37
NOTE: Do not assemble the thrust block and lock
MB990326 pin yet.
MB990685
Wedge
Side gear
ACX01062AB
thrust
Side gear spacer
7. Use special tools to measure the drive pinion thrust spacer ACX01035 AB
turning torque (with oil seal) to verify that the drive
pinion turning torque complies with the standard 3. Insert a wedge between the side gear and the
value. pinion shaft to lock the side gear.
Standard value: 4. While locking the side gear with the wedge,
measure the differential gear backlash with a dial
Bearing Companion Turning torque indicator on the pinion gear.
division flange
lubrication Standard value: 0.01 − 0.25 mm
New None (with anti- 0.84 − 1.12 N⋅m 5. Measure by the same procedure for the other
rust agent) pinion gear.
6. If the backlash exceeds the limit value, replace
Gear oil applied 0.64 − 0.73 N⋅m
side bearing adjustment spacers.
8. If the turning torque is not within the standard 7. If adjustment is not possible, replace the side
value, check the tightening torque of the gears and pinion gears as a set.
companion flange self-locking nut, and the
8. Check that the backlash is within the limit value
installation of the oil seal.
and that the differential gear turns smoothly.
>>E<< DIFFERENTIAL GEAR BACKLASH
>>F<< LOCK PIN INSTALLATION
ADJUSTMENT
1. Align the pinion shaft lock pin hole with the
Adjust the differential gear backlash by the following
differential case lock pin hole, and drive in the lock
procedure:
pin.
ACX01066
ACX02429
Tap ACX01068AB
MB991385
ACX02430
When backlash is
insufficient MB092153 MB092154
Loosen Tighten
Tighten Loosen
When backlash is
excessive AC004947AB AC004949 AB
3. Using special tools, adjust the backlash to 5. Choose and install the lock plate (two kinds).
standard value by moving the side bearing nut as 6. Check the final drive gear tooth contact. If poor
shown. contact is evident, make adjustment. (Refer to
NOTE: First loosen the side bearing nut then GROUP 26, Inspection Before Disassembly .)
tighten the side bearing nut the same amount as
when it was loosened.
MB991367
MB991385 AC004950 AB
AC004948 AB
7. Measure the drive gear run-out.
Limit: 0.05 mm
4. Using special tools, apply the preload, turn down
both right and left side bearing nuts on half the 8. When drive gear run-out exceeds the limit,
distance between centres of two neighboring remove the differential case and then the drive
holes. gears, moving them to different positions and
reinstall them.
9. If adjustment is not possible, replace the
differential case or drive gear and drive pinion as
a set.
27-40 REAR AXLE
DIFFERENTIAL CARRIER ASSEMBLY
5
7
1 8 15 14
21 20 6
19
18 4
17 3
16 2
15
14 13 10
12
11
9 AC511011
5 16 7
17 8
14 3, 17
6
13
15 15
10 14
12 3
9 4
AC511013 11 AC511012 AC511014
Thickness
gauge
Differential
case A
Side
gear LH
AC511076 AB
Mating marks
AC511032AB
1. Insert a thickness gauge from the hole of
differential case (A) between the differential case 1. Align the mating marks (the same numeral on
(A) and side gear LH and measure the clearance. each case) of differential case (A) and differential
2. Select the spacer so that the clearance will meet case (B).
the standard value. 2. Tighten the screw so that the cases are in close
contact.
31-1
GROUP 31
SERVICE SPECIFICATIONS
M1311000300644
Item Limit
Tread depth of tyre mm Minimum 1.6
Wheel runout Radial runout mm 1.2 or less
<Steel wheel> Lateral runout mm 1.2 or less
Wheel runout Radial runout mm 1.0 or less
<Aluminium wheel> Lateral runout mm 1.0 or less
TROUBLESHOOTING
DIAGNOSIS
M1311000700835
ACX00925AB
ACX00926AB
Cracked Under-inflation
treads
ACX00927AB
WHEEL AND TYRE
TROUBLESHOOTING
31-3
Symptom Probable cause Remedy Reference page
Wear on one Excessive Check the camber. Refer to GROUP
side camber 33, On-vehicle
service − Front
wheel alignment
check and
ACX00928 AB
adjustment <2WD
ACX00929 AB (Except HIGH
RIDER) > , <2WD
Feathered Incorrect toe-in Adjust the toe-in.
(HIGH RIDER) and
edge
4WD> .
