F&G Series EURO 5

2011MY
2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL GENERAL INFORMATION

GENERAL INFORMATION
No.MGGEN-WE-1101AU
MGGEN-WE-1101AU_67039_前書 2010.11.5 4:24 PM ページ 1
This Workshop Manual deals only with the screen toned section(s) in the table below.
Section Sub Section
0 GENERAL INFORMATION 0A General Information
1 ENGINE 1A Engine Control System
1B Engine Mechanical
1C Engine Cooling
1D Engine Fuel
1E Engine Electrical
1F Emission Control
1G Engine Exhaust
1H Engine Lubrication
1I Engine Speed Control System
1J Induction
1K Pre-Heating System
1L Power Take-Off (PTO)
2 SUSPENSION 2A1 Air Suspension Control System
2B Front Suspension
2C Rear Suspension
2D Wheel and Tire System
3 DRIVELINE/AXLE 3A1 Front Differential
3A2 Rear Differential
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4 BRAKES 4A2 Brake Control System (Air Over)
4A3 Brake Control System (Full Air)
4B2 Brake (Air Over)
4B3 Brake (Full Air)
4C Anti-Lock Brake (ABS)
4C1 Anti-Lock Brake (ABS)/Anti-Slip Regulator (ASR)
4D Parking Brake
4E Hill Start Aid (HSA)
4F Speed Retarder System
5 TRANSMISSION/TRANSAXLE 5A Transmission Control System
5B Automatic Transmission
5C Manual Transmission
5E Clutch
5G1 Side Power Take-Off
5G3 Rear Power Take-Off
6 STEERING 6B Power Steering
7 HVAC 7A Heating and Ventilation
7B Manual Air Conditioning
7C Automatic Air Conditioning
8 RESTRAINTS 8A Seat Belt
8B Supplemental Restraint System (SRS)
8C SRS Control System
9 BODY, CAB AND ACCESSORIES 9A Lighting System
9B Wiper/Washer System
9C Entertainment
9D Wiring System
9E Instrumentation/Driver Info.
9F Body Structure
9G Cab
9H Seats
9I Security and Lock
9K Exterior/Interior Trim
9L Cab Mounting
10 CONTROL SYSTEMS 10B Vehicle Control
11 FRAME AND FRAME ACCESSORIES 11A Frame
MGGEN-WE-1101AU_67039_前書 2010.11.5 4:24 PM ページ 2
MGGEN-WE-1101AU.book 1 ページ２０１０年１２月６日　月曜日　午後２時２１分
General Information 0A-1
GENERAL INFORMATION
General Information
TABLE OF CONTENTS
General Information . . . . . . . . . . . . . . . . . . . . . . . 0A-2 Diesel Fuel / Applicable Standard
General Repair Instructions . . . . . . . . . . . . . . . 0A-2 (Sulfur content below 10 ppm) . . . . . . . . . . . . 0A-53
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . . 0A-54
Chassis Number/Engine Number Stamping Oil Viscosity Chart . . . . . . . . . . . . . . . . . . . . . . 0A-54
Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-3 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . 0A-55
Option Code List . . . . . . . . . . . . . . . . . . . . . . . . 0A-4 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . 0A-55
Vehicle Identification Number (VIN) . . . . . . . . 0A-10 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-59
General Precaution . . . . . . . . . . . . . . . . . . . . . . 0A-12 Greasing Point . . . . . . . . . . . . . . . . . . . . . . . . 0A-59
General Precautions . . . . . . . . . . . . . . . . . . . . 0A-12
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . . 0A-14
Lifting Instruction . . . . . . . . . . . . . . . . . . . . . . . 0A-14
Caution for The Maintenance of Electrical Parts 0A-17
Battery Cable . . . . . . . . . . . . . . . . . . . . . . . . . 0A-17
Connector Handling Requirements . . . . . . . . . 0A-17
Handling Electronic Parts . . . . . . . . . . . . . . . . 0A-20
Cable Harness . . . . . . . . . . . . . . . . . . . . . . . . 0A-20
Regarding The Scan Tool. . . . . . . . . . . . . . . . . . 0A-22
Trouble Diagnosis Using The Scan Tool . . . . . 0A-22
Recommended Liquid Gasket . . . . . . . . . . . . . . 0A-27
Recommended Liquid Gasket. . . . . . . . . . . . . 0A-27
Recommended Thread Locking Agent. . . . . . . . 0A-29
Recommended Thread Locking Agent . . . . . . 0A-29
Maintenance Schedule. . . . . . . . . . . . . . . . . . . . 0A-30
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-30
Maintenance Schedule . . . . . . . . . . . . . . . . . . 0A-31
Transmission Oil - ZF6S1000/ZF9S1110 Type 0A-37
Transmission Oil - FS8209A/FSO5206B Type 0A-44
RS23/RS40 Type Axle . . . . . . . . . . . . . . . . . . 0A-45
RS25 Type Axle . . . . . . . . . . . . . . . . . . . . . . . 0A-46
Maintenance Schedule for Severe-condition . . . 0A-47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-47
Maintenance Schedule for Severe-condition . 0A-47
Recommended Fluids, Lubricants and
Diesel Fuels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-50
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 0A-50
Diesel Engine Crankcase with DPD
(Low Ash Oil). . . . . . . . . . . . . . . . . . . . . . . . . . 0A-50
Manual Transmission (MZW/MLD models),
Transfer Case, Differential (without LSD)
and Oil Lubricated Hub Bearing . . . . . . . . . . . 0A-51
Differential (with LSD) . . . . . . . . . . . . . . . . . . . 0A-51
Smoother Clutch Oil (Smoother) . . . . . . . . . . . 0A-51
Automatic Transmission, Power Steering . . . . 0A-51
Center Bearing, Clutch Shift Block,
Grease Lubricated Hub, Water Pump,
Propeller Shaft Sliding Yoke, Universal
Joint (Multi Purpose Grease) . . . . . . . . . . . . . 0A-52
Engine Cooling System. . . . . . . . . . . . . . . . . . 0A-52
Electric-hydraulic Cab Tilt Pump . . . . . . . . . . . 0A-53
Clutch and Brake Fluid Reservoir . . . . . . . . . . 0A-53
Diesel Fuel / Applicable Standard . . . . . . . . . . 0A-53
0A-2 General Information
General Information
General Repair Instructions 20. Prior to start the welding work, the following
operations are required:
1. Park the vehicle on level ground and chock the
front or rear wheels before lifting the vehicle. • Disconnect all connectors of electronic control
unit.
2. Use covers on the vehicle body, seats, and floor to
prevent damage and/or contaminations. • Disconnect battery ground terminal.
3. Disconnect the grounding cable from the battery • Welding machine ground cable must be
before performing service operations. connected near the welding point.
This will prevent cable damage or burning due to • Turn off the all switches.
shortcircuiting.
4. Raise the vehicle with a jack set against the axle or
the frame.
5. Support the vehicle on chassis stands.
6. Handle brake fluid and antifreeze solution with
great care.
Spilling these liquids on painted surfaces will
damage the paint.
7. The use of the proper tool(s) and special tool(s)
where specified is efficient, reliable, and safe
service operations.
8. Always use genuine ISUZU replacement parts.
9. Discard used cotter pins, gasket, O-rings, oil seals,
lock washers, and self-locking nuts at disassembly.
Normal function of these parts cannot be
guaranteed if they are reused.
10. Keep the disassembled parts neatly in groups.
This will facilitate smooth and correct reassembly.
11. Keep fixing nuts and bolts separate.
Fixing nuts and bolts vary in hardness and design
according to installation positions.
12. Clean all parts before inspection or reassembly.
13. Clean the oil ports and other openings with
compressed air to make certain that they are free
of dirt and obstructions.
14. Lubricate the rotating and sliding faces of all
moving parts with oil or grease before installation.
15. Use the recommended liquid gasket to prevent
leakage.
16. Be sure to tighten nuts and bolts to the specified
torque, using a properly maintained torque wrench.
17. When service operation is completed, male a final
check to be sure service has been done properly
and problem has been corrected.
18. When removing or replacing parts that require
refrigerant to the discharged from the Air
conditioning system, be sure to use the ACR4 or
equivalent to recover and recycle Refrigerant -
134a (HFC-134a), to promote the movement for
the protection of the ozone layer covering the
earth.
19. To assure safety, always slowly release air
pressure from the air tanks before disconnecting
pipes, hoses or other parts from any unit under
pressure.
Identification
Chassis Number/Engine Number Stamping Engine number (6HK1 Engine)
Position The engine number is stamped on the right side of the
Chassis number cylinder body.
It is stamped on the front right-hand side face of the
chassis side member.
MFW80ASH000401
Service Parts ID Plate

MFW70ASH000101
The service parts ID plate is attached to the passenger
Engine number (4HK1 Engine) side lower dashboard.
The service parts ID plate has the following information;
The engine number is stamped on the right side of the
• Vehicle identification number (VIN)
cylinder body.
• Wheelbase dimensions
• Paint information
• Production options or special equipment installed
on the vehicle at the factory
Refer to the service parts ID plate when ordering
replacement parts.
LNWB0ASH000101
MFU8Z0SH043301

Option Code List Option
Option Description
Code
Option DNB O/S rear view mirror - pillar mounted

Option Description
Code D20 Assist side sun visor
AJ3 Driver side air bag D31 Rear view mirror
Front seat belt & shoulder D6M User - export government
AK3
with retractor
D94 Touch-up paint
AK5 Driver and passenger side air bag
EBB Digital tachograph
AU4 Automatic door lock
EBE Front under run protector
A31 Power window - front & rear door
ECF Speed limitter - 60km/h
A32 Power window - front door
ECY Speed limitter - 70km/h
A56 Driver seat - air suspension
EDG Header console - driver & assist
A83 Vinyl seat with reclining
EDH Round curtain rail
BDM Power take off - transmission rear
EDW Speed limitter - 80km/h
BFK Transfer TF56
EDX Speed limitter - 85km/h
Power take off - engine rear,
BHW EFE Regulation - ECE R29
electromagnetic clutch
B1S Parking brake drum - 8.5 inch EFK Floor mat - vinyl mat Var.2
B1T Parking brake drum - 10 inch E2N Fuel pipe - steel
B13 Australia equipment E29 Auxiliary steps
Rear wheel parking brake - air E40 Sleeper cab with mattress
B3A
control Disc wheel - 10 studs 20 x 8.50V
FJC
B30 Floor carpet - vinyl (138-13)
B84 Body side molding F59 Front stabilizer
CE4 Head lamp washer GL6 Rear shock absorber
C13 Wiper with intermittent GN1 Rear stabilizer
C2C Transmission oil cooler G86 Limited slip differential - no spin
C2M Propeller shaft - P60 type JAQ Lighting system - Saudi Arabia
C3N Final differential lock JBZ Lighting system - Japanese standard
C3U Air suspension - high control JCA Anti-noise equipment - ECE R51.02
C4M Air breather with flex hose JE5 Anti-lock brake system
C4Z Propeller shaft - P46 type J55 Brake system - heavy duty Var.1
C41 Heater & defroster J91 Trailer brake control
C5K Hub lubrication - oil bath KF0 Fuel filter - low quality
C5T Propeller shaft - P90 type KG2 Generator 24V60A
C60 Manual air conditioning K30 Auto cruise
Manual air conditioning K44 Generator 24V-90A

C65
without heater core K89 Generator 24V-50A
C68 Automatic air conditioning NF7 Fuel tank 200L + 200L
DH2 O/S rear view mirror - long arm NMJ Speed limitter - 90km/h
O/S rear view mirror - remote control NMU Speed limitter - 100km/h
DL8
with heated
Option Option
Option Description Option Description
Code Code
NNR 3 speaker system R32 KD frame
NT5 Emission system - Euro5 R46 Spare tire & disc wheel
N02 Fuel tank 100L - frame side mount R9C Deletion - service cab with electric
N05 Fuel tank cap with key lock R9D Deletion - service cab without electric
N19 Fuel tank - 140L frame side Deletion - service cab conversion
R9F
without electric
N20 Fuel tank 200L - frame side mount
SAQ Front suspension - multi leaf spring
N79 Spare disc wheel
SAR Front suspension - taper leaf spring
PM1 Rear hook - double
SAS Rear suspension - multi leaf spring
PP7 Pintle hook
Rear helper suspension - taper leaf
PR2 Driving position - wide leg space SAU
spring
PS7 Air dryer
SAY Standard cab
Disc wheel - 8 studs 22.5 x 6.75
PT1 SAZ Ventilator & defroster
(145-11)
Disc wheel - 8 studs 20 x 6.00S
P10 Spare tire carrier - frame rear mount SBB
(135-10)
P13 Spare tire carrier - frame side mount
SBG
P38 Tire delete (135-9)
Disc wheel - 10 studs 22.5 x 8.25 SDF Room lamp with all door switch
QM8
(165-13)
SDH Fuel tank 400L
Disc wheel - 8 studs 20 x 6.50T
Q47 SDK Cab suspension - semi floating type
(145-10)
Disc wheel - 8 studs 20 x 7.00T
Disc wheel - 8 studs 20 x 6.50T SDP
Q50 (152-12)
(152-11)
Disc wheel - 8 studs 205 x 7.50V
Disc wheel - 8 studs 20 x 7.00T SEG
Q54 (130-13)
(162-12)
Q58 Disc wheel - 10 studs 20 x 7.00T SFC
(137-10)
Disc wheel - 8 studs 20 x 7.50V
Q62 SFT Electric outlet - one
(165-13)
SGA Front under spoiler delete
Q64 Disc wheel - 10 studs 20 x 7.50V
SG4 Tire inflator device
Q87
(162-12) Disc wheel - 6 studs 16x6.00GS
SG7
(135-9)
RC4 Dump control lever
Power take off - transmission side
RC5 Tool box with key lock SH5
without lever
RE3 Spare tire fixing
SJA Driver seat - Isringhausen
Clutch - 15 inch single plate
RE9 Disc wheel - 8 studs 22.5 x 7.50
strap drive SKU
(162-13)
RJS 4HK1-TCS engine
SKV
RQZ G.V.W. - 8.0 - 11.0 ton (165-13)
RRA G.V.W. - 11.0 - 14.0 ton SK4 Engine overrun buzzer
RR9 O/S rear view mirror - under SLB Front bumper with headlamp
RSW Manual transmission - MZX6P SLC Lighting system - ECE
RWE Chevrolet brand SLK Anti-noise equipment - ECE
Option Option
Code Code
SMS Rear bumper - steel wide Front bumper reinforcement
VG7
- heavy duty
SP9 Assist seat without center seat
VP1 Front under spoiler
SR6 Rearward double tire
VR7 Two eye rear hook
SV6 Power take off control
V22 Radiator grille - chrome
SY8 Spare tire carrier - lifting type
V4F Chassis for fire car
O/S rear view mirror - under & side
TAF
under WB7 Electrical horn
TAK Anti-noise equipment - Var.2 WC7 Tachograph - 140km/h
TAZ Driver seat - rigid without arm rest Clutch - 14 inch single plate
WF6
strap drive
TDU Brake regulation - ADR
WG3 Brake system - heavy duty Var.2
TDV Brake regulation - ECE
WH2 Spare tire - front tire
TEC Roof marker lamp
WJ7 Cautions - Arabian
TEE
(147-12) WJ8 Cautions - French
TFD Cab all painting WL5 Inspection lamp
Driver’s seat belt with pre-tension WM3 Interior trim - full trimming
TFN
reducer
WV2 Automatic cab tilt
TGL Anti corrosion package
WX8 Shift control - assister
TM1 Battery - 80D26L
Final drive gear ratio - 5.571 (39/7)
W1H
TR6 Headlamp leveling system - manual 14.5 inch hypoid
TT5 Halogen headlamp Final drive gear ratio - 6.500 (39/6)
W1J
14.5 inch hypoid
TT6 High intensity discharge headlamp
Injection pump Q set - special W1K
T1A 14.5 inch hypoid
+5%Q
T5X 3 way catalysis control W1L
16.5 inch hypoid
T62 Battery - dry
W1R
T64 Battery delete 15.5 inch hypoid
T79 Rear fog lamp Final drive gear ratio - 4.875 (39/8)
W1U
14.5 inch hypoid
T87 Cornering lamp
W12 Front locking hub - manual
T96 Front fog lamp
W14 Deluxe cab
UC1 Speedometer - miles per hour (MPH)
W16 Cab suspension - full floating
UC9 Tachograph- Kienzle
W18 Transfer TF36
UF3 Map lamp
W20 Disc wheel special painted (white)
UG3 Engine oil temperature gauge
UL5 Radio delete W3B
16.5 inch hypoid
UT3 AM/FM radio with CD player
W3D
U18 Speedometer - kilometer 18.5 inch hypoid
U69 AM/FM radio Final drive gear ratio - 6.167 (37/6)
W3F
18.5 inch hypoid
U95 2 speaker system
Option Option
Code Code
Final drive gear ratio - 6.667 (40/6) Final drive gear ratio - 6.43 (45/7)
W3G W6M
18.5 inch hypoid 18.0 inch hypoid Rockwell
W3K W6N
W3L W6R
W3M W6S
Final drive gear ratio - 4.556 (41/9) W66 Disc wheel with step
W3N
18.5 inch hypoid
W71 Cab suspension - rigid type
W3P Final drive gear ratio - 4.56 (41/9)
16.5 inch hypoid W8C
18.0 inch hypoid Rockwell
W3S Final drive gear ratio - 6.43 (45/7)
15.5 inch hypoid W8D
W3X Final drive gear ratio - 4.555 (41/9)
17.5 inch hypoid W8F
14.5 inch hypoid
W3Y Final drive gear ratio - 6.83 (41/6)
17.5 inch hypoid W8L
W3Z X5J Manual transmission - MLD6Q
17.5 inch hypoid
X7W Manual transmission - MLD6S
W4A
17.5 inch hypoid X9C Transmission - manual
Final drive gear ratio - 4.875 (39/8) X9D Transmission - automatic
W4B
17.5 inch hypoid
Injection pump - high altitude
YC4
Final drive gear ratio - 4.556 (41/9) compensator, aneroid type
W4C
17.5 inch hypoid
YK3 Rearward single tire
W4F YM9 Reversing warning buzzer
14.5 inch hypoid
YN1 Caution - Spanish
W4H
15.5 inch hypoid YS1 O/S rear view mirror - flat type
Final drive gear ratio - 4.333 (39/9) Y2C Manual transmission - MLD6W
W4T
18.5 inch hypoid
Y21 Light duty package truck
W4W Manual transmission
17.5 inch hypoid Y3A
- Fuller FS8209
W4X Automatic transmission
14.5 inch hypoid Y3B
- Allison MD3560P
W5M Automatic transmission
14.5 inch hypoid Y4F
- Allison LCT2000
W5Z Automatic transmission
18.0 inch hypoid Rockwell Y4G
- Allison MD3060P
W6A Manual transmission
18.0 inch hypoid Rockwell Y4V
- Fuller FSO5206B
W6B Y48 Heavy duty package truck
Y5D Manual transmission - ZF 6S1000
W6C
18.0 inch hypoid Rockwell Y5E Manual transmission - ZF 9S1110
Option Option
Code Code
Brake system - air over hydraulic 46W Wheel base 4,600mm
Z05
dual circuit
48W Wheel base 4,800mm
Z06 Brake system - full air dual circuit
Z1V Equipment - additional key
Tire - front & rear
5E0
01R Tire - front & rear 8.25-20-14 lug 295/80R22.5-152/148J rib
05R Tire - front & rear 8.25R20-14 rib 5E1 Tire - front & rear 10R22.5-14
Tire - front 8.25-20-14 rib, Tire - front 295/80R22.5,
09X 5G2
rear 8.25-20-14 lug rear 11R22.5-16
10T Tire - front & rear 9.00-20-14 rib Tire - front 10.00-20-16 rib,
5H1
rear 10.00-20-16 lug
Tire - front 9.00-20-14 rib,
10X
rear 9.00-20-14 lug Tire - front 9.5R17.5 129/127L rib,
5J6
rear 9.5R17.5 129/127L traction
100 Interior color - In white
Tire - front & rear 11R22.5 148/145L
Tire - front 10.00-20-14 rib, 5J7
11X rib
rear 10.00-20-14 lug
5J8 Tire - front & rear 245/70R19.5 rib
12X
rear 10.00-20-16 lug 5J9 Tire - front & rear 235/75R17.5 rib
15N Tire - front & rear 9R22.5-14 rib 5K0 Tire - front & rear 265/70R19.5 rib
155 Interior color - Charcoal gray Tire - front & rear 11R22.5 148/145K
5K4
rib/lug
21R Tire - front & rear 9.00-20-14 lug
Tire - front & rear 12R22.5 152/148K
25R Tire - front & rear 9.00R20-14 rib 5K5
rib/lug
27X 5L1 Tire - front & rear 12.00R20-18
rear 11.00-20-16 lug
Tire - front & rear 275/70R22.5
30T Tire - front & rear 10.00-20-14 rib 5L4
148/145M rib
5N5 Tire - front & rear 265/70R19.5 rib (BS)
35N Tire - front & rear 10R22.5-14 rib
5P0 Tire - front & rear 235/75R17.5 rib (BS)
Tire - front 295/80R22.5,
5P1
37W Wheel base 3,700mm rear 11R22.5-16 6x2 (BS)
38W Wheel base 3,800mm Tire - front 295/80R22.5,
5P2
rear 11R22.5-16 (BS)
5P3 Tire - front & rear 10R22.5-14 rib (BS)
40S Tire - front & rear 8.25-16-14 rib
40T Tire - front & rear 10.00-20-16 rib
Tire - front & rear 295/80R22.5
43P Tire - front & rear 9R22.5-14 55P
152/148M rib
55R Tire - front & rear 10.00R20-16 rib
45P Tire - front & rear 275/70R22.5
58N Tire - front & rear 11.00R20-16 rib
45R Tire - front & rear 10.00R20-14 rib
Option Option
Code Code
59W Wheel base 5,900mm Good quality ethylene glycol
8AC
antifreeze 30%
6DY Rear under run protector
8EJ Battery - 65D23L
6EP HSA system
8GF Transmission with Smoother
6HF KD preparatory package
8GJ Transmission without Smoother
6ND OK window
8JM Diesel particulate defuser
6NF Remote control door lock
8LF Rear window glass
LSPV - Load sensing proportioning
6PH
valve 8LX Ash tray - assist side
6SZ Power take off - flywheel 8MA Battery 115E41L
6UC Fluorescent lamp 8MH Fuel tank 370L
O/S rear view mirror - assist side short 8ML O/S rear view mirror - middle arm
6UH
stay
O/S rear view mirror - extended long
8MV
6VE O/S rear view mirror - door mount arm
6WX Floor mat - vinyl 80L 6HK1-TCS engine
6XH ASR system 80R Tire - front & rear 11.00-20-16 rib
60W Wheel base 6,000mm 800 Body color - In white
609 Body color - FT orange 81L 6HK1-TCC engine
61P Tire - front & rear 225/90R17.5 81R Tire - front & rear 11.00-20-16 lug
63W Wheel base 6,300mm 81U Tire - front & rear 8.25-16-14 lug
64N Tire - front & rear 8.25R20-14 rib 82L 6HK1-TCN engine
65W Wheel base 6,500mm 829 Body color - Sahara beige
7BC Assist seat with center seat 83N Tire - front & rear 9.5R17.5
7FL Seat material - cloth 85N Tire - front & rear 11R22.5-16
7HZ Rear bumper 85R Tire - front & rear 11.00R20-16 rib
7KC Immobilizer system 85U Tire - front & rear 8.25R16-14 rib
7NY Multi information display 87N Tire - front & rear 10.00R20-14PR rib
7SV O/S rear view mirror - heated 89N Tire - front & rear 9.00R20-14PR rib
7TV KD preparatory package 89T Tire - front & rear 11.00R20-16
70T Tire - front & rear 11.00-20-14 rib 90S Tire - front & rear 8.25-20-14 rib
71R Tire - front & rear 11.00-20-14 lug 904 Body color - golden yellow
71S Tire - front & rear 7.50-20-12 lug 915 Body color - fire red
71W Wheel base 7,100mm 92N Tire - front & rear 8.25R16-14PR rib
729 Body color - Arc white Tire - front 12.00R20-18,
93N
rear 12.00R20-18 lug
736 Body color - Cardinal red
94K Tire - front & rear 10.00R20-16
78N Tire - front & rear 8.25R16
94N Tire - front & rear 12.00R20-16
79R Tire - front & rear 11.00R20-14
951 Body color - arc white
Good quality ethylene glycol
8AA
antifreeze 50% Tire - front 295/80R22.5,
97N
rear 11R22.5-16
Option
Option Description
Code
99N Tire - front & rear 11R22.5-16
999 Body color - trans blue
Vehicle Identification Number (VIN)

The ID plate indicates the vehicle identification number
(VIN).
This single number contains multiple pieces of
information including the vehicle and engine model
codes as shown below.
J A L F R R 3 4 L 8 7 0 0 0 0 0 1
1 2 3 4 5 6
MFW80ASF000201
Legend
1. World manufacturer identifier (WMI) 4. Wheel base code
2. Vehicle model code 5. Model year code
3. Engine code 6. Production sequential number
1. World manufacturer identifier (WMI) 2. Vehicle model code

Code Code
ISUZU Brand FRR 4x2 Truck FRR model
JAL Medium & Heavy Duty
FSR 4x2 Truck FSR model
Incomplete Vehicle
FTR 4x2 Truck FTR model
FVR 4x2 Truck FVR model
FVZ 6x4 Truck FVZ model
FVM 6x2 Truck FVM model
FSS 4x4 Truck FSS model
FTS 4x4 Truck FTS model

3. Engine code
Code
34 6HK1 Engine
90 4HK1 Engine
4. Wheel base code

Code
3,201 - 3,500 mm
H
(126.02 - 137.80 in)
3,501 - 3,800 mm
J
(137.83 - 149.61 in)
3,801 - 4,100 mm
K
(149.65 - 161.42 in)
4,101 - 4,400 mm
L
(161.46 - 173.23 in)
4,401 - 4,700 mm
M
(173.27 - 185.04 in)
4,701 - 5,000 mm
N
(185.08 - 196.85 in)
5,001 - 5,300 mm
P
(196.89 - 208.66 in)
5,301 - 5,600 mm
Q
(208.70 - 220.47 in)
5,601 - 5,900 mm
R
(220.51 - 232.28 in)
5,901 - 6,200 mm
S
(232.32 - 244.09 in)
6,201 - 6,500 mm
T
(244.13 - 255.91 in)
6,501 - 6,800 mm
U
(255.94 - 267.72 in)
6,801 - 7,100 mm
V
(267.76 - 279.53 in)
7,101 - 7,400 mm
W
(279.57 - 291.34 in)
5. Model year code

Code
B 2011MY
General Precaution
General Precautions
2
1
MFW70AMF000201
Legend
1. Clean and safe costume 3. Support by stand after jack up
2. Installation of Chock blocks
Work preparations • When lifting up the vehicle using a lift, make sure
• Prepare the tools, instruments, and special tools in to set the safety device.
advance. • When performing a procedure with two or more
• Prepare the parts that require replacement and people, make sure to ensure each other's safety
parts that cannot be re-used in advance. before performing an action.
• Do not leave the engine running for an extended
Clothing period of time or perform painting in a poorly
ventilated working environment.
• The service technician must wear a clean service
technician uniform, hat, and safety footwear. • Make sure to use only the special tools if the
procedure requires them for the work. Performing
Protect the vehicle. the procedure using other tools may cause
damage to parts or personal injury.
• Make sure to use a seat cover, etc.
• Do not use tools such as a wrench that has lost its
• Disconnect the terminal of the battery (–) in
edges, a hammer with frayed edges, or a chipped
advance.
chisel.
Always focus on safety • When performing work using a device such as a
grinder, crane, or welder, make sure that a
• Make sure to use chock block when the vehicle is qualified technician performs the procedure while
jacked up. paying sufficient attention to the handling
• After jacking up, make sure to support the precautions.
specified position using a stand.

• When performing maintenance on fuel systems,
make sure that there is no fuel leakage. (may
possibly catch fire)
• When handling volatile materials, take care that
they do not catch fire.
Also make sure to wipe away any oil that sticks to
rubber parts, as it can cause deterioration.
Work Precaution
• Arrange removed parts in the correct order and
ensure they do not get mixed up with parts that
cannot be re-used.
• Perform sufficient cleaning and washing when
performing assembly / installation.
Also perform sufficient grease removal for areas to
apply liquid gasket, etc.
After-procedure check
• After completing the procedure, perform a final
check to confirm that the problem has been solved.
• Check that there is no fuel, oil, or coolant leakage.
Lifting Instruction
Lifting Instruction F*R/FVM/FVZ models
If it necessary to use a lifting device other than the
original equipment jack, see illustration for acceptable
lifting points.
Lifting should only be done at the positions indicated to
prevent possible damage to the vehicle.
CAUTION:
Failure to observe the acceptable lift points may result
in unsatisfactory vehicle performance or a durability
failure which may result in loss of control of the vehicle.
Garage Jack and Safety Stand

Lifting Point and Supportable Point Location
MFW80ASH000101
FSS model
3 1 2 4
MFW70ASH000201
Legend
1. Front axle
2. Rear axle center
3. Side member front side
4. Side member rear side
MFU770SH015801
Lifting Point Positions - Front side

CAUTION:
Do not lift or support on engine oil pan.

FTS model FRR/FSR/FTR/FVR models (with leaf spring
suspension), FSS/FTS models
MFU8Z0SH025501
MFW80ASH000201
Lifting Point Positions - Rear side FVR/FVM/FVZ models (with air suspension)
CAUTION:
Do not lift or support on rear axle tube.
FRR/FSR models (with air suspension)
MFU8Z0SH037501
FVR model (with air suspension)
MFU770SH002801
MFU8Z0SH077401

FVM/FVZ models (with leaf spring suspension)
MFW80ASH000301
Caution for The Maintenance of Electrical Parts

Battery Cable • Check that no foreign material or water has
entered the inside of the connectors.
Disconnecting the battery cables
Remove any foreign material or water that has
1. Turn all the switches "OFF". entered the connector using an air brush, etc. If the
2. Disconnect the battery ground cable (1). material cannot be removed, replace them.
3. Disconnect the battery plus cable (3). • Check that no foreign material is stuck to the
4. Disconnect the battery cable (2). terminals, and there is no corrosion or
deformation.
CAUTION: Remove any foreign material by cleaning with an
Make sure to disconnect the battery ground cable first. air brush, or clean rag, etc. If the material cannot
Disconnecting the plus cable first may cause a short be removed by cleaning, or there is corrosion or
circuit. deformation, replace them.
• Gently pull the wires to check that no terminals are
missing from the connector and there is no
breakage in the terminal area.
3 If a terminal is missing, reinsert it until it locks into
place. If you find a disconnection, replace them.
• Insert the male connector into the same female
1
connector, and check that there is no abnormality
in the terminal contact pressure.
If you find an abnormality, replace them.
• For waterproof connectors, check that there is no
2
damage or foreign material stuck to the seal parts
(wire seal of wiring, O-ring or waterproofing seal of
connector, etc.) or seal area of the connector
housing.
Remove any foreign material by cleaning with an
air brush, or clean rag, etc. If the material cannot
be removed by cleaning, or there is damage,
replace them.
MFW70ASH000401
CAUTION:
Connecting the battery cables • Do not perform polishing that would remove the
Connect the battery cables in the reverse order of the plating of the terminals, nor wash the inside of the
disconnection procedure. connector. If there is dirt that requires washing,
replace them.
CAUTION: • Be careful when attaching the seal areas of
Clean the area surrounding the battery terminal, and waterproof connectors, as some have specific
apply a thin layer of grease to the terminal to prevent positions and directions they must be attached.
corrosion. Also do not attach them in a twisted state.
Regarding vehicle washing

Connector Handling Requirements
Even for electric parts that are installed outside the cab
Visual inspection and are waterproofed, try to avoid exposing them
With the male and female connectors connected directly to high pressure water when washing the
• Gently pull the connector and check whether the vehicle (cover them with plastic sheets, etc.) as much
connector becomes disconnected or partially as possible.
disconnected, and that the lock is properly set.
If a problem is found, reconnect the connectors.
• Check that there is no damage to the connector
housing.
If a problem is found, perform replacement.
With the male and female connectors disconnected

Disconnecting the connector Connecting the connector
Many connectors have a lock to ensure secure Make sure that all connections are clean and secure.
connections. Securely grasp the female side and male side of the
The two types of locks generally used are those that connector, and align them correctly.
open by lifting the release area of the lock (1), and Firmly push them together until both sides click into
those that open by pressing the release area (2). place.
Before disconnecting the connector, determine in
advance which type of lock the connector is using.
OK
NO
1 2
LNW20ASH001401
HCW90ASH000201 Connector circuit inspection requirements

Check the continuity of the connector using a circuit
When disconnecting the connector, first securely grasp
tester. Insert the probes (1) of the tester from the
the male side and female side of the connector.
harness side of the connector, as indicated in the
Release the lock, and carefully disconnect the
diagram.
connector.
Do not pull the harness when disconnecting the
connector, as this may cause wires to come out or
break.
OK
OK
NO
LNW20ASH001501
LNW20ASH001301

Never insert the probes (1) from the connection closure 2. Push the lock (2) up in the direction of the arrow
area of the connector, as this will cause the connector using the metal rod to release the lock. In that
terminals to break. state, pull out the harness (3) together with the
terminal (4).
NO
1 2
5 4 3
LNW20ASH001601
LNW20ASH001801
Inspection requirements for waterproof connector

circuit —Terminal lock type
For waterproof connectors, the probes of the tester 1. Insert a metal rod (1) from the connector closure
cannot be inserted from the wiring side, due to the area (5).
structure of the connectors. 2. As indicated in the diagram, release the terminal
Therefore, perform the continuity inspection as lock (2) by pushing it to the harness side, pull out
indicated in the diagram, by connecting a testing the harness (3) together with the terminal (4).
connector (1) prepared in advance to the connector (2)
to test, and connect the probes (3) of the tester to the
harness of the testing connector.
1
2
1
2
5 4
LNW20ASH001901
3
Connecting connector terminals

LNW20ASH001701
1. Check that the terminal lock (1) area is raised fully
and can be locked.
Disconnecting connector terminals
2. Insert the terminal (3) from the harness (2) side of
—Built-in lock type the connector, and push it in until the lock area
1. As indicated in the diagram, insert a thin clicks.
screwdriver-shaped metal rod (1) from the
connector closure area (5).

3. Gently pull the harness and check whether the Handling Electronic Parts
terminal is completely locked inside the connector.
Handle electronic parts with sufficient care, and do not
damage the parts by dropping or throwing them.
LNW20ASH002001
LNW20ASH002201
Replacing the fuse
WARNING:
If a fuse melts down, make sure to replace it with a non- Cable Harness
defective fuse of the same capacity, after identifying the 1. When installing electronic parts, take care to
cause of the melt down. ensure the harness does not get stuck and do not
If you use a fuse with high capacity, the fuse will not forcibly push the harness in.
perform its function when excess current flows. This
may cause parts or wires, etc. to burn, and can result in
a vehicle fire.
30A 60A
10
15
LNW20ASH002301
LNW20ASH002101

2. When the harness will be contacting sharp edges 4. For wiring between the engine and chassis, give
or surfaces of other parts, protect the harness the wiring sufficient free length to prevent wear and
using a grommet or tube to prevent damage due to damage caused by vibrations.
the contact.
NO
OK
NO
OK
LNW20ASH002601
LNW20ASH002401
3. When wiring the harness by diverting it around

other parts, give the harness a sufficient amount of
free length, and use a protective tube (2) and clip
(1) to ensure it does not contact surrounding parts.
NO
1 2
OK
LNW20ASH002501
Regarding The Scan Tool

Trouble Diagnosis Using The Scan Tool
Regarding the scan tool (Tech 2) / Tech 2 24 volt
adaptor 2 /CAN-di module
This tool is effective for diagnosing electrical failures in
electronic control units and performing system checks.
If you connect the Tech 2 to the DLC installed in the
vehicle, it performs communication with the control
units of the vehicle, and enables various diagnoses and
tests to be performed.
HCW35ALF001301
Legend
1. PCMCIA card (dedicated) 3. DLC cable
2. Tech 2 (body)
1 2
3
LNW7Z0SF000101
Legend
1. Tech2 24V adaptor 2 (body) 3. Tech2 connecting cable
2. Signal change switch 4. DLC connecting cable
3
LNW7Z0SF000401
Legend
1. CAN-di module (body) 3. DLC connecting cable
2. Tech2 connecting cable
Features and cautions regarding the scan tool • To select a menu, press the selection key or
(Tech 2) / Tech 2 24 volt adaptor 2 / CAN-di module choose a menu with a function key and press the
• The Tech 2 has a 12 V power system. Do not ENTER key.
directly use 24 V power. Do not directly supply • You can return to the main menu at any time by
power from the cigar lighter. pressing the EXIT key.
• Remove/install the PCMCIA card after turning the • To clear the diagnostic trouble codes (DTC), open
power off. the application menu and select "Clear DTC
• The Tech 2 has the capacity for two snapshots. Information".
• As the PCMCIA card is sensitive to magnetism and • The Tech 2 adaptor 2 has a built-in DC to DC
static electricity, take care when handling it. converter (that converts 24 V to 12 V).
• The Tech 2 is able to draw graphs of snapshots.

• The Tech 2 adaptor 2 has a selector for switching • The CAN-di module has a built-in signal converter
signals (the signals for each electronic control unit (that converts CAN serial data to keyword serial
(ECU)). data)
Parts of the Tech 2
2
3
13
4
8
14
3
5 6
15
16
7 12
11
9
10
HCW35ALF001401
Legend
1. Soft key 10. VCI module fastening bar
2. Selection key (arrow key) 11. DLC cable connecting connector
3. Action keys (YES, NO, ENTER, EXIT) 12. AC adaptor connector
4. Function key (F0 – F9) 13. PCMCIA card insertion opening (with cover)
5. Help key (?) 14. PCMCIA card release (removal) button
6. Control key (PWR or SHIFT) 15. Connector for external communication (RS-485
7. Wide stand port)
8. Display (liquid crystal display) 16. Connector for external communication (RS-232
9. Vehicle communication interface (VCI) Module port)
1. Soft keys displayed on the screen.

When operating the Tech 2, the selection box is 2. Selection key (arrow key)
displayed on the top of the screen. The soft keys Selects menu items on the Tech 2 screen, and
correspond to that selection box. The soft keys switches the display. The highlighted area of the
cannot be used unless the selection box is screen display indicates what is being selected.

3. Action keys (YES, NO, ENTER, EXIT) 10. VCI module fastening bar
Confirm Tech 2 operations, respond to screen Operate the bar to attach/fix, or remove the VCI.
instructions/questions, switch/move to the various 11. DLC cable connecting connector
menu screens. Connector for using (connecting) the Tech 2 with
4. Function keys (F0 - F9) the vehicle. Connect the DLC cable.
Confirm menu functions displayed on the screen. 12. AC adaptor connector
Also when "F0" etc., is displayed on the menus on Connector for connecting the included AC adaptor.
the screen, the keys correspond to that display. Enables the Tech 2 to be used away from the
5. Help key (?) vehicle.
Displays a screen explaining the Tech 2 function 13. PCMCIA card insertion opening (with cover)
being used. Open the cover to insert a PCMCIA card into the
6. Control key (PWR or SHIFT) Tech 2. Insert the PCMCIA card with the cover
The PWR key turns the power of the Tech 2 ON/ opened. Never insert/remove the PCMCIA card
OFF. The SHIFT key is used when adjusting the with the Tech 2 turned ON.
screen contrast. The LED (orange) lights up when 14. PCMCIA card release (removal) button
the SHIFT key is available. At this time, the key Used when removing the PCMCIA card from the
and functions other than the selection key are Tech 2. The PCMCIA card can be removed when
locked. The LED (green) lights up when the power the button is pressed. Never remove the PCMCIA
is turned ON. card with the Tech 2 turned ON.
7. Wide stand 15. Connector for external communication
Used as a stand. The operating angle of the stand (RS-485 port)
is 0 to 180°. This port is for connecting to a telephone line, but
8. Display (liquid crystal display) is currently not used for the Tech 2. Do not connect
The liquid crystal display has a contrast a telephone line, etc., to this port.
adjustment function. Displays the ECM information 16. Connector for external communication
and the various instruction screens. (RS-232 port)
9. Vehicle communication interface (VCI) module This port is for connecting the Tech 2 to another
The module that enables communication between computer.
the vehicle and Tech 2.
Parts of the Tech 2 24 V adaptor 2
2
3
LNW7Z0SF000301
1. Signal change switch • “3” : —

The Tech 2 adaptor 2 has a selector for switching 2. DLC connecting cable
signals (the signals for each electronic control unit Connects the Tech 2 adaptor 2 to the vehicle DLC
(ECU)). (pole 16, blue).
(The position of the switch is free for other than the
3. Tech 2 connecting cable
following device)
Connects the Tech 2 adaptor 2 to the Tech 2.
• “1” : —
• “2” : HSA

Parts of the CAN-di module
2
LNW7Z0SF000501
1. Tech 2 connecting cable

Connects the CAN-di module to the Tech 2.
2. DLC connecting cable
Connects the CAN-di module to the Tech 2 adaptor
2.
Connection method
1. Insert the ISUZU system PCMCIA card into the
Tech 2 unit.
2. Connect the DLC cable to the Tech 2 unit.
3. Connect the CAN-di module to the DLC cable. Press (ENTER) To Continue
4. Connect the Tech 2 24 V adaptor 2 to the CAN-di
module.
5. Confirm that the ignition is turned "OFF".
6. Connect the Tech 2 24 V adaptor 2 to the vehicle
side DLC connector (pole 16, blue).
HCW46ESH001901
CAUTION:
Remove/install the PCMCIA card after confirming that
power is not being supplied to the Tech 2.
9 1
10 2
11 3
12 4
13 5
14 6
15 7
16 8
MFA7Z0SH000201
7. Turn the ignition "ON", and press the "PWR" key of

the Tech 2.
8. Confirm the display of the Tech 2.
Recommended Liquid Gasket

Recommended Liquid Gasket
Type Product name Manufacturer name Area used (reference)

ThreeBond 1207B ThreeBond Engine oil seal retainer
Silicon type ThreeBond 1207C ThreeBond Engine oil pan
(Room temperature ThreeBond 1215 ThreeBond Timing gear case
vulcanization process) ThreeBond 1216 ThreeBond Cylinder head cover
ThreeBond 1281 ThreeBond Fuel pump
Water pump
Water Base ThreeBond 1141E ThreeBond
Rear axle
ThreeBond 1102 ThreeBond Etc.
Solvent ThreeBond 1104 ThreeBond
ThreeBond 1194 ThreeBond
LOCTITE 515 LOCTITE Engine oil seal retainer
LOCTITE 518 LOCTITE Water pump
Anaerobic
LOCTITE 17430 LOCTITE Transaxle
FMD127 LOCTITE Etc.
• Make sure to use a liquid gasket with the above Application method
product name or equivalent. 1. Wipe any water or oil from the contact surface.
• Do not use LOCTITE 515, 518 or FMD 127, as Make sure the contact surface is dry.
they are anaerobic, and do not provide sufficient 2. Apply liquid gasket of the specified bead width to
effect when there is a gap larger than 0.25 mm one side of the contact surface. Make sure there
(0.010 in) between the contact surfaces of metals. are no cuts in the beads.
• Use an appropriate amount of liquid gasket. Follow
the handling precautions for the product.
1. Completely remove lubricant and moisture from the connecting surfaces.