ACX00930AB
ACX00931AB
ACX00932AB
ACX00933 AB
Scalloped Lack of rotation of tyre or worn Rotate the tyre, and Refer to GROUP
wear or out-of-alignment suspension check the front 33, On-vehicle
suspension service − Front
alignment. wheel alignment
check and
ACX00934
adjustment <2WD
(Except HIGH
RIDER) > , <2WD
(HIGH RIDER) and
4WD> .
3. Install a wheel mounting cone. The appropriate 5. When installing wheel weights, hammer them at a
size cone for this vehicle is 56.0 mm. straight (not diagonal) angle.
4. Before balancing the wheel, remove any wheel
weights from both sides. Also check both sides for
any damage.
Clamping cup
Hub/shaft assembly
Wing nut
Spring plate
Wheel mounting cone AC000041AB
Standard passenger car wheel
<CONFIRMING PROPER BALANCE> • If the imbalance is 5 g or less, the wheel may not
1. After balancing the wheel, loosen the wing nut be centred on the balancer, or the balancing
and turn the wheel 180° against the balancer's cones, the cup, and/or wing nut are damaged,
hub. Then re-tighten the wing nut and check the dirty, or inappropriate for the wheel. You may
balance again. Repeat wheel balance if need to refer to the balancer manufacturer's
necessary. instructions to verify the correct attachments.
After making the necessary corrections, recheck
2. Turn the wheel again 180° against the balancer's
the wheel balance. If OK, then go to Step 4.
hub. If the wheel becomes out-of-balance each
• If the imbalance is more than 5 g, the balancer
time it is turned against the balancer's hub, the
requires calibration. Contact the balancer manu-
wheel balancer may require calibration.
facturer for calibration by their repair representa-
tive.
<WHEEL BALANCER CALIBRATION
4. <<Static Balance Check>>
CHECKS>
Attach a 5 g weight to the outer rim. Recheck the
1. Mount an undamaged original-equipment alloy
balancer. The balancer should detect 5 ± 2 g of
rim and tyre assembly (wheel) onto your off-the-
imbalance 170 to 190° away from the 5 g weight.
car wheel balancer. Balance the wheel.
• If the imbalance is within specification, the static
2. <<Zero Calibration Check>> balance calibration is correct. Go to Step 5 to
Loosen the balancer wing nut, rotate the wheel a check the dynamic balance.
half-turn (180°), and retighten the nut. Recheck • If the imbalance is out of specification, the bal-
the balance. ancer requires calibration. Contact the balancer
• If the imbalance is 5 g or less, the zero calibration manufacturer for calibration by their repair repre-
is OK. Rebalance the wheel, then go to Step 4 to sentative.
check static balance. 5. <<Dynamic Balance Check>>
• If the imbalance is more than 5 g, go to Step 3.
Attach a 5 g weight to the inner rim at 180°
3. Loosen the balancer wing nut, rotate the wheel 1/ opposite the 5 g weight that was added in Step 4.
4 turn (90°), and retighten the nut. Recheck the Recheck the balance. The balancer should detect
wheel balance. 5 ± 2 g of imbalance 170 to 190° away from both
the inner and outer 5 g weights.
• If the imbalance is within specification, the
dynamic balance calibration is correct. The bal-
ancer calibration checks are complete.
WHEEL AND TYRE
TROUBLESHOOTING
31-5
• If the imbalance is out of specification, the bal- WHEEL BALANCER CALIBRATION
ancer requires calibration. Contact the balancer CHECKING FLOW CHART
manufacturer for calibration by their repair repre-
sentative.
Balance wheel.
ZERO CALIBRATION
Rotate wheel 1/2 turn. CHECK
Rebalance wheel.
Rotate wheel 1/4 turn.
STATIC BALANCE
Attach a 5 g weight to the outer rim.
CHECK
Is the imbalance 5 ± 2 g at 170 – 190˚ away from the
5 g weight?
YES NO
DYNAMIC BALANCE
Attach a 5 g weight to the inner rim at 180˚ opposite CHECK
the weight on the outer rim.
Is the imbalance 5 ± 2 g at 170 – 190˚ away from
both 5 g weights?
YES NO
AC502720AB
31-6 WHEEL AND TYRE
ON-VEHICLE SERVICE
ON-VEHICLE SERVICE
TYRE INFLATION PRESSURE CHECK WHEEL RUNOUT CHECK
M1311000900516 M1311001100609
NOTE: For information on tyre inflation pressure,
refer to the label attached to the centre pillar on the
driver's side.
Radial
TYRE WEAR CHECK
M1311001000594
Measure the tread depth of the tyres.