The surfaces must be perfectly dry.
2. Apply specified bead width of liquid gasket to one of the connecting surfaces.
There must be no gaps in the bead.
mm (in)
SCREW DEPRESSION JUDGE
HOLE MENT
1 3
(0.040.12)
OK
1 3 More than
(0.040.12) 2 (0.08)
OK
Depression Apply liquid gasket to
the bolt hole interior
Specified
bead width
NG
Example
Anaerobic Type :2-3 mm (0.08-0.12 in)
Others :2-6 mm (0.08-0.24 in)
MFW70AMF000101

NOTE:
If the repair manual specifies an application method,
follow that method.
Recommended Thread Locking Agent

Recommended Thread Locking Agent
Type Color
LOCTITE 242 Blue
LOCTITE 262 Red
LOCTITE 271 Red
Work procedure
1. Completely wipe off any water or oil from the
contact surface of the bolt and bolt hole, and the
threaded portion of nut. Make sure the contact
surface is dry.
2. Apply LOCTITE to the end 1/3 of the screw.
LNW20ASH003201
3. Tighten the bolt at the specified torque.
CAUTION:
After tightening, do not apply excessive torque or
vibrations for at least an hour until the Loctite hardens.
Maintenance Schedule
Introduction
When performing the checks on the following items,
regular inspection items should also be checked.
Abbreviations Used in This Manual
I: Inspect, clean, or repair or replace as required
A: Adjust
R: Replace
T: Tighten to the specified torque
L: Add lubricant
I : Inspect, clean, or repair or replace as required A : Adjust R : Replace T : Tighten to the specified torque L : Lubricate
Service Interval x1,000 km 1 5 8 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 Odometer reading or months,
x1,000 miles 0.6 3 5 6 9 12 15 18 21 24 27 31 34 37 40 43 46 49 52 55 59 62 65 whichever comes first
Engine startability and abnormal noise - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Idling speed and acceleration - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
MGGEN-WE-1101AU.book 31 ページ
or every 12 months
Air cleaner element - - - - - - - - - - - R - - - - - - - - - R - or after 6th cleaning : R
every 6 months : I
Intake and exhaust manifolds T - - - - - - - - - - T - - - - - - - - - T - or every 15 months
Maintenance Schedule
for Euro5 specification (1/6)
Valve clearance A - - - - - - - - - - A - - - - - - - - - A - or every 15 months

Compression pressure for each cylinder - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Oil contamination - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Engine oil R - - I - R - I - R - I - R - I - R - I - R - or every 3 months : I
every 6 months : R
Engine oil (main and partial) filter (combined type) - - - - - R - - - R - - - R - - - R - - - R - or every 6 months
Engine oil main filter (separate type) - - - - - R - - - R - - - R - - - R - - - R - or every 6 months
Engine oil partial filter (separate type) - - - - - R - - - R - - - R - - - R - - - R - or every 6 months
Engine oil separator (4HK1 engine model) - - - - - R - - - R - - - R - - - R - - - R -
Engine oil separator (6HK1 engine model) Every 12 months : R
Fuel filter - - - - - - - - - R - - - - - - - R - - - - - or every 9 months
２０１０年１２月６日　月曜日　午後２時２１分
Fuel tank strainer - - - I - I - I - I - I - I - I - I - I - I - or every 3 months

Inside fuel tank - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Fuel injection pressure and spray pattern - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Fuel injection timing - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Air compressor, governor and unloader valve - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
functions
Radiator cap function - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Damage to fan belt I - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Loose or otherwise improper installation of I - - I - I - I - I - I - I - I - I - I - I - or every 3 months
exhaust pipe
Cooling circuit and radiator Every 24 months : I
Engine coolant Every 24 months : R (When Isuzu recommended coolant is used)
Turbocharger to air duct connection and gasket - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Clutch fluid (manual transmission) - - - I - I - I - I - R - I - I - I - I - R - or every 3 months : I
every 15 months : R
Clutch system function (manual transmission) - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Clutch pedal free play and stroke - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
(manual transmission)
Clutch booster exhaust cover (manual transmission) - - - I - I - I - I - I - I - I - I - I - I - or every 3 months : I
Rubber parts and gaskets of clutch Every 48 months : R
General Information
booster (manual transmission)

: The vehicle needs to be maintained more often if it is driven in severe condition. Refer to "Maintenance Schedule for Severe-condition" in this section.
MFWB0AXF000901
0A-31
0A-32
or every 3 months : I
Transmission oil (MZW model) R - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
Transmission oil (MLD model) R - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
Transmission oil (ZF6S1000 model) Refer to Maintenance Schedule (Transmission Oil - ZF6S1000/ZF9S1110 Type)
Transmission oil (ZF9S1110 model) Refer to Maintenance Schedule (Transmission Oil - ZF6S1000/ZF9S1110 Type)
Transmission oil (FSO5206B model) Refer to Maintenance Schedule (Transmission Oil - FS8209A/FSO5206B Type)
Transmission oil (FS8209A model) Refer to Maintenance Schedule (Transmission Oil - FS8209A/FSO5206B Type)
General Information
Transmission fluid (ALLISON2500 model) - - - - - - - - - - - - - - - - - R - - - - - or every 24 months
or 2,000 hours
Transmission main filter (ALLISON2500 model) - - R - - - - - - - - - - - - - - R - - - - -
or 24 months : R
Transmission cooling system filter or 2,000 hours

- - - - - - - - - - - - - - - - - R - - - - -
(ALLISON2500 model) or 24 months : R
Transmission internal filter (ALLISON2500 model) Replace the filter at overhaul
Transmission fluid (ALLISON3000/3500 model) - - R - - - - - - R - - - - - - - R - - - - - or every 12 months
or 1,000 hours
Transmission main filter (ALLISON3000/3500 model) - - R - - - - - - R - - - - - - - R - - - - -
or 12 months : R
Transmission cooling system filter or 1,000 hours

- - - - - - - - - R - - - - - - - R - - - - -
(ALLISON3000/3500 model) or 12 months : R
Transmission internal filter

Replace the filter at overhaul
(ALLISON3000/3500 model)
Smoother clutch oil or every 3 months : I

R - - I - I - I - I - R - I - I - I - I - R -
(Vehicle equipped with the Smoother system) every 15 months : R
Loose gear control mechanism - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Transfer gear case oil (F S model) R - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
Function of transfer gear control mechanism - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose propeller shaft joints - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Worn propeller shaft universal joint and splines - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose propeller shaft bearing and related parts - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Rear axle differential gear oil or every 3 months : I

R - - I - I - I - I - R - I - I - I - I - R -
(ISUZU production model) every 15 months : R
Rear axle differential gear oil

Refer to "Maintenance Schedule for RS23/RT40 Type Axle"
(Arvin Meritor production model)
Rear wheel hub bearing oil (FVM model-Vehicle or every 3 months : I

R - - I - I - I - I - R - I - I - I - I - R -
equipped with Arvin Meritor production axle) every 15 months : R
Inter-differential gear oil (FVZ model) R - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
Rear wheel hub bearing grease - - - - - - - - - - - R - - - - - - - - - R - or every 15 months
MFWB0AXF001001

Damaged or distorted rear axle case - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Front axle differential gear oil (F S model) R - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
Front wheel hub bearing grease - - - - - - - - - - - R - - - - - - - - - R - or every 15 months
Front wheel hub bearing oil or every 3 months : I

R - - I - I - I - I - R - I - I - I - I - R -
(Vehicle equipped with Arvin Meritor production axle) every 15 months : R
Damaged or distorted front axle case - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Leaf spring U-bolt nuts T - - - - - - - - - - T - - - - - - - - - T - or every 15 months
Air suspension's beam bolt nuts/U-bolt nuts T - - - - - - - - - - T - - - - - - - - - T - or every 15 months
Damaged leaf spring - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Uneven suspension due to leaf spring fatigue - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose or damaged leaf spring mounting - - - - - - - I - - - - - I - - - - - I - - - or every 9 months
Spring leaves for misalignment - - - - - - - I - - - - - I - - - - - I - - - or every 9 months
Oil leaks from or damage to shock absorbers - - - - - - - I - - - - - I - - - - - I - - - or every 9 months

Loose shock absorber mounting - - - - - - - I - - - - - I - - - - - I - - - or every 9 months
Loose or damaged air suspension main support

- - - - - - - - - - - I - - - - - - - - - I - or every 15 months
members
Damaged air spring - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Air leaks from air suspension - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Loose or damaged air suspension mounting - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Air spring height - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Function of height sensor or leveling valve - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose or damaged torque rod - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose or damaged traverse rod - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose or damaged V-rod - - - - - I - - - I - - - I - - - I - - - I - or every 6 months
Foreign object in wheels - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Wheel nuts T - - T - T - T - T - T - T - T - T - T - T - or every 3 months
Damaged disc wheels - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Loose front wheel hub bearings - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose rear wheel hub bearings - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Power steering fluid - - - I - I - I - I - R - I - I - I - I - R -
every 15 months : R
General Information
MFW80AXF001501
0A-33
0A-34
Power steering fluid filter - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Loose power steering system mounting - - - I - I - I - I - I - I - I - I - I - I - or every 3 months

Excessive play in power steering bearing - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Damage to, loose or excessive play in power

I - - - - - - I - - - - - I - - - - - I - - - or every 9 months
steering joints
Knuckle-to-front axle clearance - - - - - - - - - - - I - - - - - - - - - I - or every 15 months

Wheel alignment - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Steering angle range for right and left turns - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
General Information
King pin-to-bearing clearance - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Brake fluid (Vehicle equipped with the air-over or every 3 months : I

- - - I - I - I - I - R - I - I - I - I - R -
hydraulic brake system) every 12 months : R
Brake lining wear - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Brake drum wear or damage - - - - - - - - - - - I - - - - - - - - - I - or every 12 months
Brake hose - - - I - I - I - I - R - I - I - I - I - R -
every 24 months : R
Function of brake valves (Vehicle equipped with

the air-over hydraulic brake system)
Brake booster exhaust cover (Vehicle equipped

- - - I - I - I - I - I - I - I - I - I - I - or every 12 months
with the air-over hydraulic brake system)
Leaks from, damage to, or loose connection of

brake hose or pipe
Excessively worn cams and wheel brakes (Vehicle

equipped with Arvin Meritor production axle)
Brake chamber rod stroke (Vehicle equipped with

- I - I - I - I - I - I - I - I - I - I - I - or every 3 months
the full-air brake system)
Function of brake chamber (Vehicle equipped with

the full-air brake system)
Functions of brake and relay valves (Vehicle

equipped with the full-air brake system)
Change the desiccant, filter and rubber parts of air dryer

Air dryer
at 100,000 km (62,000 miles) or every 12 months.
ABS modulator (Vehicle equipped with ABS) Every 24 months : R
ASR valve (Vehicle equipped with ASR) Every 120 months : R
Rubber parts of wheel cylinder Every 12 months : R
Rubber parts of HSA valve Every 24 months : R
Rubber parts of brake valve, relay valve, parking

brake valve, quick release valve, reducing valve,
Every 24 months : R
double check valve, multi-protection valve, air
master
Rubber parts of brake chamber Every 3 months : I, Every 24 months : R
MFWB0AXF001101

Brake chamber piggy-bag Every 36 months : R
Every 12 months : I
Brake expander
Every 36 months : overhaul
Worn parking brake lining

(center parking brake model)
Worn or damaged parking brake drum

(center parking brake model)
Loose parking brake system mounting - - - I - - - I - - - - - I - - - - - I - - - or every 3 months
Damaged or loosely connected rod or cable - I - I - I - I - I - I - I - I - I - I - I - or every 3 months
Function of parking brake control valve system

(wheel parking brake model)
Function of brake chamber

Brake chamber rod stroke

Electro-hydraulic cab tilt pump oil - - - - - - - I - - - - - I - - - - - I - - -
every 24 months : R
Function of cab tilt system - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Specific gravity of battery fluid - - - - - - - I - - - - - I - - - - - I - - - or every 9 months
Function of starter motor - - - - - - - I - - - - - I - - - - - I - - - or every 9 months
Wear of starter motor brushes - - - - - - - - - - - I - - - - - - - - - I - or every 15 months
Function of generator - - - I - I - I - I - I - I - I - I - I - I - or every 3 months
Damage to or loose connection of wiring harness

terminals
Exhaust pressure check or filter cleaning - - - - - - - - - - - - - - - - - - - - - I - or every 12 months
Exhaust differential pressure sensor rubber piece - - - - - - - - - R - - - - - - - R - - - - - or every 12 months

General Information
MFWA0AXF004301
0A-35
0A-36

General Information
Engine water pump bearing (6HK1 engine model) - - - - - - L - - - - L - - - - L - - - - L - or every 6 months
Front spring pins - L - L L L L L L L L L L L L L L L L L L L L or every month
Front spring shackles - L - L L L L L L L L L L L L L L L L L L L L or every month
King pin - L - L L L L L L L L L L L L L L L L L L L L or every month
Tie rod end (FTR/FVR/FVM/FVZ models) - - - - - - L - - - - L - - - - L - - - - L - or every 6 months
Shimmy damper (F S models) - L - L L L L L L L L L L L L L L L L L L L L or every month
Transfer input flange (F S models) - L - L L L L L L L L L L L L L L L L L L L L or every month
Propeller shaft universal joints and sliding sleeves - L - L L L L L L L L L L L L L L L L L L L L or every month
Propeller shaft center bearing - L - L L L L L L L L L L L L L L L L L L L L or every month

Rear spring pins - L - L L L L L L L L L L L L L L L L L L L L or every month
Rear spring shackle pins or rear spring sliding

- L - L L L L L L L L L L L L L L L L L L L L or every month
shackles
Trunnion shaft
(FVM/FVZ models, with leaf spring suspension)
Rear spring pads

(FVM/FVZ models, with leaf spring suspension)
Front wheel brake cam shaft and slack adjuster

(Vehicle equipped with Arvin Meritor production axle)
Rear wheel brake cam shaft and slack adjuster

(Vehicle equipped with Arvin Meritor production axle)
Steering shaft sliding sleeve - L - L L L L L L L L L L L L L L L L L L L L or every month
Clutch shift block (ZF9S1110 model transmission) - L - L L L L L L L L L L L L L L L L L L L L or every month
Clutch booster joint pin (manual transmission) - L - L L L L L L L L L L L L L L L L L L L L or every month
Cab mounting - L - L L L L L L L L L L L L L L L L L L L L or every month
MFWB0AXF001201

Transmission Oil - ZF6S1000/ZF9S1110
Type
The transmission of the vehicle can stay in good condition through regular maintenance. Above all, make sure to
replace the transmission oil regularly in accordance with the specified maintenance schedule.
Oil Class
Driving Condition 02E
02A 02B 02D/02L
(ZF-Ecofluid M)
Service condition
60,000 km 120,000 km 240,000 km
(local/long-haul transport,
(36,000 miles) (72,000 miles) (144,000 miles)
tough operating
or 12 months or 12 months or 24 months
conditions)
Normal condition 90,000 km 160,000 km 300,000 km
(long-haul goods (54,000 miles) (96,000 miles) (180,000 miles)
transport) or 12 months or 12 months or 24 months
Change oil at the above-indicated distance or time, whichever comes first.

Low Temperature Limits
Oil Pan Temperature SAE Viscosity Rating Oil Type
- 25°C (- 13°F) or above 80W/80W-85/80W-90 02A/02B
- 40°C (- 40°F) or above 75W/75W-80/75W-85/75W-90 02E (ZF-Ecofluid M)/02D/02L
Oil Classes and Approved Trade Products NOTE:

Oil Class 02A In moderate climate zones, shift quality is impaired if
viscosity grades higher than SAE 80W are used.
• Gear oil of viscosity grades: SAE 80W/80W-85
/80W-90/85W-90/90
Manufacturer (02A) Trade name (02A)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W
ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GS 80W-90
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL GETRIEBEÖL 80W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP 80W-90
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA GEAR OIL MZ 80
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA GEAR OIL MZ 90
BAYWA AG, MÜNCHEN/D BAYWA MEHRZWECKGETRIEBEÖL SAE 80
BAYWA AG, MÜNCHEN/D TECTROL UNIGEAR 80
BEHRAN OIL CO., TEHRAN/IR BEHRAN SAMAND MB 80W-90
BELGIN MADENI YAGLAR, GEBZE KOCAELI/TR BELGEAR EP MB 80
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W-100
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W-68
BLASER SWISSLUBE AG, HASLE-RÜEGSAU/CH EP-GETRIEBEÖL 80W90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR EP 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB OJS FRONTOL MEHRZWECK-GETRIEBEÖL MZ
80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB OJS FRONTOL MEHRZWECKGETRIEBEÖL MZ 80
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX GEAR OIL EP 80W/90
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MP GEAR OIL 80W GL 4

CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MP GEAR OIL 85W90 GL4
CASTROL INTERNATIONAL, PANGBOURNE CASTROL EP 80W
READING/GB
CASTROL INTERNATIONAL, PANGBOURNE CASTROL EP 80W90
READING/GB
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES 80W-90
CEPSA LUBRICANTS S.A., MADRID/E ERTOIL TRANSMISIONES F SAE 80
CHEVRON BRASIL LTDA., RIO DE JANEIRO/BRAZIL UNIVERSAL EP SAE 80W
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 80W-90
CHEVRONTEXACO, GHENT/B GEARTEX EP-A 85W-90
CLAAS KGAA MBH, HARSEWINKEL/D CLAAS AGRISHIFT 4SC 80W90
COMP.BRASIL. D. PETRO. IPIRANGA, RIO DE IPIRGEROL EP 80W
JANEIRO/BR
CONDAT LUBRIFIANTS, CHASSE SUR RHONE/F GEAR A (80W)
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MULTIPURPOSE GEAR OIL SAE 80W90
ENI S.P.A. REFINING & MARKETING DIVISION, ROTRA HY 80W-90
ROME/I
ENI S.P.A. REFINING & MARKETING DIVISION, ROTRA HY DB 80W
ROME/I
EXXON MOBIL CORPORATION, FAIRFAX, ESSO GEAR OIL GP-D 80W
VIRGINIA/USA
EXXON MOBIL CORPORATION, FAIRFAX, MOBILUBE GX-A 80W
VIRGINIA/USA
FUCHS PETROLUB AG, MANNHEIM/D TITAN GEAR MP SAE 80W
GAZPROMNEFT-ONPZ, OMSK/RUS TRANS KP-2 (SAE 80W85)
GINOUVES GEORGES SA, LA FARLEDE/F YORK 791 SAE 80W85
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP 80W
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR XP 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO EP 80W-90
IGOL FRANCE SA, AMIENS/F TRANS EPA SAE80W-85W
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 80W(T)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 80W-90(T)
INDIAN OIL CORPORATION LTD., MUMBAI/IND SERVO GEAR HP 90(T)
KOMPRESSOL-OEL VERKAUFS GMBH, KÖLN/D KOMPRESSOL-MEHRZWECK-GETRIEBEOEL SAE
80W-90
KRAFFT S.L., ANDOAIN/E HIDROIL SAE 80W90
KROON-OIL B.V., ALMELO/NL GEARLUBE GL-4 80W-90
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 T 35 SAE 80 W
NL
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 T 35 SAE 80W-90
NL
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 T 35 SAE 90
NL
LIQUI MOLY GMBH, ULM/D LIQUI MOLY GETRIEBEÖL GL 4 SAE 80W
LIQUI MOLY GMBH, ULM/D LIQUI MOLY GETRIEBEÖL GL 4 SAE 85W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL DB 80W
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL HD 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE
SAARLOUIS/D 80W
MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL MEHRZWECKGETRIEBEOEL GL 4 SAE
SAARLOUIS/D 85W-90
MOL-LUB KFT., ALMASFÜZITÖ/H MOL HYKOMOL 80W

MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR MB 80W
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE GEAR EP 80W-90
NEW PROCESS AG, TÜBACH/CH EP GEAROIL SAE 80W
OEST, GEORG MINERALÖLWERK, OEST MEHRZWECK-GETRIEBEÖL SAE 80W
FREUDENSTADT/D
OEST, GEORG MINERALÖLWERK, OEST MEHRZWECK-GETRIEBEÖL SAE 80W-90
FREUDENSTADT/D
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL MP SAE 80W-85
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL MP SAE 85W-90
OPET PETROLCÜLÜK A.S., IZMIR/TR ORSA EP MT 80W
ORLEN OIL SP. Z O.O., KRAKOW/PL HIPOL SUPER GL-4 80W/90
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR GL-4 80W
ORLEN OIL SP. Z O.O., KRAKOW/PL PLATINUM GEAR GL-4 80W/90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GEAR OIL EP/FZ SAE 80W/90
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W
PANOLIN AG, MADETSWIL/CH PANOLIN EP GEAR 80W/90
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE LUBRAX TRM-4 (SAE 80W)
CAXIAS/BR
PETROBRAS DISTRIBUIDORA S.A., DUQUE DE LUBRAX TRM-4 SAE 90
CAXIAS/BR
PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W90
PETROGAL S.A., LISBOA/P GALP TRANSOIL 80W
PRISTA OIL EAD, ROUSSE/BG PRISTA EP 80W
PT PERTAMINA (PERSERO), JAKARTA/RI RORED EP-A SAE80W-90
PT PERTAMINA (PERSERO), JAKARTA/RI RORED EP-A SAE90
RAVENSBERGER SCHMIERSTOFFVERTRIEB RAVENOL MZ-GETRIEBEÖL 80 GL 4
GMBH, WERTHER/D
RAVENSBERGER SCHMIERSTOFFVERTRIEB RAVENOL MZ-GETRIEBEÖL 80W-90 GL 4
GMBH, WERTHER/D
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, CS EP M SAE 80W
MADRID/E
S-OIL CORPORATION, SEOUL/KOREA DRAGON GEAR TM 80W
S-OIL TOTAL LUBRICANTS CO. LTD., SEOUL/ROK TOTAL EP 80W-90
S.A.E.L., MADRID/E GULF GEAR LUBRICANT 80W-85
SHELL BRASIL, BARRA DA TIJUCA - RIO DE SHELL SPIRAX G 80W (IN BRASIL ONLY)
JANEIRO/BR
SHELL INTERNATIONAL PETROLEUM COMP LTD, SEHLL SPIRAX EP 80
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL SPIRAX MA 80W
LONDON/GB
SRS SCHMIERSTOFF VERTRIEB GMBH, SRS WIOLIN MEHRZWECK-GETRIEBEÖL 80
SALZBERGEN/D
SRS SCHMIERSTOFF VERTRIEB GMBH, SRS WIOLIN MEHRZWECK-GETRIEBEÖL 80W-90
SALZBERGEN/D
SRS SCHMIERSTOFF VERTRIEB GMBH, SRS WIOLIN MEHRZWECK-GETRIEBEÖL 90
SALZBERGEN/D
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL EP SAE 80W
SUOMEN PETROOLI OY, HAMINA/FIN TEBOIL EP SAE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EP 80W
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EP 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC N 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC N 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-85
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL EP 80W-90

TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF EP 80W-90
UNIL OPAL, SAUMUR CEDEX/F UNIL OPAL GEAR EP SAE 80W85W
YACCO, ST PIERRE LES ELBEUF/F BVX M 100 80W85
Oil Class 02B NOTE:

• Gear oil of viscosity grades: SAE 75W-80 In moderate climate zones, shift quality is impaired if
/75W-85/75W-90/80W/80W-85/80W-90 viscosity grades higher than SAE 80W are used.
/85W-90/90
Manufacturer (02B) Trade name (02B)

ADDINOL LUBE OIL GMBH, LEUNA/D ADDINOL GETRIEBEÖL GX 80 W 90 ML
AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AGIP ROTRA TRUCK GEAR S, SAE 75W-90
ARAL AG, BOCHUM/D ARAL GETRIEBEOL EP PLUS 80W-90
ARMORINE S.A., LANESTER CEDEX/F BM 80
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 75W-90 EP
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA SYNTOGEAR FE 80W-90
BAYWA AG, MÜNCHEN/D BAYWA SUPER 8090 MC
BAYWA AG, MUNCHEN/D TECTROL MULTIGEAR PLUS 8090
BEHRAN OIL CO., TEHRAN/IR BEHRAN SAMAND OEM 1 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR DL 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB BP ENERGEAR HT 80W-90
BP INTERNATIONAL, PANGBOURNE, READING/GB ENERGEAR SHX-M SAE 75W-90
BUCHER AG LANGENTHAL, LANGENTHAL/CH MOTOREX UNISYNT TX
CALPAM MINERALÖL-GMBH, ASCHAFFENBURG/D CALPAM MULTI GEAR OIL FE 80W90
CASTROL INTERNATIONAL, PANGBOURNE CASTROL DYNADRIVE 80W-90
READING/GB
CASTROL INTERNATIONAL, PANGBOURNE CASTROL DYNADRIVE PLUS 75W90
READING/GB
CASTROL INTERNATIONAL, PANGBOURNE CASTROL MULTIDRIVE 80W90
READING/GB
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES EP FE+LD 75W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR 80W-90
CHEVRONTEXACO, GHENT/B MULTIGEAR S 75W-90
CHEVRONTEXACO, SYDNEY/AUS CALTEX TRANSLUBE LD SAE 80W
CHEVRONTEXACO, SYDNEY/AUS CALTEX TRANSLUBE LD SAE 90
DAF TRUCKS N.V., EINDHOVEN/NL DAF SUPER 80W90
DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR UNIGEAR 75W90 LD
ENI S.P.A. REFINING & MARKETING DIVISION, ROTRA LSX 75W-90
ROME/I
ENI S.P.A. REFINING & MARKETING DIVISION, ROTRA TRUCK GEAR 80W-90
ROME/I
EXXON MOBIL CORPORATION, FAIRFAX, MOBILUBE 1 SHC 75W-90
VIRGINIA/USA
EXXON MOBIL CORPORATION, FAIRFAX, MOBILUBE S 80W-90
VIRGINIA/USA
FALCON OIL COMPANY LTD., SHARJAH/UAE FALCON SUPER EP GEAR OIL 80W/90 GL-4
FINKE MINERALÖLWERK GMBH, VISSELHÖVEDE/ AVIATICON FINKOGEAR SUPER 80W-90
D
FUCHS PETROLUB AG, MANNHEIM/D TITAN SUPERGEAR MC 80W-90
GENOL GMBH & CO., WIEN/A GENOL GEAR-SYN 80W-90
GINOUVES GEORGES SA, LA FARLEDE/F YORK 896
GRUPA LOTOS SA, GDANSK/PL TITANIS SUPER GL-5 80W/90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 80W

GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 85W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR MZ 90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR TDL 80W-90
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF SYNGEAR 75W-90
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENDALL TOTAL DRIVE LINE ED 75W90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA P ECO 80W-90
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA TCX ECO 75W-90
IGOL FRANCE SA, AMIENS/F GEAR M 80W90
IGOL FRANCE SA, AMIENS/F SYNTHEGEAR SAE75W90
KROON-OIL B.V., ALMELO/NL TRANSMISSION OIL SP 1011
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 GEAR OIL XG SAE 80W-90
NL
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 TRANS XGS SAE 75W-90
NL
LIQUI MOLY GMBH, ULM/D HYPOID GETRIEBEÖL TDL SAE 80W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL SHD 75W-90
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA HIPENOL TDL 80W-90
MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL GETRIEBEOEL TRUCK-SYNTH SAE 75W-
SAARLOUIS/D 90
MEGUIN GMBH & CO. KG MINERALOELWERKE, MEGOL HYPOID-GETRIEBEOEL TDL SAE 80W-90
SAARLOUIS/D
MILLERS OILS LIMITED, BRIGHOUSE/GB SYNTRAN FE
MINERALÖL-RAFFIN. DOLLBERGEN, UETZE- PENNASOL MEHRZWECK-GETRIEBEOEL GL 4
DOLLBERGEN/D SAE 80W
DOLLBERGEN/D SAE 85W-90
DOLLBERGEN/D SAE 90
MODRICA OIL REFINERY, MODRICA/BIH TRANSLUBE GL-4 SAE 80W
MODRICA OIL REFINERY, MODRICA/BIH TRANSLUBE GL-4 SAE 90
MORRIS LUBRICANTS, SHREWSBURY/GB LODEXOL SS 80W
MORRIS LUBRICANTS, SHREWSBURY/GB SERVOL EP 80W/90
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL GEAR SYNT TDL 75W-90
NESTE MARKKINOINTI OY, ESPOO/FIN NESTE HYPOIDI TDL S 75W-90
NEW PROCESS AG, TÜBACH/CH GEAROIL SYNTH
OEST, GEORG MINERALÖLWERK, OEST MEHRZWECK-GETRIEBEÖL FE SAE 80W-90
FREUDENSTADT/D
OEST, GEORG MINERALÖLWERK, OEST SYNTH GETRIEBEÖL SAE 75W-90
FREUDENSTADT/D
OK NEDERLAND, STAPHORST/NL OK UNI-CARDAN OIL LD-SAE 75W/90
OK NEDERLAND, STAPHORST/NL QUINTOL TRANSMISSION OIL VS-45 SAE 75W/90
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL XD-4 SAE 80W-85
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR S SAE 75W-90
OMV REFINING & MARKETING GMBH, WIEN/A OMV UNIGEAR SAE 80W-90
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR CBS SAE 75W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL GEAR SA SAE 80W/85
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GLOBAL MULTIGEAR TS SAE 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN SUPER DUTY SYNTH 75W/90
PANOLIN AG, MADETSWIL/CH PANOLIN TOPGEAR 80W/90
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL 75W90

RAVENSBERGER SCHMIERSTOFFVERTRIEB RAVENOL SLG SPEC. LKW GETR.ÖL 80W90
GMBH, WERTHER/D
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, CARTAGO FE LD 75W90
MADRID/E
S.A.E.L., MADRID/E GULF SYTHETIC GEAR LUBRICANT 75W-90
SHARJAH NATIONAL LUBE OIL CO. LTD., SHARLU EP GEAR LUBE 80W/90 (GL-4)
SHARJAH/UAE
SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL SPIRAX GX 80W
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL SPIRAX GX 80W-90
LONDON/GB
SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL SPIRAX MX 80W-90
LONDON/GB
SRS SCHMIERSTOFF VERTRIEB GMBH, SRS GETRIEBEFLUID SML 80W-90
SALZBERGEN/D
SRS SCHMIERSTOFF VERTRIEB GMBH, SRS WIOLIN RSG 80
SALZBERGEN/D
STATOIL LUBRICANTS, STOCKHOLM/S GEARWAY G4 80W
STRUB + CO AG, REIDEN/CH STRUB MULTIGEAR SGO 80W-90
STRUB + CO AG, REIDEN/CH VULCOGEAR SYNT SGX 75W-90
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW TEDEX GEAR OIL SAE 80W
MAZOWIECKI/PL
TEDEX PRODUCTION SP.Z.O.O., TOMASZOW TEDEX SUPER GEAR OIL (3343M) SAE 80W90
MAZOWIECKI/PL
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR EPS 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR UNIVERSAL FE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC FDL 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION MDL 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION RS FE 80W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION SYN FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF SYNTHESE FE 75W-90
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF UNIVERSAL FE 80W-90
VALVOLINE EUROPE, DORDRECHT/NL SYNPOWER GEAR OIL TDL 75W-90
VIAL OIL LTD., MOSCOW/RUS CONSOL TRANS LUX SAE 75W-90
VIAL OIL LTD., MOSCOW/RUS CONSOL TRANS LUX SAE 80W-90
YACCO, ST PIERRE LES ELBEUF/F BVX 1000
ZELLER + GMELIN GMBH & CO., EISLINGEN/D DIVINOL GEAR OIL STO SAE 80W-90
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID X
Oil Class 02D

• Gear oil of viscosity grades: SAE 75W-80 (semi-
synthetic, synthetic)
Manufacturer (02D) Trade name (02D)

AGIP SCHMIERTECHNIK GMBH, WÜRZBURG/D AUTOL GETRIEBEÖL VSL-4 75W-80
ARAL AG, BOCHUM/D ARAL GETRIEBEÖL SNS SAE 75W-80
AVIA MINERALÖL-AG, MÜNCHEN/D AVIA MULTIGEAR SL 75W-80W
BP INTERNATIONAL, PANGBOURNE, READING/GB CASTROL SYNTRANS Z
BUCHER AG LANGENTHAL LANGENTHAL/CH MOTOREX PRISMA TF 75W/80
CEPSA LUBRICANTS S.A., MADRID/E CEPSA TRANSMISIONES FE+LD 75W-80
CHEVRONTEXACO, GHENT/B MULTIGEAR MTF 75W-80W
COMERCIAL ROSHFRANS, S.A. DE C.V., MEXICO, GEAR OIL EUROFLEET SAE 75W-80
D.F/MEX
DAF TRUCKS N.V., EINDHOVEN/NL DAF PREMIUM 75W80W
Manufacturer (02D) Trade name (02D)

DE OLIEBRON B.V., ZWIJNDRECHT/NL TOR MT/LD GEAR OIL 75W80
ENI S.P.A. REFINING & MARKETING DIVISION, ROTRA MULTIGEAR 75W-80
ROME/I
EXXON MOBIL CORPORATION, FAIRFAX, MOBILUBE XHP 75W-80
VIRGINIA/USA
FUCHS PETROLUB AG, MANNHEIM/D TITAN CYTRAC LD 75W-80
GINOUVES GEORGES SA, LA FARLEDE/F YORK 894 75W-80
GULF OIL INTERNATIONAL, PITTSBURG/USA GULF GEAR TX 75W-80
HANDEL MIJ NOVIOL B.V., NIJMEGEN/NL KENNOCO FLEET TRANSMISSION LUBE ED SAE
75W-80W
HUILES BERLIET S.A., SAINT PRIEST/F RTO LONGEVIA ECO 75W-80
IGOL FRANCE SA, AMIENS/F TRANS GEAR ZF 75W80
KROON-OIL B.V., ALMELO/NL GEAR SYNTH MT/LD 75W-80
KUWAIT PETROLEUM R&T B.V., EUROPOORT RT/ Q8 T 60 SAE 75W-80
NL
MAZIVA ZAGREB D.O.O, ZAGREB/HR INA TRANSMOL HD 75W-80
MOTUL SA, AUBERVILLIERS CEDEX/F MOTUL MOTYLGEAR 75W-80
OK NEDERLAND, STAPHORST/NL OK CARDAN OIL MT/LD SAE 75W/80
OMV REFINING & MARKETING GMBH, WIEN/A OMV GEAR OIL LDI SAE 75W-80
PAKELO MOTOR OIL S.R.L, SAN BONIFACIO (VR)/I PAKELO GOLDENGEAR LD SAE 75W/80
PANOLIN AG, MADETSWIL/CH PANOLIN TRANSGEAR 75W/80W
PETROGAL S.A., LISBOA/P GALP TRANSVEX TDL ULTRA 75W80
PETRONAS LUBRICANTS INTERN., KUALA TUTELA TRUCK GEAR FE (SAE 75W80)
LUMPUR/MAL
PETRONAS LUBRICANTS INTERN., KUALA TUTELA TRUCK GEARLITE SAE 75W80
LUMPUR/MAL
RALOY LUBRICANTES S.A. DE C.V., NEW EXPERIENCE SYNTHETIC OIL 341
TIANGUISTENCO/MEX
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, CARTAGO CAJAS FE LD 75W-80
MADRID/E
REPSOL YPF LUBRICANTES Y ESPECIALIDADES, REPSOL CARTAGO FE LD 75W-80
MADRID/E
S.A.E.L., MADRID/E GULF INTARDER GEAR OIL 75W-80
SHELL INTERNATIONAL PETROLEUM COMP LTD, SHELL TRANSMISSION OIL ZFLD 75W-80
LONDON/GB
TOTAL LUBRIFIANTS S.A., PARIS/F ANTAR LD 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F FINA PONTONIC TI 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F TOTAL TRANSMISSION TI 75W-80
TOTAL LUBRIFIANTS S.A., PARIS/F TRANSELF LD 75W-80
UNIL OPAL, SAUMUR CEDEX/F GERION LD 75W80
VALVOLINE EUROPE, DORDRECHT/NL DURABLEND GEAR OIL GL-4 SAE 75W-80
YACCO, ST PIERRE LES ELBEUF/F BVX Z-500 75W-80
Oil Class 02E

• Gear oil of viscosity grades: SAE 75W-80
(synthetic)
Manufacturer (02E) Trade name (02E)

CASTROL INTERNATIONAL, PANGBOURNE CASTROL SYNTRANS MAX 75W-80
READING/GB
ZF FRIEDRICHSHAFEN AG, FRIEDRICHSHAFEN/D ZF-ECOFLUID M
Oil Class 02L

• Gear oil of viscosity grades: SAE 75W-80 (semi-
synthetic, synthetic)
Manufacturer (02L) Trade name (02L)

BAYWA AG, MÜNCHEN/D TECTROL SYNTOGEAR MA 7580
FUCHS PETROLUB AG, MANNHEIM/D FUCHS TITAN CYTRAC MAN SYNTH/75W-80
Transmission Oil - FS8209A/FSO5206B

Type
Carry out periodic maintenance on the transmission in order to maintain its original performance. It is particularly
important to replace the transmission oil according to the Maintenance Schedule.
The Maintenance Schedule varies according to the type of oil uesd.
Mineral Oil
Operating
Replacement interval Inspection and replacement item
conditions
First 5,000 to 10,000 km
Change transmission oil at the driver’s discretion
(3,000 to 6,000 miles)
Every 20,000 km
Highway Check oil level and inspect for leakage
(12,000 miles)
use
Every 100,000 km
(62,000 miles) Change transmission oil
or every 12 months
First 30 hours Change transmission oil at the driver’s discretion
Off-highway Every 40 hours Check oil level and inspect for leakage
use Every 500 hours Change transmission oil (driving on unpaved roads)
Every 1,000 hours Change transmission oil (driving on normal paved roads)
Recommended lubricants
Type Grade (SAE) Outside temperature
50 - 12°C (10°F) or higher
Heavy Duty Engine Oil
40 - 12°C (10°F) or higher
API-CD
30 Up to - 12°C (10°F)
Mild EP Gear Oil 90 - 12 to 38°C (10 to 100°F)

API-GL-4 80W - 26 to 21°C (-15 to 70°F)
Synthetic Oil
Operating
conditions
Every 20,000 km Check oil level and inspect for leakege
(12,000 miles) (all recommended oils)
Every 500,000 km
Change transmission oil
(300,000 miles)
[when COGNIS (HENKEL/EMERY) is used]
or 36 months
Highway
use Every 400,000 km
(240,000 miles)
[when CASTROL SYNTRANS is used]
or 36 months
Every 300,000 km
(180,000 miles)
[when MOBILUBE 1 SHC is used]
or 36 months
Operating
conditions
Every 40 hours Check oil level and inspect for leakage
Off-highway Every 500 hours
(all recommended oils; driving on unpaved roads)
use
Every 36 months
(all recommended oils; driving on normal paved roads)
Recommended oil • CASTROL SYNTRANS

• COGNIS (HENKEL/EMERY) • MOBILUBE 1 SHC
Semi-Synthetic Oil
Operating
conditions
Every 20,000 km Check oil level and inspect for leakege
(12,000 miles) (all recommended oils)
Highway
use Every 300,000 km
(180,000 miles)
(all recommended oils)
or 36 months
Check oil level and inspect for leakage
Every 40 hours
(all recommended oils)
Off-highway Change transmission oil
Every 500 hours
use (all recommended oils; driving on unpaved roads)
Every 36 months
(all recommended oils; driving on normal paved roads)
Recommended oil NOTE:

• ELF TRANSEIF 75W/80W (known as RVI • When an oil filter elements is installed, replace it
Longevia) when changing the oil.
• MOBIL MOBILUBE XHP • If your vehicle is used under service
• KUWAIT Q8 T 60 conditions,change the oil accordingly.
• FUCHS DEA DEAGEAR LD & TITAN CYTRAC LD
• FIAT LUBRIFICANTI TUTELA TRUCK GEAR FE RS23/RS40 Type Axle
• DE OLIEBRON TOR MT/LD GEAR OIL The differential gear of your vehicle can stay in good
• OMV AKTIENGESELLCCHAFT OMVLDL 75W-80 conditions through regular maintenance. Above all,
• PAKELO MOTOR OIL PAKELO GOLDENGEAR make sure to replace the differential oil and filter
LD element regularly in accordance with the specified
maintenance schedule.
• TEXACO MULTIGEAR MTF 75W/80W
Driving Inspection and refilling Differential oil change and

Differential oil change
conditions (as required) filter element replacement
After first 5,000 km Every 80,000 km
Off-highway Every 5,000 km (3,000 miles) (50,000 miles)
use (3,000 miles) or first regular service time or 6 months
(whichever is earlier) (whichever is earlier)
After first 5,000 km Every 160,000 km
Highway Every 5,000 km (3,000 miles) (100,000 miles)
use (3,000 miles) or first regular service time or 6 months
(whichever is earlier) (whichever is earlier)

Recommended Oil
Type API/MIL rating SAE viscosity rating
Mineral oil (O-76A) GL5/MIL-L-2105D SAE 85W-140
GL5/MIL-L-2105D
Synthetic oil (O-76M) SAE 75W-140/75W-90
(if approved by the body manufacturer)
RS25 Type Axle

The differential gear of your vehicle can stay in good
conditions through regular maintenance. Above all,
make sure to replace the differential oil and filter
element regularly in accordance with the specified
maintenance schedule.
Check and Replacement Interval
Construction, Refuse, Yard
Vocation or Vehicle Tractor, Logging, Heavy
Linehaul City Delivery
Operation Haul, Mining, Oil Field,
Rescue
Initial Oil Change Not required Not required Not required
Every 40,000 km Every 16,000 km Every 8,000 km
Check Oil Level
(25,000 miles) (10,000 miles), (5,000 miles),
Add the correct type
or the fleet maintenance once a month or the fleet once a month or the fleet
and amount of oil as
interval, whichever comes maintenance interval, maintenance interval,
required.
first whichever comes first whichever comes first [1]
Every 160,000 km Every 40,000 km
Every 80,000 km (50,000
Petroleum-Based Oil (100,000 miles) (25,000 miles)
miles) or annually,
Change on Axles or annually, whichever or annually, whichever
whichever comes first
comes first comes first
Every 800,000 km Every 400,000 km Every 160,000 km
Synthetic Oil (500,000 miles) (250,000 miles) (100,000 miles)
Change on Axles [2] or every 4 years, whichever or every 3 years, whichever or every 2 years, whichever
comes first comes first comes first
[1] For continuous heavy-duty operation, check the oil level every 1,600 km (1,000 miles).
[2] These intervals apply to approved semi-synthetic and full-synthetic oils only.For a list of approved extended-
drain axle oils, refer to TP-9539, Approved Rear Drive Axle Lubricants.
Recommended Oil
Type API/MIL rating SAE viscosity rating
Mineral oil (O-76A) GL5/MIL-L-2105D SAE 85W-140
GL5/MIL-L-2105D
Synthetic oil (O-76M) SAE 75W-140/75W-90
(if approved by the body manufacturer)
Maintenance Schedule for Severe-condition

Introduction
The vehicle needs to be maintained more often if it is
driven in severe condition.
A : Driving with a trailer

B : Operation involving frequent starts and stops
C : Driving on rough roads, mountain roads or uphill
roads
D : Driving in dusty areas
Driving on snowy roads or along the seashore
Maintenance Schedule for Severe-condition
Condition
Item Distance covered
A B C D E B+E
Replace
every 24,000 km
Air Cleaner Element (15,000 miles) D
or
after 6th cleaning
Change
4HK1 Engine model
Engine Oil every 10,000 km A D B+E
6HK1 Engine model
(6,000 miles)
Change
4HK1 Engine model
Engine Oil Filter every 10,000 km A D B+E
6HK1 Engine model
(6,000 miles)
Inspect
Loose or otherwise improper installation
every 2,000 km A B C E
of Exhaust Pipe
(1,250 miles)
Replace
MZW type every 24,000 km A C
(15,000 miles)
Replace
MLD type every 24,000 km A C
Transmission Oil (15,000 miles)
ZF6S1000 type Refer to “Maintenance Schedule” in this section.
ZF9S1110 type Refer to “Maintenance Schedule” in this section.
FSO5206B type Refer to “Maintenance Schedule” in this section.
FS8209A type Refer to “Maintenance Schedule” in this section.
Replace
ALLISON2500 type 20,000 km A B C
(12,000 miles)
Transmission Fluid
Replace
ALLISON3000/3500 type every 20,000 km A B C
(12,000 miles)
Condition
A B C D E B+E
Replace
every 20,000 km
ALLISON2500 type (12,000 km), A B C
500 hours
Transmission or 6 months
Main Filter Replace
every 20,000 km
ALLISON3000/3500 type (12,000 km), A B C
500 hours
or 6 months
Replace
every 20,000 km
ALLISON2500 type (12,000 km), A B C
500 hours
Transmission or 6 months
Cooling System
Filter Replace
every 20,000 km
ALLISON3000/3500 type (12,000 km), A B C
500 hours
or 6 months
Change
Clutch fluid Manual Transmission Vehicle every 24,000 km B
(15,000 miles)
Change
Smoother Vehicle equipped
every 24,000 km A C
Clutch Oil with the Smoother System
(15,000 miles)
Replace
Transfer
4WD model every 12,000 km A C
Gear Case Oil
(7,500 miles)
Inspect
Worn Propeller Shaft Universal Joints
every 24,000 km C
and Splines
(15,000 miles)
Vehicle equipped Change
Rear Axle Differential
with ISUZU every 24,000 km A C
Gear Oil
produced Axle (15,000 miles)
FVR/FVM/FVZ
models with Refer to “Maintenance Schedule” in this section
Rear Axle Differential Oil
ARVIN MERITOR for RS23/RT40 type axle.
produced Axle
FVM model
Change
Rear Wheel Hub with
every 24,000 km A C
Bearing Oil ARVIN MERITOR
(15,000 miles)
produced Axle
Change
Inter-differential
FVZ model every 24,000 km A C
Gear Oil
(15,000 miles)
Change
Front Axle Differential
4WD model every 24,000 km A C
Gear Oil
(15,000 miles)
Condition
A B C D E B+E
Vehicle equipped
Replace
Front Wheel Hub with
every 24,000 km A C
Bearing Oil ARVIN MERITOR
(15,000 miles)
produced Axle
Tighten to the
Specified Torque
Leaf Spring U-bolt Nuts C
every 24,000 km
(15,000 miles)
Tighten to the
Air Suspension’s Beam Bolt Air Suspension Specified Torque
C
Nuts/U-bolt Nuts model every 24,000 km
(15,000 miles)
Loose or damaged air Inspect
Air Suspension
suspension main support every 24,000 km C
model
members (15,000 miles)
Inspect
Damage to, or Looseness or Excessive Play
every 6,000 km C
in Power Steering Joint
(3,750 miles)
Inspect
Brake Lining Wear every 6,000 km A B C D
(3,750 miles)
Inspect
Brake Drum Wear or Damage every 24,000 km A B C D
(15,000 miles)
Inspect
Brake Pad Wear
every 2,500 km A B C D
(Vehicle equipped with Disk Brake)
(1,500 miles)
Inspect
Brake Disk Wear or Damage every 20,000 km
A B C D
(Vehicle equipped with Disk Brake) (12,000 miles)
or every 6 months
Recommended Fluids, Lubricants and Diesel Fuels

Introduction
In order to obtain the maximum performance and the
longest service life from your ISUZU vehicles, it is very
important to select and use correctly best lubricant and
diesel fuels.
When lubricating, be sure to use ISUZU genuine
lubricants or recommended lubricants listed below,
according to the maintenance schedule for each
vehicle model.
The lubrication intervals in the maintenance schedule
and the coverage and period of new vehicle warranty
are based on the use of ISUZU genuine lubricants or
recommended lubricants as given in the chart which
will serve as a guide for selecting lubricants of proper
brand name.
Diesel Engine Crankcase with DPD (Low Ash Oil)
GRADE
MAKE BRAND
API ACEA JASO
ISUZU GENUINE BESCO MULTI-Z TYPE CF-4 (10W-30) DH-2
ISUZU GENUINE BESCO CLEAN SUPER (10W-40) DH-2
ISUZU GENUINE BESCO CLEAN (10W-30, 40) DH-2
CI-4/CH-4/
Shell Rimula R6 LM (10W-40) CG-4/CF-4/ E7/E6/E4 DH-2
CF
ExxonMobil Delvac XHP LE (10W-40) E6
ExxonMobil Delvac MX ESP (15W-40) CJ-4 DH-2
ExxonMobil Delvac 1300 Super (15W-40) CJ-4 DH-2
Castrol Tection Global ES (15W-40) CJ-4
BP Vanellus Eco (10W-40) E6
BP Vanellus Multi Fleet Eco (15W-40) CJ-4
Caltex/Chevron Delo 400 LE (15W-40) CJ-4 E9 DH-2
Caltex/Chevron Delo XLE Multigrade (10W-40) E6/E7
Caltex/Chevron Ursa Ultra X (10W-40) E6/E7
NOTE:
The oils recommended in the "Diesel Engine
Crankcase" list can also be used for DPD-equipped
vehicles.
If you use a low ash content engine oil, increased
exhaust pressure may extend the required distance
between DPD filter cleanings.

Manual Transmission (MZW/MLD models), Transfer Case, Differential (without LSD) and Oil
Lubricated Hub Bearing
GRADE
MAKE BRAND
API ACEA JASO
ISUZU GENUINE BESCO GEAR OIL SH (80W-90), (90), (140) GL-5
ExxonMobil Mobilube HD (80W-90) GL-5
Castrol Dynadrive (80W-90) GL-5
BP Hypogear (80W-90) GL-5
Caltex Thuban GL-5 EP (80W-90), (85W-140) GL-5
Differential (with LSD)
GRADE
MAKE BRAND
API ACEA JASO
Shell Spirax A LS 90 (90) GL-5
ExxonMobil Mobilube LS (85W-90) GL-5
Castrol LSX (85W-140) GL-5
BP Limslip (85W-140) GL-5
Caltex Gear Oil LSD (90) GL-5
Smoother Clutch Oil (Smoother)
GRADE
MAKE BRAND
API ACEA JASO
ISUZU GENUINE BESCO ATF III
Automatic Transmission, Power Steering
GRADE
MAKE BRAND
API ACEA JASO
ISUZU GENUINE BESCO ATF II (Power Steering only)
ISUZU GENUINE BESCO ATF III
Shell Donax TG (Dexron III)
Castrol TQ DIII (Dexron III)
BP Autoran DXIII (Dexron III)
Caltex/Texaco Texamatic 1888 (Dexron III)

Center Bearing, Clutch Shift Block, Grease
Lubricated Hub, Water Pump, Propeller
Shaft Sliding Yoke, Universal Joint (Multi
Purpose Grease)
GRADE
MAKE BRAND
API ACEA JASO
ISUZU GENUINE BESCO L-2 GREASE (No.2)
ISUZU GENUINE BESCO L-3 GREASE (No.3)
Shell Retinax LX2 (No.2)
ExxonMobil Mobilgrease XHP 222/223 (No.2), (No.3)
Caltex/Texaco Starplex-2 (No.2)
Engine Cooling System
MAKE BRAND
ISUZU GENUINE BESCO LLC SUPER TYPE E, AS
Caltex/Texaco/Chevron Extended Life Coolant
Caltex/Texaco/Chevron Havoline XLC
Caltex/Texaco/Chevron Delo ELC
Engine coolant prevents engine damage due to

freezing and protects the cooling system from
corrosion. Use a mixture of the engine coolant
concentrate solution and distilled water or deionized
water as the engine coolant. Use only an Isuzu-
recommended engine coolant solution. Mix with for 30
or 50% solution and the rest water.
Coolant concentration
Usage region Outside temperature Other than Isuzu
Isuzu genuine coolant
genuine coolant*
Warm region Up to -12°C(10°F) 30% 50%
Cold region Up to -30°C(-22°F) 50% 50%
*For other than Isuzu genuine coolant(TEXACO/ NOTE:

CALTEX/CHEVRON, etc.), it is recommended to use • If the engine or vehicle is used at -30°C(-22°F) or
directly “ 50/50 Pre-diluted” product which is already below, the coolant concentration of 55% is
diluted to 50% concentration. recommended.
• Using coolant at any coolant concentration other
If the mixture contains over 60% engine coolant, the
than that specified may reduce anti-freezing
possibility of overheating increases; conversely, if the
performance, and engine coolant may freeze.
mixture contains less than 30%, protection against
corrosion will be inadequate. Accordingly, the mixture
should contain between 30% and 50% engine coolant.

Electric-hydraulic Cab Tilt Pump
GRADE
MIL-H-5606E aviation oil or equivalent
Clutch and Brake Fluid Reservoir
MAKE BRAND GRADE*

ISUZU GENUINE BESCO brake fluid super DOT 3
AC DelcoTM Delco supreme11 DOT 3
* : This material meets GENERAL MOTORS

ENGINEERING STANDARDS GM4653M,FMVSS 116
or SAE J1703 requirements.
Diesel Fuel / Applicable Standard
Japanese Industrial Standards (JIS) Based on K2204 GAS OIL

Deutsche Industrie Normen (DIN) Based on EN590 : 1997
SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) Based on SAE J-313C
British Standards (BS) Based on EN590 : 1997
Diesel Fuel / Applicable Standard (Sulfur content below 10 ppm)
Japanese Industrial Standards (JIS) Based on K2204 Diesel Fuel

Deutsche Industrie Normen (DIN) Based on EN590 : 2004
American Society for Testing and Materials (ASTM) Based on D975-04c NO.1-D S15 or NO.2-D S15
(below 15 ppm)
British Standards (BS) Based on EN590 : 2004
NOTE:
Be sure to use extra-low-sulfur diesel fuel (with sulfur
content no higher than 10 ppm).
If you supply the vehicle with poor-quality fuel, water-
removal additive or other additive, gasoline, kerosene
or alcohol-based fuel, it could harm the fuel filter,
prevent proper movement of fuel-lubricated parts in the
injectors and adversely affect engine components,
possibly resulting in a breakdown.
If you accidentally put the wrong fuel in the tank, drain it
all out. Starting the engine with the wrong fuel in the
tank could result in a fire and engine damage.
Oil Viscosity Chart

Oil Viscosity Chart
ENGINE OIL VISCOSITY CHART

ENGINE OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
[Single grade] SAE 40, 50
SAE 30
SAE 20, 20W
*
SAE 10W
-30 C -25 C -15 C 0 C 15 C 25 C 30 C
-22 F -13 F 5 F 32 F 59 F 77 F 86 F
SAE 10W-30
SAE 10W-40
*
SAE 5W-40
SAE 15W-40, 20W-40, 20W-50
DO NOT USE SYNTHETIC OILS.
* At ambient temperatures below-25 C (-13 F), starting aids (oil pan

heater, block heater, etc.) are recommended to prevent hard starting
and other engine problems.
[Multi grade]
MFW80AMF000101
GEAR OIL VISCOSITY CHART

(ISUZU production components)
GEAR OIL VISCOSITY GRADE - AMBIENT TEMPERATURE
[Single grade]
SAE 140
SAE 90
SAE 80W
SAE 75W
-25 C -10 C 0C 15 C 30 C 35 C
-13 F 14 F 32 F 59 F 86 F 95 F
SAE 75W-90
SAE 80W-90
SAE 80W-140
[Multi grade]
MFW80AMF000301
Lubrication Chart
Lubrication Chart
FRR/FSR/FTR/FVR models without FG941 (MFS66) Type Axle
CHECK or SUPPLY ....ENGINE OIL ...BRAKE FLUID
CHANGE ....GEAR OIL ...AUTOMATIC TRANSMISSION FLUID
....MULTIPURPOSE TYPE GREASE
....MULTIPURPOSE TYPE GREASE or WHEEL BEARING GREASE
M/T Clutch fluid B B
Water pump bearing grease

M
(6HK1 engine model)
Wheel hub bearing M/W
grease
Tie rod end grease
M
(FTR/FVR models)
Power steering fluid A A
*Engine E E E
SA Smoother clutch oil A A A
AHB Brake fluid B B
Transmission G G G
MZX/MZW/MLD model
Transmission
FS8209A/FSO5206B model
(Refer to "Maintenance
Schedule" in this section.)
ZF6S1000/ZF9S1110 model
Transmission A
ALLISON2500 model
grease
Differential gear G G G
Initial 1,000 km (600 miles)

Every 3 months or 10,000 km (6,000 miles)
M/T : Manual transmission vehicle
SA : Vehicle equipped with the Smoother system
AHB : Vehicle equipped with the air-over hydraulic brake system
MFWB0AXF000601

FVR model with FG941 (MFS66) Type Axle


Water pump bearing
grease M
(6HK1 engine model)
Wheel hub bearing G G G
oil
*Engine E E E
Transmission
FS8209A model
ZF9S1110 model
Transmission A A
ALLISON3000 model
MER Differential gear

Schedule" in this section.) Initial 1,000 km (600 miles)
Initial 8,000 km (5,000 miles)

MER : Vehicle equipped with Arvin Meritor production axle
MFWB0AXF000701

FVM/FVZ models
Water pump bearing grease M

(6HK1 Engine model)
ISZ Wheel hub bearing M/W
grease
MER Wheel hub bearing G G G

oil
ISZ Tie rod end grease M
*Engine E E E
Transmission
ZF6S1000 model
ZF9S1110 model
Schedule" in this
section.)
Transmission A A
ALLISON3500 model
grease
ISZ Differential gear G G G
MER Differential gear

MER Wheel hub bearing G G G

oil (FVM model)

Initial 8,000 km (5,000 miles)
ISZ : Vehicle equipped with Isuzu production transmission or axle
MER : Vehicle equipped with Arvin Meritor production axle
MFWB0AXF000801

FSS/FTS models
CHANGE ....GEAR OIL ...POWER STEERING FLUID
Clutch fluid B B
Water pump bearing

grease M
(6HK1 engine model)
Front axle G G G
differential gear
grease
Power steering fluid P P
*Engine E E E
AHB Brake fluid B B
Transmission G G G
MZX/MZW/MLD model
Transfer case G G G
grease
Differential gear G G G

AHB : Vehicle equipped with the air-over hydraulic brake system
MFWA0AXF004001
Greasing Point
Greasing Point
FRR/FSR/FTR/FVR models with leaf suspension
Every month or every 5,000km (3,000miles)
1 2 3 5 9 11 6 4 6 8 6 10
2 3 5 12 7 8 10
1. Steering shaft sliding sleeve 7. Propeller shaft sliding yoke

2. Front spring pin 8. Rear spring pin
3. Kingpin 9. Clutch shift block (ZF9S1110 type transmission)
4. Propeller shaft center bearing 10. Rear shackle pin or
5. Front shackle pin Rear spring sliding pad
6. Propeller shaft universal joint 11. Clutch booster joint pin (MZW type transmission)
12. Clutch booster joint pin (ZF9S1110 type transmission)
MFWB0AXF000101

FRR/FSR/FTR/FVR models with air suspension
1 2 3 5 8 9 6 4 6 6
2 3 5 10 7
1. Steering shaft sliding sleeve 6. Propeller shaft universal joint

2. Front spring pin 7. Propeller shaft sliding yoke
3. Kingpin 8. Clutch shift block (ZF9S1110 type transmission)
4. Propeller shaft center bearing 9. Clutch booster joint pin (MZW type transmission)
5. Front shackle pin 10. Clutch booster joint pin (ZF9S1110 type transmission)
MFWB0AXF000201

FVM/FVZ models with leaf suspension
1 2 3 54 7 6 7 9 7 8 7 9
2 3 5 10 9 8 9
: For FVZ model only
1. Steering shaft sliding sleeve

2. Front spring pin
3. Kingpin
4. Clutch shift block
5. Front spring pin and shackle pin
6. Propeller shaft center bearing
7. Propeller shaft universal joint and sliding sleeve
8. Trunnion shaft
9. Rear spring sliding pad
10. Clutch booster joint pin
MFWB0AXF000301

FVM/FVZ models with air suspension
1 2 3 5 4 6 7 6 6 6
2 3 5 8
: For FVZ model only
1. Steering shaft sliding sleeve

2. Front spring pin
3. Kingpin
4. Clutch shift block
5. Front spring pin and shackle pin
6. Propeller shaft universal joint, sliding sleeve and center bearing
7. Propeller shaft center bearing
8. Clutch booster joint pin
MFWB0AXF000401

FSS/FTS models
1 2 13 3 4 5 9 6 6 8 6 11 6 12
2 13 10 3 4 5 7 11 12
1. Steering shaft sliding sleeve 7. Propeller shaft center bearing

2. Front spring pin 8. Parking brake relay lever
3. Kingpin 9. Clutch booster joint pin (MZW type transmission)
4. Tie rod end 10. Shimmy damper
5. Front shackle pin 11. Rear spring pin
6. Propeller shaft universal joint and 12. Rear shackle pin
sliding sleeve 13. CV (Constant velocity) joint
MFWB0AXF000501
MEMO
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67039_MGGEN-WE-1101AU_奥付 10.10.25 3:28 PM ページ 1
Published: Nov., 2010 All rights reserved.