Minimum limit: 1.6 mm
If the remaining tread depth is less than the minimum
limit, replace the tyre. Lateral
ACX00651AB
NOTE: When the tread depth of the tyres is reduced Jack up the vehicle so that the wheels are clear of
to 1.6 mm or less, wear indicators will appear. the floor. While slowly turning the wheel, measure
wheel runout with a dial indicator.
Limit:
Item Steel wheel Aluminium
wheel
Radial runout 1.2 or less 1.0 or less
mm
Lateral runout 1.2 or less 1.0 or less
mm
If wheel runout exceeds the limit, replace the wheel.
13 ± 2 N·m
AC501849AB
32-1
GROUP 32
POWER PLANT
MOUNT
CONTENTS
GENERAL INFORMATION
M1321000101699
For engine and transmission mounts, gravity-centre • Cup-type stopper cover made of heat-resistant
support engine type has been adopted as follows: 3- material has been adopted to abolish the heat
point support type (two places at the engine and one protector for light weighting.
place at the transmission) for A/T vehicles, and 4- • Low-speed action spring material has been
point support type (two places at the engine, one adopted for front engine support insulator and
place at the transmission and one place at the trans- rear engine support insulator to reduce vibration
fer) for 4WD-M/T vehicles. transmission ratio of the power plant.
• The clearance of the stopper for front engine sup-
port insulator has been enlarged to improve
vibration at the vehicle start-up.
POWER PLANT MOUNT
FRONT ENGINE MOUNTING
32-3
CONSTRUCTION DIAGRAM
Front engine support insulator
Stopper cover
Stopper
Transfer roll
stopper <4WD-M/T>
<4WD-M/T>
No.2 crossmember
Rear engine
support insulator
AC903785 AB
CAUTION
Do not distort rubber portions, and never stain rubber portions with fuel oil.
Pre-removal and Post-installation Operation
• Engine Assembly Removal and Installation (Refer to
GROUP 11A − Engine Assembly ).
32-4 POWER PLANT MOUNT
FRONT ENGINE MOUNTING
1
26 ± 5 N·m
3
1
26 ± 5 N·m
2
48 ± 7 N·m
2
48 ± 7 N·m
3
AC505370AC
INSPECTION
M1321006700016
Check the front engine support insulator for cracks,
separation or deformation.
POWER PLANT MOUNT
REAR ENGINE MOUNTING
32-5
REAR ENGINE MOUNTING
REMOVAL AND INSTALLATION
M1321005600232
2
2
1
1
83 ± 12 N·m
23 ± 2 N·m
83 ± 12 N·m
23 ± 2 N·m
83 ± 12 N·m 83 ± 12 N·m
<4WD-A/T> <4WD-M/T>
46 ± 8 N·m 3
2
46 ± 8 N·m
44 ± 10 N·m
44 ± 10 N·m 44 ± 10 N·m
44 ± 10 N·m
2
83 ± 12 N·m
46 ± 8 N·m
83 ± 12 N·m
46 ± 8 N·m
83 ± 12 N·m
83 ± 12 N·m
AC903789 AB
REMOVAL SERVICE POINT Use a transmission jack to support the manual trans-
<<A>> SUPPORT THE MANUAL TRANSMISSION mission assembly or automatic transmission assem-
ASSEMBLY OR AUTOMATIC TRANSMISSION bly.
ASSEMBLY
INSPECTION
M1321005700079
Check the rear engine support insulator for cracks,
M/T assembly or separation or deformation.
A/T assembly
Transmission jack
AC503630 AB
25 ± 5 N·m
45 ± 9 N·m
1
25 ± 5 N·m
3
25 ± 5 N·m
25 ± 5 N·m
AC806115AB
Removal steps
>>A<< 1. Transfer roll stopper
(B) Approx. 6 mm
2. Transfer mount bracket
3. Transfer mount bracket assembly Approx.
10 mm
INSTALLATION SERVICE POINT (A)
>>A<< TRANSFER ROLL STOPPER INSTALLA-
TION (B)
1. Tighten the transfer roll stopper provisionally. Approx. 6 mm
Approx. 6 mm (B)
AC503956AB
GROUP 33
FRONT
SUSPENSION
CONTENTS
GENERAL INFORMATION
M1332000102168
The Independent-wishbone, coil springs has been
adopted.
CONSTRUCTION DIAGRAM
<2WD (except High rider)>
Upper arm
Shock absorber
Strut bar
Coil spring
Lower arm
AC501759 AB
Coil spring
Stabilizer bar
Lower arm
AC608652 AC
FRONT SUSPENSION
SERVICE SPECIFICATIONS
33-3
<4WD>
Coil spring