First Edition
WORKSHOP MANUAL
GENERAL INFORMATION
Issued by ISUZU MOTORS LIMITED

E-Solutions & Service Marketing Dept.
Shinagawa-ku, Tokyo, 140-8722 Japan
0-XXXKI
67039_MGGEN-WE-1101AU_奥付 10.10.25 3:28 PM ページ 2
2011MY
2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL GENERAL INFORMATION

GENERAL INFORMATION
No.MGGEN-WE-1101AU
2011MY
2011MY
WORKSHOP MANUAL ENGINE (4HK1 model)

WORKSHOP MANUAL
ENGINE
(4HK1 model)
No.MG4HK-WE-1101AU
MG4HK-WE-1101AU_67038前書 2010.11.5 4:22 PM ページ 1
Section Sub Section
1C Engine Cooling
1D Engine Fuel
1F Emission Control
1G Engine Exhaust
1J Induction
2B Front Suspension
2C Rear Suspension
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4D Parking Brake
5E Clutch
9C Entertainment
9D Wiring System
9F Body Structure
9G Cab
9H Seats
9L Cab Mounting
MG4HK-WE-1101AU.book 1 ページ２０１０年１１月２６日　金曜日　午前９時８分
Engine Mechanical (4HK1) 1B-1
ENGINE
Engine Mechanical
(4HK1)
TABLE OF CONTENTS
4HK1Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-3 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-48
Maintenance Precautions . . . . . . . . . . . . . . . . . 1B-3 Timing Gear Train. . . . . . . . . . . . . . . . . . . . . . . . 1B-50
Service Technology Information . . . . . . . . . . . . 1B-3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50
Reading the Model . . . . . . . . . . . . . . . . . . . . . . 1B-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-50
Description of Function and Operation . . . . . . . 1B-6 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-53
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1B-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-55
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-13 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-64
Phenomenon: Engine does not run. . . . . . . . . 1B-14 Valve Stem Seal and Valve Spring . . . . . . . . . . . 1B-65
Phenomenon: Engine cranks but does Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
not start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-65
Phenomenon: There is Much Black Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-66
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . 1B-16 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-67
Phenomenon: There is Much White Rocker Arm Shaft Assembly . . . . . . . . . . . . . . . 1B-70
Exhaust Smoke . . . . . . . . . . . . . . . . . . . . . . . . 1B-17 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-70
Phenomenon: Engine is Experiencing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-70
Knocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
Phenomenon: Engine Rotation Problem. . . . . 1B-19 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-71
Phenomenon: Charging failure . . . . . . . . . . . . 1B-20 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-73
Primary Specifications. . . . . . . . . . . . . . . . . . . 1B-20 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-74
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-22 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-76
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-24 Camshaft Assembly . . . . . . . . . . . . . . . . . . . . . . 1B-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-24 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-26 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-77
Engine Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-78
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-32 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-80
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-33 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-80
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-34 List of Tightening Torques . . . . . . . . . . . . . . . . 1B-82
Cylinder Head Cover . . . . . . . . . . . . . . . . . . . . . 1B-35 Camshaft Position Sensor . . . . . . . . . . . . . . . . . 1B-83
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-35 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-83
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-38 Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-39 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-39 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89
Maintenance Precautions . . . . . . . . . . . . . . . . 1B-39 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-92
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-39 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-98
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-39 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-106
Intake Throttle Valve. . . . . . . . . . . . . . . . . . . . . . 1B-41 List of Tightening Torques . . . . . . . . . . . . . . . 1B-117
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-41 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Inlet Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-120
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-121
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-43 List of Tightening Torques . . . . . . . . . . . . . . . 1B-124
List of Tightening Torques . . . . . . . . . . . . . . . . 1B-45 Crankshaft Position Sensor . . . . . . . . . . . . . . . 1B-125
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-125
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-125
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-126
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-47 Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-126
1B-2 Engine Mechanical (4HK1)

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-126
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-127
List of Tightening Torques . . . . . . . . . . . . . . . 1B-129
Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . 1B-130
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-130
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-130
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-131
Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . 1B-138
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-138
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-139
Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-143
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-143
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-144
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-145
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-150
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-151
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-155
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-155
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-160
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-160
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-165
Components . . . . . . . . . . . . . . . . . . . . . . . . . 1B-165
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-165
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-166
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-167
4HK1Engine
Maintenance Precautions Precautions for work particular to this engine
To prevent damaging the engine and to ensure the Including the inside of the injector, the holes and gaps
reliability of engine performance, be careful of the that are the fuel paths for the fuel system have an
following points when performing engine maintenance. extremely precise finish. Therefore, because there is
Note that information relating to working safely can be the possibility of damage if foreign material becomes
found in the Overview. mixed in, cover the cap after removing parts, etc., to
• When lifting or supporting the engine, do not prevent the entry of foreign material.
directly attach the jack to the oil pan.
When lowering the engine to the ground, do not let Service Technology Information
the oil pan directly contact the ground. Use a
frame, etc. to support it with the engine foot or Using the Plastigage
flywheel housing.
(There is only a small gap between the oil pan and
oil pump strainer, so be careful not to damage the Type Measurable Range mm(in)
oil pan and oil pump strainer.) PG-1 (Green) 0.025 - 0.076 (0.00098-0.00299)
• When the air intake system, such as the air duct or PR-1 (Red) 0.051 - 0.152 (0.00201-0.00598)
air cleaner, has been removed, cover the air intake
to prevent foreign material from entering the PB-1 (Blue) 0.102 - 0.229 (0.00401-0.00902)
cylinder.
• To perform maintenance on the engine, always (Example) Measuring the Clearance Between the
remove the battery ground terminals. If the battery connecting rod Bearing and Crank Pin
ground terminals are not removed while • Clean the connecting rod and bearing, and
performing work, there is the possibility of assemble that to the connecting rod.
damaging the wire harness or electrical
• Cut the plastigage to the width of the crank pin and
components. Take adequate precautions for
lay it parallel avoiding the crank pin oil hole.
safety, such as short circuits, when inspections
require an energized state. • Align the markings on the connecting rod and on
the cap for assembly to the crank pin. Apply
• To protect and lubricate the sliding surfaces when
molybdenum disulfide to the threaded portion of
running for the first time, apply an adequate
the tightening bolts and seat surface. Alternately
amount of engine oil to the sliding surfaces.
tighten them so that the cap is at the specified
• When the valve related parts, injector, pistons, torque.
piston rings, connecting rod, connecting rod
bearing, crankshaft journal bearing, etc. have been NOTE:
removed, organize them in order for storage. Absolutely never move the connecting rod when the
• When reinstalling them, use the same part and plastigage is in use.
install it in the same position as when it was
removed.
• Whenever disassembling the gasket, oil seals and
O-rings, replace them with new ones.
• Completely wipe off old liquid gasket from the
locations where it is used. After cleaning to
completely remove any oil, moisture and filth,
apply the specified liquid gasket for assembly.
• After applying the liquid gasket, install it within a
specified amount of time. If the specified amount of
time is exceeded, wipe away the liquid gasket and
reapply it.
• When assembling and installing, tighten at the
specified torque.

• Gently remove the cap and connecting rod and NOTE:
use a scale printed on the packaging of the Absolutely never rotate the crankshaft when the
plastigage to measure the flattened plastigage plastigage is in use.
(clearance).
• Gently remove the crankcase and use a scale
printed on the packaging of the plastigage to
measure the flattened plastigage (clearance).
HCW30ASH002001
HCW30ASH002201
HCW30ASH002101
(Example) Measuring the Clearance Between the

HCW30ASH002301
Crankshaft Bearing and Crankshaft Journal
• Clean the bearing and the bearing installation
surfaces of the cylinder block and crankcase, and
assemble them to the cylinder block and
crankcase.
• Gently place the crankshaft on the cylinder block,
and settle it by turning it approximately 30°.
• Cut the plastigage to the width of the crank journal
and lay it parallel avoiding the journal oil hole.
• Gently place the crankcase on the cylinder block,
and apply molybdenum disulfide to the threaded
portion of the tightening bolts and seat surface.
Tighten in order, at the specified torques.

Reading the Model
MFWA1BMF000101
Legend
1. Engine number stamping (******)

Description of Function and Operation
External appearance of engine
MFWA1BMF000201
MFWA1BMF000301
MFWA1BMF000401
Description of Function and Operation Connecting rod cap bolt

Electronic Control Engine Control Tighten the mounting bolt of the connecting rod cap
This controls from injection to air intake and exhaust, using the plastic region rotational angle tightening
such as fuel injection amounts, injection timing, the air method.
intake throttle, EGR and idling speed, using the engine Common rail type electronic control injection
control module (ECM). system
Cylinder block The common rail type control injection system is
The cylinder block is cast iron. The pitches between composed of a supply pump that sets and supplies the
bores are equal, and it is a highly rigid structure with target pressure of high-pressure fuel, a common rail
symmetry to the right and left centering on the that measures that high-pressure fuel, and an injector
crankshaft. Tighten the bearing cap using the plastic that injects the high-pressure fuel after it has been
region rotational angle tightening method, with the micronized. Each control system regulates the injection
ladder frame structure. timing and amount based on various signals when the
ECM is in all traveling conditions.
Cylinder liner
The cylinder liner is selected and assembled to match Injector
the inner diameter of the cylinder block bore and its The injector is a multi-hole nozzle, and adjusts the
grade is marked on the left side surface of the cylinder. injection timing and amount using the opening and
closing of a solenoid valve at the top of the injector.
Piston
The pistons are autothermatic pistons cast with Fuel filter with sedimenter
aluminum alloy struts, and the combustion chamber is This is a fuel filter that has a sedimenter to remove
a spherical re-entrant system. moisture content by using the difference of the relative
density of light diesel oil and water.
Cylinder head
The cylinder head is cast iron. It has 4 valves per EGR device
cylinder. Tighten the head bolts using the plastic region The ECM applies controls based on information such
rotational angle tightening method. as water temperature, engine speed and engine load.
Also, some of the exhaust gas is re-circulated to be
Crankshaft cleaned.
Apply TUFFTRIDE treatment. Gradations of the journal The primary components are the EGR valve, EGR
diameter are marked on the No.1 balance weight. cooler, exhaust brake valve and various sensors.

Lubricating system
This is a full-flow bypass unitized oil filter. Oil flows
through the oil cooler and around the sliding sections
from the oil gallery for lubrication.
Glow control system
The glow control system makes it easier to start the
engine in low temperatures, and reduces the amount of
white smoke and noise generated immediately after
starting the engine. When the ignition switch is turned
"ON", the ECM detects the temperature of the engine
coolant from a signal sent from the engine coolant
temperature (ECT) sensor. This can change the glow
time to always start the engine under optimum
conditions. Also, an after-glow function stabilizes the
idling immediately after starting the engine. ECM
determines the glow time according to the engine
coolant temperature, and starts the glow relay and glow
plug (preheat) indicator light.

Functional Inspection:
Inspecting and Adjusting Valve Clearance
1. Inspecting Valve Clearance Position to inspect when the 4th cylinder is
at the compression top dead center
NOTE:
Work while the engine is cooling.
Valve clearance mm (in)

Intake valve 0.4 (0.016 )
Exhaust valve 0.4 (0.016 )
• When the 1st cylinder is at the compression top

dead center, a circle is marked in the table;
when the 4th cylinder is at the compression top
dead center, an X is marked in the table for
inspection of valve clearance.
Cylinder No. 1 2 3 4
LNW21BSH030001
Valve
In Ex In Ex In Ex In Ex
arrangement
a. Put the engine 1st cylinder at the compression
1st cylinder
top dead center.
at compression { { { {
top dead center • Rotate the crankshaft in the forward
direction. Align the crank pulley alignment
4th cylinder mark (1) and the front cover BTDC 0° mark
at compression X X X X (2).
top dead center
Parts to inspect when the 1st cylinder is at

the compression top dead center
1
MFWB1BSH002601
b. Insert the thickness gauge between the rocker

LNW21BSH029901
arm and bridge cap, and measure the
clearance.
c. Put the engine 4th cylinder at the compression
top dead center.

• Rotate the crankshaft in the forward
direction 360°. Align the crank pulley b. Insert a 0.4 mm (0.016 in) thickness gauge
alignment mark and the front cover BTDC 0° between the rocker arm end (valve side) and
mark. cap (assembly on bridge top), and tighten the
d. Insert the thickness gauge between the rocker rocker arm adjust screw. When the movement
arm and bridge cap, and measure the of the thickness gauge becomes stiff, fasten the
clearance. adjust screw nut of the rocker arm.
e. When the measured value is not standard,
adjust the valve clearance.
Tightening torque 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
2. Adjusting Valve Clearance
Valve clearance mm (in)

Inlet valve 0.4 (0.016)
Exhaust valve 0.4 (0.016 )
• When the 1st cylinder is at the compression top

dead center, a circle is marked in the table;
when the 4th cylinder is at the compression top
dead center, an X is marked in the table for
adjustment of valve clearance.
Cylinder No. 1 2 3 4
Valve
In Ex In Ex In Ex In Ex
arrangement
1st cylinder
at compression { { { { MFW81BSH002001
top dead center

4th cylinder
c. When lightly tightening the bridge adjust screw
at compression X X X X
while the thickness gauge is inserted, check
top dead center
that the leading end of the adjust screw and the
valve shaft touch and that the movement of the
NOTE: thickness gauge is stiff.
Adjust so that the bridge is level. (It should touch the
two valve shaft ends.)
a. Completely loosen each adjust screw of the

bridge and the rocker arm.
LNW21BSH029801
BLW51BSH005501

d. Next, check whether the valve shaft end on the
opposite side is floating, or touching at an
angle. If it is floating or touching at an angle,
slightly loosen the bridge adjust screw and
adjust the valve shaft ends on both sides to
touch properly.
Valve bridge gap 0.1 mm (0.004 in) or less
e. When both sides of the valve shaft have been

adjusted to touch properly, use a flat-blade
screwdriver to tighten the bridge adjust screw
nut so that it does not rotate.
1

LNW21BSH057101
Legend
1. Harness connector
4. Install the battery ground terminal.

5. Engage the starter to discharge foreign material
from inside the cylinders.
6. Install the compression gauge adaptor and the

gauge (special tools).
Special Tool
Compression gauge adaptor:
5-8840-2815-0
Compression gauge: 5-8840-2675-0
BLW51BSH005701
NOTE:
If the bridge adjust screw adjustment is poor, the bridge
will be pushed downward at an angle causing problems
of seizure or breakage of the bridge guide. Perform
accurate adjustment.
Compression pressure inspection

1. Warm-up the engine.
2. Remove the battery ground terminal and remove
all glow plugs.
3. Remove the injector harness connector installed to
the lower head cover. (This will prevent fuel
injection.)
NOTE:
When the harness connector is removed, the ECM LNW71BSH003501
determines a malfunction and records the DTC. Delete
the DTC after completing the measurements.
For details on how to delete the DTC, refer to the 7. Engage the starter to inspect the compression
"Diagnostic Information and Procedures" in Section 1A, pressure.
Engine Control System
Compression pressure MPa (kg/cm2/psi) / r/min

2.75 ± 0.15
(28 ± 1.5/398± 21) / 220
2.65 ± 0.15
Standard values
(27 ± 1.5/384±21) / 185
2.55 ± 0.15
(26 ± 1.5/370±21) / 150
Limit 2.16 (22/313)
Cylinder differences 290kPa (3.0/43)
• Sequentially measure each cylinder.
NOTE:
To ensure the engine speed of more than 200 r/min,
use a completely charged battery.
8. Remove the compression gauge.

9. Disconnect the battery ground terminal.
10. Install the injector harness connector installed to
the lower head cover.
11. Install all of the glow plugs.
12. Install the battery ground terminal.
Determining the overhaul period

Increasing engine oil consumption amounts
If the consumption rate (the traveling distance on
consumption of 1L of oil) of a new vehicle is set as
100%, an overhaul is required when that rate falls
below 50%.
Increasing the fuel consumption rate

The fuel consumption rate (km/L) of a new vehicle is
set as 100%. An overhaul is required when that rate
falls below 60%.
Abnormal noises in engine

If the cause of the abnormal noise is inside the engine,
overhaul the engine immediately for repair.
* A variety of causes of abnormal noises are
conceivable. However, there are many cases of the
parts of the engine being worn, or foreign material
causing chewing of the engine.

Failure Phenomenon List
• Engine does not run
• Engine cranks but does not start
• There is much black exhaust smoke
• There is much white exhaust smoke
• The engine is experiencing knocking
• Engine rotation problem
• Charging problem

Phenomenon: Engine does not run
Condition Possible Cause Correction

Starter does not run The Immobilizer is activated Check the key
For details on the immobilizer, refer to
"Immobilizer Control System" in Section
Insufficient battery charge Recharge or replace the battery
Defective battery relay Replace
Defective wiring Connect or repair
Defective starter unit Inspect the starter. If defective, replace
it
The starter works, but it does not rotate Wear of the ring gear Repair or replace
the flywheel Improper adjustment of the starter Adjust or repair
magnetic switch
The starter pinion meshes with the ring Insufficient battery charge Recharge or replace the battery
gear, but the engine does not run Insufficient tightening of the wiring Perform a repair
circuit terminal
Defective starter unit Inspect the starter. If defective, replace
it
Seizure inside the engine Disassemble and repair

Phenomenon: Engine cranks but does not start

No fuel in supply pump Air entering into the fuel system Remove air
Air taken-in from the fuel pipe Remove the air or replace
Fuel out Refill
Clogging of the strainer in the fuel Clean or replace
suction unit
Clogging of the fuel pipe Clean or replace
Malfunction of the supply pump Replace
Extremely cold periods = fuel is not for Replace it with the proper fuel
use in cold climates
Clogging of the fuel filter Replace
Engine control system problem Diagnose engine control system
For details, refer to "Diagnostic
Information and Procedures" in Section
1A Engine Control System
Fuel has made it to the supply pump Looseness of the injection pipe Further tightening of each part
connection
Poor air-tightness of the over-flow valve Replace
Malfunction inside the supply pump Replace
Improper wiring connection or open Repair or replace
circuit
Fuel injection amount is insufficient or Air entering into the fuel system Remove air
unstable Clogging of the fuel pipe Clean or replace
Malfunction of the supply pump Replace
Locking of the injector nozzle Replace
Improper wiring connection or open Repair or replace
circuit
Clogging of the fuel filter Replace

Phenomenon: There is Much Black Exhaust Smoke

Improper fuel injection timing Engine control system problem Diagnose engine control system
Improper fuel injection condition of the Locked nozzle Replace
injector Engine control system problem Diagnose engine control system
Improper compression pressure Excessive valve clearance Adjust
Sticking of valve stem (valve open Disassemble and repair
condition)
Defective valve spring Replace
Valve seat wear Disassemble and repair
Compression leak caused by defective Disassemble and repair
piston ring, etc.
Defective gasket Disassemble and repair
Piston seizure Disassemble and repair
Improper fuel Fuel contains moisture Replace
Bad quality fuel used Replace
Air intake problem Clogging of the air intake pipe Repair or replace
Clogging of the air cleaner element Clean or replace
Locking of the throttle valve Disassemble and repair
Defective diesel particulate diffuser Melted or broken filter Replace
(DPD)
Error detected by engine control system Abnormalities in each sensor, etc. Repair or replace
EGR or intake throttle valve malfunction Locking of the intake throttle valve Repair or replace
Locking of the EGR valve Repair or replace
Locking of the exhaust brake valve Repair or replace
Defective turbocharger Deformed or damaged turbine fin Replace
Unsmoothness or catching of the Replace
turbine shaft
Air leakage at the compressor outlet Repair
side

Phenomenon: There is Much White Exhaust Smoke

Error detected by engine control system Abnormalities in each sensor, etc. Replace
ECM error Replace
Improper compression pressure Excessive or insufficient valve Adjust
clearance
Sticking of valve stem (valve open Disassemble and repair
condition)
Defective valve spring Replace
Compression leak caused by defective Disassemble and repair
piston ring
Defective gasket Disassemble and repair
Piston seizure Disassemble and repair
Improper fuel Moisture in fuel Replace
Large oil consumption amount Piston ring wear or breakage Disassemble and repair
Defective valve stem oil seal Disassemble and repair
Defective turbocharger oil seal Replace turbocharger

Phenomenon: Engine is Experiencing Knocking

Error detected by engine control system Abnormalities in each sensor, etc. Replace
ECM error Replace
Fuel Bad quality fuel used Replace
Air intake problem Clogging of the air intake pipe Repair or replace
Engine malfunction Foreign material in cylinders Repair or replace
Seizure of the piston or bearing Repair or replace

Phenomenon: Engine Rotation Problem

Rotation does not increase ECM error Replace
Unstable rotation ECM error Replace
Clogging of the fuel filter element Replace the element
Injector failure Replace
Fuel contains moisture Replace
Air entering into the fuel system Remove air
Locking of the exhaust brake valve Repair or replace
Locking of the intake throttle valve Repair or replace

Phenomenon: Charging failure

Will not charge Open circuit or short circuit, or improper Repair or replace
connection of wiring
Malfunction inside the generator Disassemble and repair
Insufficient charge Wire short circuit, improper connection Connect or repair
Loosening of the generator drive belt Replace
Defective battery Replace
Overcharge Wire short circuit Connect or repair
Primary Specifications
Item 4HK1-TCS
Type Diesel, 4-cycle, water-cooled inline OHC
Combustion chamber model Direct injection
Cylinder liner model Dry type
Number of cylinders - inner diameter mm(in) 4 - 115 - 125
stroke (4.53 - 4.92)
Total piston displacement L(in3) 5.193(316.9)
Compression ratio 17.5
2
Compression pressure MPa (kg/cm /psi) 2.75(28/398) / 220
/ r/min
Idling speed r/min 650(Smoother) 575(M/T)
Valve clearance Inlet 0.4(0.016) (while cool)
mm(in) Exhaust 0.4(0.016) (while cool)
Ignition method Compressed ignition
Injection order 1-3-4-2
Injection period (top dead center) deg 0°
Lubrication device
Lubricating method Force feed method
Oil pump type Gear type
Lubricant capacity [reference values] L(Imp⋅gal) 13.0(2.86)
Oil filter type Full-flow filter (cartridge type)
Oil cooler type Built-in type, water cooled
Item 4HK1-TCS
Cooling device
Cooling method Water cooled
Radiator type Corrugated type (force feed type)
Water pump type Centrifugal type, belt type
Thermostat type Wax type (2 pcs.)
Thermostat open valve temperature °C(°F) 82(180), 85(185)
Coolant capacity [reference values] L(Imp⋅gal) 19.0(4.18)
(Including radiator)
Fuel device
Injection pump type Electronic control common rail type
Injection nozzle type Multi-hole nozzle
Charging device
Generator type Alternating current type
Output V-A 24 - 50, 24 - 60, 24 - 90
Regulator type IC
Starter device
Starter type Reduction type
Output V-kW 24 - 4.5
Preheat device model Glow plugs(QOS II)
Glow plug rated voltage and current V-A 23 - 3.5

Special Tool
Illustration Tool Number/ Description Illustration Tool Number/ Description
5-8840-2815-0
5-8840-0019-0
Compression gauge
Sliding hammer
adaptor
5884028150
5-8840-2675-0 5-8840-2628-0
Compression gauge Valve guide replacer
5884026750
5-8840-2230-0 5-8840-2222-0
Crankshaft stopper Sealing cup installer
5884022300 5884022220
5-8840-2621-0 5-8840-0266-0
Valve spring replacer Angle gauge
5884026210
5-8840-2808-0 5-8840-2826-0
Pivot Injector remover
5884028080 5884028260
5-8840-2625-0 5-8840-2623-0
Valve stem seal installer Nozzle sleeve remover
5-8840-2627-0 8-9439-6818-0
Oil seal installer Crankshaft gear puller
5884026270 8943968180
5-8840-2626-0 8-9439-6819-0
Bridge guide setting tool Crankshaft gear installer
5884026260
5-8840-2624-0 1-8522-1097-0
Nozzle sleeve setting tool Oil filter wrench
5884026240 1852210970
5-8840-9018-0 5-8840-2930-0
Piston setting tool Valve guide installer
5884090180 5884029300
5-8840-2360-0
Slinger puller
5-8840-2703-0
Oil seal installer kit
5884027030
Engine Assembly
Removal • Disconnect the front frame harness connector
near the transmission control box and remove
CAUTION:
each of the clips fastening the harness.
• Always apply chock blocks to the vehicle wheels.
• Remove the two bolts (upper and lower)
• Select an engine hoist that is able to withstand the attaching the starter, and remove the starter
weight of the engine. from the clutch housing.
• Never get under the engine while it is hoisted. • Fasten with a wire, etc. to a position where it
• Never put your hands where they can get easily will not interfere with the removal of the
caught. transmission.
1. Disconnect the battery cable ground terminal (1).

4. Remove the transmission assembly.
• Refer to "Transmission ASM" in Section 5B,
1 Automatic Transmission Smoother (MZW).
Also, refer to "Transmission ASM" in Section
5C, Manual Transmission (MZW).
5. Remove the engine harness.

• Remove the ECM.
• Remove the two main harness connectors from
the ECM.
• Remove the engine ground cable.
6. Remove the intake duct (2) and the rubber hose

(1) located between the intake duct and the
intercooler.
• Remove the boost pressure sensor connector.
LNW71BSH008101
2. Drain the coolant. 1 2
MFWA1BSH001101
1 7. Disconnect the rubber hose located between the

MFW71CSH000201
intercooler and turbocharger.
Legend
8. Disconnect the radiator upper hose.
1. Radiator drain plug
• Remove the upper hose at the engine side.
3. Disconnect the starter ground cable. 9. Disconnect the coolant reserve tank hose.
• Disconnect the coolant reserve tank hose (1) at
the radiator side.
MFW71CSH000501 LNW21BSH027501
11. Disconnect the fuel return hose.

• For Smoother, disconnect the oil hose.
1 12. Disconnect the fuel feed hose.

• Remove from the supply pump side and put a
plug and tie closed pointing upward so that fuel
is not spilled.
13. Disconnect the radiator lower hose (1) at the

engine side.
4
MFW71CSH001501
Legend
1. Radiator stay
2. Intercooler
3. Radiator
4. Oil hose
1
10. Disconnect the heater hose. MFW71CSH001801
• Remove the two heater hoses at the engine

side. 14. Remove the fan guide and hang it on the fan
assembly.
15. Remove the radiator.

• Remove the radiator by removing the mounting
nuts and bolts on the left and right sides of the
radiator, and the radiator stay.
• Remove the fan guide that has been hanged on
the fan assembly.

• Slowly operate the hoist to raise the engine
above the surface of the chassis frame.
MFW71BSH005901
MFW71BSH006801
16. Remove the front exhaust pipe.
• Remove the front exhaust pipe from the
exhaust adapter and the exhaust brake.
• Turn the engine 90° and move it from the
chassis frame top surface to remove the engine
17. Remove the power steering oil pump. assembly.
• Remove the power steering oil pump from the
engine side together with the bracket. Fasten to
appropriate position with a wire along with the
hoses.
• Remove the oil level gage.
• Remove the rubber hose clip of the oil level
gage guide tube and the rubber hose.
18. A/C compressor

• Remove the A/C compressor drive belt.
• Remove the compressor from the A/C
compressor bracket. Fasten to appropriate
position with wire along with the hoses.
19. Disconnect the air pipe flexible joint section of the

air compressor.
• Remove the hose at the air compressor side. MFW71BSH006901
20. AC generator harness

Installation
• Remove the B terminal cable and harness
connector from the generator. 1. Install the engine assembly.
• Install the hoist wire to the engine hanger and
hoist to lift the engine.
21. Engine mount
• Before removing the engine from the engine
mount, use a hoist to suspend the engine.
• Remove the installation nut on the engine foot
side of the engine mount.
22. Install or remove the engine assembly.


• Operate the hoist to move the engine to the 4. Install the AC generator harness.
installation position. • Install the harness connector (one pole) and B
terminal cable to the generator.
5. Install the A/C compressor.
• Install the A/C compressor as shown in the
diagram, and tighten at the specified torque.
MFW71BSH006901
• Turn the engine over 90° and slowly lower the

engine to the installation position.
• At this time, operate the hoist so that the
transmission side is low, while pulling to the
rear of the engine.
MFW51ESH000301
CAUTION:
Never get under the engine while it is hoisted.
• Install the drive belt and adjust its tension using

the adjustment bolt of the tension pulley.
• Refer to "Drive Belt" in Section 1C, Engine
Cooling for details on the belt tension
adjustment.
Belt tension adjustment value
Frequency
Amount of
of
Belt types flex
vibrations
mm(in)
(Hz)
Generator 4.9 - 5.9
New belt 208 - 232
drive belt (0.19-0.23)
a ; 50, 60A
Reused 6.9 - 7.7
specifications 178 - 190
belt (0.27-0.30)
Generator 5.4 - 6.6
New belt 190 - 212
MFW71BSH006801
b ; 90A
Reused 7.5 - 8.5
specification 163 - 175
2. Install the engine mount. belt (0.30-0.33)
• Install the engine to the engine mount and 19.6 - 23.6
New belt 59 - 73
tighten the nut at the specified torque. (0.77-0.93)
A/C drive belt
Reused 24.1 - 27.5
51 - 59
belt (0.95-1.08)
3. Connect the charge air pipe of the air compressor.


NOTE:
• A V-ribbed belt is used for the generator drive belt,
which requires a more accurate tension adjustment
than conventional V belt. Therefore, use a sonic
tension meter to check that the measured frequency
of vibrations is within the adjustment value. Perform
adjustment if the value is improper. Improper
tension causes the belt life to shorten or the belt to
squeak.
• After the adjustment, securely tighten each bolt.
• After adjusting the belt tension, tighten the lock

nut of the tension pulley.
1
MFW71BSH003301
a
1 7. Front exhaust pipe
• Install the front exhaust pipe (1) and tighten it at
2 the specified torque.
Tightening torque
Exhaust adaptor side 67 N⋅m (6.8 kg⋅m/49 lb⋅ft)
Exhaust brake side 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Side of the engine
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
(clamp)
b 1
LNW71EMH000201
Legend
(a) 50,60A specifications
(b) 90A specification
1
MFW71GSH004201
6. Power steering oil pump
• Install the power steering oil pump and tighten it
at its specified torque.
8. Install the radiator.
• Place the fan guide on the fan assembly.
Power steering oil pump mounting bolt (1)

• Install the left and right bracket sections of the • For Smoother, connect the oil hose.
radiator to the frame side bracket as shown in
the drawing.
Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
Tightening torque
Upper side nut 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Lower side nut 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
1
MFW71CSH000401
13. Connect the fuel feed hose.

14. Connect the fuel return hose.
MFW71BSH005901
15. Connect the heater hose.
• Attach the hose so that the mark is facing
upward.
9. Install the fan guide.
10. Connect the radiator lower hose (1).
LNW21BSH027501
16. Install the air intake duct assembly (3) and rubber
hose.
1
• Install the bolt and clip band and tighten them at
the specified torques.
MFW71CSH001801
11. Connect the coolant reserve tank hose.

12. Connect the radiator upper hose.

• Connect the connector of the boost pressure
sensor (1).
Refer to "Boost Pressure Sensor" in this
section.
Tightening torque
Bolt 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
Clip 7 N⋅m (0.7 kg⋅m/61 lb⋅in)
1 2 3
LNW21BSH011601
21. Connect the front frame harness connector.

• Install the guide tube of the oil level gage and
the oil level gage.
• Install the rubber hose to the second spool or
the bracket of guide tube, and fix with the clip.
MFWA1JSH000101
1
17. Install the inlet manifold duct.
2
18. Install the engine harness. 3
• Install the engine ground cable.
• Install the two main harness connectors to the
ECM.
• Install the ECM.
19. Install the transmission assembly.
4
Automatic Transmission Smoother (MZW). 6 5
Also, refer to "Transmission ASM " in Section
MFWA1BSH003601
20. Install the starter motor.
Legend
1. 25mm
Tightening torque 127 N⋅m (12.9 kg⋅m/94 lb⋅ft) 2. Second spool
3. Oil level gage guide tube
• Install the starter to the clutch housing with a 4. Clip
bolt, and tighten at the specified torque. 5. First spool
6. Rubber hose
3
6 5 4
MFWA1BSH003701
Legend
1. 25mm
2. Bracket
3. Oil level gage guide tube
4. Clip
5. First spool
6. Rubber hose
22. Refill the coolant.

23. Connect the battery cable ground terminal.
Engine Mount
Components
1 2
2
1
3
MFW71BMF003501
Legend
1. Engine mount 3. Lock plate
2. Engine foot
Removal • Slightly raise the engine assembly to remove

the engine mount.
1. Remove the engine mount.
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the nuts mounting the engine foot and
engine mount.
• Remove the mounting bolts on the chassis
frame side of the engine mount.
MFW71BSH006801

Installation
1. Install engine mount, and tighten at the specified
torque.
Tightening torque
Chassis frame side
103 N⋅m (10.5 kg⋅m/76 lb⋅ft)
bolt
Engine foot side nuts 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
• Start the engine to verify whether there are any

abnormalities in the engine mount.

List of Tightening Torques
c
b
d
f
MFW81BMF002701
(a) 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)

(b) 51 N⋅m (5.2 kg⋅m / 38 lb⋅ft)
(c) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
(d) 51 N⋅m (5.2 kg⋅m / 38 lb⋅ft)
(e) 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
(f) 83 N⋅m (8.5 kg⋅m / 61 lb⋅ft)
Cylinder Head Cover

Components
d
c
a
MFWB1BLF001601
Legend
1. Cylinder head cover 4. Lower case
2. Gasket 5. Gasket
3. Noise cover 6. Rubber plug
Removal
1. Remove the EGR cooler.
Refer to “EGR Cooler” in Section 1F,
Emission Control.
2. Remove the noise cover (1).

3. Remove the cylinder head cover (2).
1
1
2 1
2
2
2
2 LNW81BSH005101
MFWB1BSH002701
2. Install the gasket to the lower case (1).

4. Disconnect the injector harness connector (2). 3. Install the lower case (1).
5. Remove the lower case (1) and gasket.

1
4. Connect the injector harness connector (2).
NOTE:
Push in until the locking claw is completely raised.
LNW21BSH057001
Legend
1. Lower case
2. Injector harness connector
6. Remove the rubber plugs.

LNW21BSH057001
• Clean the liquid gasket remaining on the
cylinder head.
5. Install the gasket to the cylinder head cover.
6. Install the cylinder head cover, and tighten in the
Installation order shown in the diagram.
1. Install the rubber plugs (1).
• Apply liquid gasket (ThreeBond 1207B) to the
area indicated in the diagram (2) with a width of Tightening torque 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
3 to 4mm (0.12 to 0.16 in), and install it to the
cylinder head.
5 1 3 7
6 2 4 8
LNW21BSH030101
7. Install the noise cover (1).
Tightening torque
Noise cover 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2
MFWB1BSH002701
Legend
1. Noise cover
2. Cylinder head cover
8. Install the EGR cooler.

Refer to “EGR Cooler” in Section 1F,
Emission Control.

d
c
a
MFWB1BLF001601
(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(e) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Oil Separator
Components 4. Remove the oil separator mounting bolt and
• remove the oil separator (1) from the bracket.
1
1
2
2
3
3
4
4
MFW71BMH000201
MFW71BMH000201
Legend
1. Oil separator NOTE:
2. Rubber hose(blow-by gas OUT) Replace the oil separator element once a year.
3. Rubber hose(blow-by gas IN) Replace the O-ring at the same time.
4. Oil drain hose
Installation
1. Install the oil separator to the bracket.
• After applying the liquid gasket, install it within 5
Maintenance Precautions minutes.
Replace the element of the oil separator (1) once a
year. Remove the cap (by turning it with your hand) at
the top of the separator and replace the element and O- Tightening torque 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
ring.
2. Insert the oil drain hose (4) into the plug of the
Removal
flywheel housing and fix it with a clip.
3. Insert the rubber hose (3) between the oil
1. Disconnect the rubber hose (2) that is located separator (1) and the flywheel housing and fix it
between the oil separator and the intake duct. with a clip.
2. Disconnect the rubber hose (3) that is located
between the oil separator and the flywheel
housing.
3. Disconnect the oil drain hose (4).

4. Insert the rubber hose (2) between the oil
separator and the intake duct and fix it with a clip.
MFW71BMH000201
Intake Throttle Valve

Removal
1. Remove the air duct.
2. Disconnect the intake throttle valve harness
connector (1).
3. Remove the intake throttle valve (2).
• The installation rubber comes off easily, so be
careful not to lose it.
1 2
3
2
MFWA1BSH000101
1
LNW91BMH000301
Installation Legend
1. Installation rubber
1. Install the intake throttle valve (1).
2. Intake throttle valve
• Install the gasket (3) and intake throttle valve, 3. Gasket
and tighten at the specified torque. 4. Inlet cover outer
Tightening torque 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)

2. Connect the intake throttle valve harness
connector.
3. Install the air duct.
• Install the clip band, and tighten at the specified
torque. Use a new clip.
Clip band
Inlet Cover
Components
2
3
4
5
6
LNW91BLF002801
Legend
1. Inlet cover 4. Throttle gasket
2. Inlet gasket 5. Throttle valve assembly
3. Inlet cover outer 6. Installation rubber
Removal
1. Remove the common rail.
Refer to "Common Rail" in Section 1D, Engine
Fuel.
2. Disconnect the harness connector.
3. Remove the throttle valve assembly.
NOTE:
The installation rubber comes off easily, so be careful
not to lose it.

4. Remove the inlet cover outer. NOTE:
• Be careful not to forget tightening the bolt indicated
by the arrow.
• Tighten the stud along with the common rail.
1
3
2
1
LNW91BSH007801
Legend
1. Inlet cover outer
2. Gasket
3. Inlet cover LNW91BSH008001
Legend
1. Liquid gasket
5. Remove the inlet cover.
• There is one bolt on the throttle valve assembly
installation section (arrow) in the inlet cover. Be • Tighten in the order of the numbers in the
careful not to forget to remove it. diagram.
• Carefully remove the fluid gasket.
6
2 1 7
3 5 4
LNW91BSH007901
Installation LNW91BSH008201
1. Install the inlet cover.

• Align to the inlet cover groove, and apply liquid
gasket (ThreeBond 1207C) to the width 2.5 to 2. Install the inlet cover outer.
5.5 mm(0.10 to 0.22 in). • Install the gasket and inlet cover outer, and
• After applying the liquid gasket, install it within 5 tighten at the specified torque.
minutes.

• Tighten in the order of the numbers in the
diagram.
3 7 1
2
5 4 6
LNW91BSH008301
3. Install the throttle valve assembly.

• Securely install the installation rubber.
• Install the gasket and throttle valve assembly,
and tighten at the specified torque.
4. Connect the harness connector.

5. Install the common rail.
Fuel.

b
g
e b
a
d
LNW91BLF002901
(a) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(f) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Exhaust Manifold
Components
2
3
4 5
MFWA1BMF000501
Legend
1. Turbocharger assembly 4. A/C compressor
2. EGR cooler duct 5. Gasket
3. EGR cooler duct heat protector 6. Exhaust manifold
Removal • Remove the compressor bracket from the

cylinder head.
1. Remove the turbocharger assembly.
Refer to "Turbocharger Assembly" in Section 1J,
Induction.
2. Remove the A/C compressor bracket.
• Remove the compressor from the bracket
without disconnecting the A/C compressor
hose.
MFW51ESH000301
1 2
Flatness of the manifold installation mm(in)
Standard values 0.3 (0.012) or less
Repair limit 0.5 (0.020)
NOTE:
Replace if the flatness is beyond the repair limit.
MFWA1BSH000201
Legend
1. A/C compressor bracket
2. Front engine hanger
3. Remove the exhaust manifold.

• Remove two nuts and six bolts to remove the
exhaust manifold.
LNW71BSH009001
• Visually check the exhaust manifold for cracks.

1 2. For turbocharger assembly inspection, refer to
"Turbocharger Assembly" in Section 1J Induction.
2
LNW91BSH008501
Legend
1. Cylinder head
2. Gasket
3. Exhaust manifold
4. Distance tube (spacer)
Inspection
1. Inspecting the exhaust manifold
• Inspect the flatness of the installation surface of
the manifold and cylinder head.

Installation
1. Sandwich the gasket and install the exhaust
manifold.
5 3 4 6
1 2
1
7 8
2
4
LNW71BSH008901
2. Install the A/C compressor bracket.

LNW91BSH008501
• Install the A/C compressor bracket to the
Legend cylinder head, and tighten at the specified
1. Cylinder head torque.
2. Gasket
3. Exhaust manifold
4. Distance tube (spacer) Tightening torque 59 N⋅m (6.0 kg⋅m/44 lb⋅ft )
1 2
• Install the two nuts and six bolts, and tighten in
the order shown in the diagram.
NOTE:
Since it will expand or contract due to the heat of the
manifold, do not over-tighten.
Tightening torque
Nuts (7), (8) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
Bolts
34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
(1),(2),(3),(4),(5),(6)
MFWA1BSH000201
Legend
• Install the A/C compressor to the bracket, and

tighten at the specified torque.
Tightening torque 24 N⋅m (2.4 kg⋅m/18 lb⋅ft )

MFW51ESH000301
3. Install the turbocharger assembly.

Refer to "Turbocharger Assembly" in Section 1J,
Induction.
Timing Gear Train

Components
1 2
4
11 10
5
16
6
9
22
12
21 7
8
17
20
18
13
15
19
14
MFW81BLF003901
Legend
1. Power steering pump 12. Oil return plug
2. Idle gear B shaft 13. Flexible plate (Smoother vehicle)
3. Idle gear A 14. Flywheel
4. Idle gear B 15. Crankshaft position sensor
5. Power steering pump idle gear 16. Stiffener (RH)
6. Power steering pump idle gear cover 17. Rubber spacer
7. Pilot bearing 18. Stiffener (LH)
8. Flywheel (M/T vehicle) 19. Oil pan
9. Rear oil seal 20. Air compressor
10. Flywheel housing 21. Supply pump bracket
11. Slinger 22. Supply pump
Removal 2. Remove the rocker arm shaft assembly.

Refer to "Rocker Arm Shaft Assembly" in this
1. Remove the cylinder head cover.
section.
Refer to "Cylinder Head Cover" in this section.

3. Remove the camshaft assembly.
Refer to "Camshaft Assembly" in this section.
4. Remove the cylinder head assembly.
Refer to "Cylinder Head" in this section.
5. Remove the clutch pressure plate and clutch disk. 4
1
6. Remove the supply pump (1) and coupling (3). 3
• Remove the supply pump (including the 2
bracket) tightening bolt, and remove it from the
air compressor (4).
• Remove the coupling (3) and O-ring. 5
6
4 7
MFW41BSH033101
Legend
2 3
1 1. Supply pump
2. Key
3. O-ring
4. Supply pump bracket
5. Nut
6. Coupling
7. Flange bolt
MFW41BSH033201 8. Remove the air compressor (1).

Legend • Remove the nut and the bolt to remove the air
1. Supply pump (including bracket) compressor (1).
2. O-ring 9. Remove the gear (3) from the air compressor (1).
3. Coupling
4. Air compressor
1
7. Remove the supply pump bracket (4).

• Tighten the two bolts in the coupling (6) screw
holes for turning prevention, and remove the
nut. 2
• Remove the two tightened bolts in the coupling
(6) screw holes via the gear puller to remove 3
the coupling (6).
4
MFW41BSH021201
Legend
1. Air compressor
2. Key
3. Gear
4. Nut
5. O-ring

• Slowly loosen the bolts in the order shown in
10. Remove the crankshaft position sensor (2) from the diagram to remove the crankshaft stopper.
the flywheel housing (1). Then remove the flywheel.
Refer to "Crankshaft Position Sensor" in this
section.
1 4
1
6 7
2
3 2
8 5
MFW81BSH000501
MFW71BSH004201
12. Remove the rear oil seal and slinger.
Refer to "Crankshaft Rear Oil Seal" in this section.
11. Remove the flywheel. 13. Remove the stiffener and rubber spacer.
• Install the crankshaft stopper to the flywheel • Remove the right side stiffener (1) and the left
housing starter, and make sure the crankshaft side stiffener (3), and then remove the rubber
does not rotate. spacer (2).
NOTE:
Check that the stopper securely meshes into the ring
gear and that it is installed.
Special Tool
Crankshaft stopper: 5-8840-2230-0
2
1 3
MFW81BSH006701
14. Remove the oil pan.

15. Remove the power steering pump.
16. Remove the power steering pump idle gear cover.
LNW21BSH007701

17. Remove the power steering pump idle gear. 21. Remove the idle gear B shaft.
MFW81BSH007301 LNW81BSH004901
18. Remove the flywheel housing.

• Do not forget to remove the bolt indicated by Inspection
the arrow in the diagram.
1. Measurement of idle gear backlash
• Touch the dial indicator to the idle gear tooth to
be measured, and gently move the gear left
and right to read the inconsistency on the dial
indicator. (Always fasten the other gear)
• Replace the idle gear if the measured value
exceeds the limit.
Timing gear backlash mm (in)

0.100 – 0.170
Standard values
(0.00394 – 0.00669)
Limit 0.300 (0.0118)
• Measure idle gear backlash before removing

the idle gear A.
LNW21BSH053601
19. Remove the idle gear A.

20. Remove the idle gear B.
LNW21BSH003301
2. Measurement of play of the idle gear in the axis

direction
• Insert a thickness gauge into the gap between
the idle gear and thrust collar to measure the
gap.
• Replace the idle gear or thrust collar if the
measured value exceeds the limit.
Play of the idle gear in the axis

direction mm (in)
Standard Limit
0.150 – 0.225
Idle gear A 0.300 (0.0118)
(0.00591 – 0.00886)
0.080 – 0.155
Idle gear B 0.200 (0.00787) LNW21BSH003501
(0.00315 – 0.00610)
0.090 – 0.154
Idle gear C 0.200 (0.00787) 4. Clearance between the idle gear and the idle gear
(0.00354 – 0.00606)
shaft B, C
• Measure idle gear play in the axis direction • Measure the inner diameter of the idle gear
before removing idle gear B. bush to calculate the clearance between the
idle gear and the idle gear shaft.
• Replace the idle gear or shaft if the measured
value exceeds the limit.
Clearance between the idle

gear and shaft mm (in)
0.020 – 0.062
Standard values
(0.00080 – 0.0024)
Limit 0.200 (0.0079)
LNW21BSH003401
3. Outer diameter of the idle gear shaft B, C

• Use a micrometer to measure the outer
diameter of each idle gear shaft.
• Replace the shaft if the measured value
exceeds the limit.
Outer diameter of the idle

gear shaft mm (in)
29.959 – 29.980 LNW21BSH003601
Standard values
(1.1795 – 1.1803)
Limit 29.800 (1.1732)

Installation
1. Install the idle gear B shaft. 3. Install the idle gear A.
• Tighten the idle gear B shaft at the specified • Rotate the crankshaft in the forward direction to
torque. align the 1st cylinder piston to the top dead
Apply LOCTITE 962T to thread part. (three bolt) center.
• Align the crankshaft gear (6) and idle gear A (9)
Tightening torque 31 N⋅m (3.2 kg⋅m/23 lb⋅ft) alignment marks and install to the cylinder
block.
• After installing, apply engine oil to the shaft. • It is oil application, and the application range
does things more than 17 mm(0.67 in) to bolt
from the bolt tip.
• It is oil application to the washer both sides.
• Tighten the mounting bolt at the specified
torque.
LNW81BSH004601
2. Install the idle gear (1) B.

• Install the idle gear B to the direction shown in
the drawing, and tighten the mounting bolt (3)
at the specified torque.

LNW81BSH005301
LNW21BSH003801
Legend
1. Idle gear
2. Thrust collar
3. Bolt
2
1
9 3
0 L 0
6 5
7
LNW71BMF004401
Legend
1. Idle gear C 6. Crankshaft gear
2. Camshaft gear 7. Oil pump drive gear
3. Idle gear B 8. Supply pump gear
4. Power steering pump gear 9. Idle gear A
5. Power steering pump idle gear
4. Install the flywheel housing.

• Especially, clean the excessive liquid gasket
that comes out when the crankcase is installed.
• As shown in the diagram, uniformly apply liquid
gasket (ThreeBond 1207B) to the inside of the
bolt hole (excluding the bolt hole at the arrow).
Bead width 3.5 mm(0.14 in)

Bead height 2.0 to 4.0 mm(0.08 to 0.16 in)
LNW21BSH033201

• Position the cylinder block knock pin to install • Tighten the one marked (3) and (4) from the
the flywheel housing. cylinder block side.
Flywheel housing tightening torque

Bolts : (1) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
Bolt : (2) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
Bolt : (3) 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
Bolt : (4) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
1
1
2
4
MFWA1BMF000801
5. Install the power steering pump idle gear.

• Apply engine oil to the gear assembly sections
of the idle gear shaft.
• Assemble the idle gear and shaft, install as
shown in the drawing, and tighten at the
specified torque.
LNW21BSH053701
LNW21BSH004301
1
MFW71BSH003301
6. Install the power steering pump idle gear cover to 8. Install the oil pan.
the flywheel housing. • Apply a bead of liquid gasket (ThreeBond
• Install the O-ring to the cover, and tighten the 1207B) to 3 mm(0.12 in) in the joints of the
bolts at the specified torque. cylinder block, front cover and flywheel
housing.
• After applying the liquid gasket, install the oil
Tightening torque 19 N⋅m (1.9 kg⋅m/14 lb⋅ft) pan within 5 minutes.
LNW21BSH004601
MFW81BSH000801
7. Install the power steering pump.

• Install the power steering pump and tighten it at
its specified torque.
Power steering pump mounting bolts (1)


• Assembly the gasket (3) using the flywheel
housing, front cover and crankcase stud as a
guide, and place the oil pan (2).
Next, place the rubber assembly (1) on the oil
pan, and tighten with the bolts and nuts. 1 2
2
4
3
1
LNW21BSH013801
9. Install the stiffener (1),(3) and rubber spacer (2).

• The length of the M12 bolts differs.
Stiffener bolt tightening torque

M10 bolt 59 N⋅m (6.0 kg⋅m/44 lb⋅ft)
3 2
1
LNW21BMH000101
Legend
1. Rubber assembly
2. Oil pan
3. Gasket
• After tightening the oil pan at (1), (2), (3), and

(4), tighten the others. (No particular order is
required.) 2
1 3
MFW81BSH006701
10. Install the crankshaft position (2) sensor to the

flywheel housing (1).
section.


• Insert the gear (3) into the shaft and tighten the
nut (4) at the specified torque.

1
2
1
4
MFW71BSH004201
11. Install the rear slinger and oil seal.

Refer to "Crankshaft Rear Oil Seal" in this section. 5
12. Install the flywheel.
MFW41BSH021201
• Align to the crankshaft knock pin, install the
flywheel, and tighten at the specified torque in Legend
the order shown in the diagram. 1. Air compressor
2. Key
3. Gear
Tightening torque 4. Nut
5. O-ring
1st time 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
2nd time 120° to 150°
14. Rotate the crankshaft in the forward direction to
align the 1st cylinder piston to the compression top
dead center (BTDC 0°).
1 4 1
6 7
3 2 2
8 5
MFW81BSH000501
MFWB1BSH002601
13. Install the gear (3) to the compressor (1).
• Install the key (2) to the shaft of the compressor
(1). 15. Remove the oil return plug (viewing hole).
16. Install the air compressor to the cylinder block.
• Install the O-ring to the air compressor.

• Align the air compressor side cast line (1) and • After assembling the air compressor (2), the
gear slit (2). assembly is correct if a line joining the center of
• Use the cylinder block stud bolt as a guide to the claw, as shown in the drawing, is angled
assemble to the air compressor. approximately 15° to the level surface of the
engine, when looking from the engine front
• Look through the viewing hole in the flywheel
side.
housing to check that the gear slit (2) is near
the center of the hole. 2
1
NOTE:
If the slit is mis-positioned, redo this.
2
3
1
MFW41BSH021101
Legend
6 1. Cylinder block
4 2. Air compressor
5
3. Approximately 15°
MFW41BSH022601 4. Claw
Legend
1. Casting burr
2. Slit
3. Slit location before insertion • Tighten the air compressor at the specified
4. Slit location after insertion torque.
5. Eye hole
NOTE:
6. Air compressor
Tighten in diagonal order.
Tightening torque
M10 nut 40 N⋅m (4.1 kg⋅m/30 lb⋅ft)
M12 nut 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
17. Assembly the units of the supply pump (1) and

supply pump bracket (4).
• Insert an O-ring (3) into the supply pump (1)
and assembly to the supply pump bracket (4).
•
• Insert the key (2) into the supply pump shaft

and install the coupling (6).

• Tighten the two bolts in the coupling (6) screw
holes(M10,P=1.25) to fasten and tighten the
nuts (5) at the specified torque.
3
4 2
1
3 1
2
5
MFW81BSH011601
6
Legend
1. Supply pump
7 2. O-ring
3. Coupling
MFW41BSH033101 19. Attach the oil return plug (1) to the viewing hole,
Legend and tighten it at the specified torque.
1. Supply pump
2. Key
3. O-ring Tightening torque 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
5. Nut • Thinly apply engine oil to the O-ring (2) for
6. Coupling assembly.
7. Flange bolt
18. Install the supply pump (1) to the air compressor.

• Fit in the coupling (3) with the damper to the air 1
compressor (4). 2
NOTE:
Check that the coupling (3) rubber dampers are
assembled facing alternately.
• Insert the O-ring (2) to the supply pump bracket

and assembly the supply pump to the air
compressor.
NOTE:
There is no need to align the supply pump (1) pawl.
• Tighten the bolts in diagonal order at the

specified torque. MFW71FSH000101
Tightening torque 51 N⋅m (5.2 kg⋅m/37 lb⋅ft) 20. Install the clutch disk and clutch pressure plate.
21. Install the cylinder head assembly.
22. Install the camshaft assembly.

23. Install the rocker arm shaft assembly.
section.
24. Install the cylinder head cover.

b
c
d
e
s
l
r m
g
q h
n
p
j i
MFW81BLF004001
(s) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(a) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 31 N⋅m (3.2 kg⋅m / 24 lb⋅ft)
(d) 110 N⋅m (11.2 kg⋅m / 81.0 lb⋅ft)
(e) 157 N⋅m (16.0 kg⋅m / 116 lb⋅ft)
(f) 134 N⋅m (13.7 kg⋅m / 99 lb⋅ft)
(g) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(h) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° to 150°
(i) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° to 150°
(j) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(k) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(l) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(m) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(n) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(o) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
(p) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(q) 51 N⋅m (5.2 kg⋅m / 37 lb⋅ft)
(r) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Valve Stem Seal and Valve Spring

Components
10
9
8
MFWB1BLF001401
Legend
1. Camshaft bearing cap 6. Valve stem oil seal
2. Camshaft bearing 7. Valve spring
3. Camshaft assembly 8. Spring upper seat
4. Rocker arm shaft assembly 9. Split collar
5. Spring lower seat 10. Bridge
Removal 4. Remove the camshaft assembly.

Refer to "Camshaft Assembly".
1. Remove the cylinder head.
Refer to "Cylinder Head" in this section. 5. Remove the bridge cap (1).
2. Remove the injector (1). 6. Remove the bridge (2).
Refer to "Injector" in Section 1D, Engine Fuel.
NOTE:
3. Remove the rocker arm assembly. Be very careful not to drop the bridge cap (1) into the
Refer to "Rocker Arm Shaft Assembly". cylinder head rear-side gear case or front side oil return
hole.

NOTE: 9. Remove the valve spring.
Store the removed bridge (2) and bridge cap (1) so that Organize the removed valve springs in the order of
they can be returned to their original positions. the cylinder number.
10. Remove the valve stem oil seal.
• Remove the oil seal using pliers.
NOTE:
1 Do not reuse the removed oil seal.
LNW21BSH031301
Legend
1. Bridge cap
2. Bridge
LNW21BSH056801
7. Remove the split collar.
11. Remove the spring lower seat.
• Compress the valve spring and remove the split
collar using a replacer.
Inspection
Special Tool Inspect the valve springs
Valve spring replacer: 5-8840-2621-0 NOTE:
Pivot: 5-8840-2808-0 Visually inspect the valve spring for damage or excess
wear. Replace if necessary.
1. Free length
• Measure the spring free length. If it is lower
than the specified limit, replace the spring.
Free length of valve spring mm (in)

Inlet Exhaust
Standard values 59.9 (2.36) 70.3 (2.77)
Limit 56.9 (2.24) 67.3 (2.65)
LNW21BSH031401
8. Remove the spring upper seat.

• Remove the special tool and remove the upper
seat.
Valve spring tension N (kg/lb)

Inlet Exhaust
Installation
47.0 (1.85) 47.0 (1.85)
height mm(in)
Standard values 333 (34.0/75.0) 490 (50.0/110)
Limit 315 (32.1/71.0) 463 (7.3/104)
LNW21BSH017001
2. Degree of perpendicular condition

• Measure the degree of perpendicular condition
with a right-angle gauge. Replace the valve
spring if the measured value exceeds the limit.
Degree of perpendicular condition of

valve spring mm (in)
Limit 1.0 (0.04) LNW21BSH056701
Installation
1. Install the spring lower seat.
2. Install the valve stem oil seal.
• Apply engine oil to outer edge of the valve
guide and install the oil seal using the valve
stem seal setting tool.
NOTE:
After installing the valve stem oil seal, check that it is
securely inserted all the way in, and that the oil seal is
not inclined or that the garter spring will not come
loose.
Special Tool
LNW21BSH017101
Valve stem seal installer: 5-8840-2625-0
3. Tension
• Using a spring tester, compress the spring to
the installation height. Measure the
compressed spring tension. If the measured
tension is lower than the limit, replace the
spring.

• Using a replacer, compress the valve spring to
install the split collar.
Special Tool
Valve spring replacer: 5-8840-2621-0
Pivot: 5-8840-2808-0
LNW21BSH031901
3. Install the valve spring.

• Install either the side with the paint mark (2) or
narrower spring pitch (2) to the lower side
(cylinder head side).
LNW21BSH031401
Paint mark
Inlet Blue 6. Apply engine oil to the bridge (2) for assembly.
Exhaust Red
NOTE:
Move it up and down to confirm that it moves smoothly.
7. Apply engine oil to the bridge cap (1) for assembly.
NOTE:
Be very careful not to drop the bridge cap into the
cylinder head rear-side gear case or front side oil return
hole.
LNW21BSH016701
Legend
1. Spring pitch
2. Paint mark
4. Install the spring upper seat.

5. Install the split collar.
MFW61BSH000401
Legend
1. Bridge cap
2. Bridge

section.
10. Install the injector.
Refer to "Injector" in this section 1D, Engine Fuel.
11. Install the cylinder head.
Rocker Arm Shaft Assembly

Components
5
4
3
2
1
6
LNW21BLF003701
Legend
1. Camshaft bracket 5. Rocker arm bracket
2. Rocker arm 6. Camshaft bracket
3. Wave washer 7. Rocker arm shaft
4. Rocker arm
Removal
2. Remove the rocker arm shaft assembly.
• Remove the rocker arm shaft assembly
together with the camshaft bracket.

• The bolt in the drawing is for fastening the 6. Remove the camshaft bracket (6), and remove the
rocker arm shaft and does not need to be shaft.
removed.
5
4
3
2
1
6
7 LNW21BSH058101
LNW21BSH002001
Legend
1. Camshaft bracket
NOTE: 2. Rocker arm
Be very careful not to drop the bridge cap into the 3. Wave washer
cylinder head rear-side gear case or front side oil return 4. Rocker arm
hole. 5. Rocker arm bracket
6. Camshaft bracket
7. Rocker arm shaft
Disassembly
1. Remove the camshaft bracket (1).
2. Remove the rocker arm (2).
Inspection
3. Remove the wave washer (3).
1. Inspect for clogging in the oil hole of the camshaft
4. Remove the rocker arm (4). bracket (rear side).
5. Remove the rocker arm bracket (5).
• Disassemble in the order of (2) to (4) hereafter.
LNW21BSH018901
2. Inspect the rocker arm shaft for run-out.

• Set the rocker arm shaft on the V-block.
• Touch the dial indicator to the center of the
shaft to inspect for run-out while rotating the
shaft.

• If the run-out is minor in the measurement,
correct it using the press (when cooled).
• Replace the shaft if the measured value of the
run-out in the shaft exceeds the limit.
Rocker arm shaft run-out mm (in)

Limit 0.3 (0.012)
LNW21BSH019101
4. Inspect the clearance between the rocker arm and

rocker arm shaft.
• Use a cylinder gauge to measure the inner
diameter of the rocker arm bush and measure
the clearance with the shaft outer diameter.
• Replace the rocker arm and shaft if the
LNW21BSH056601
Clearance between the rocker arm and

3. Inspect the rocker arm shaft for wear. rocker arm shaft mm (in)
• Use a micrometer to measure the rocker arm
sliding portion at eight places. 0.010 – 0.056
Standard values
(0.0004 – 0.0022)
• Replace the shaft if the measured value is
under the limit. Limit 0.2 (0.0079)
Outer diameter of the rocker arm shaft mm (in)

21.979 – 22.000
Standard values
(0.8653 – 0.8661)
Limit 21.85 (0.86023)
LNW21BSH019201
5. Inspect the clearance between the rocker arm

roller and rocker arm pin.

a. Pass a cord through the clearance between the • Assembly in the reverse order of disassembly.
rocker arm and roller, and pull firmly in the
direction of the arrows to measure the level
difference between the rocker arm and roller
with the roller raised. (In the diagram (1))
b. After applying a mark at the measurement
point, pull out the cord. Measure the level of the
mark position with the roller pushed all the way
in. (In the diagram (2))
c. The difference in dimension measured at a. and
at b. is the clearance between the roller and the
rocker arm pin. Replace the rocker arm if the
clearance exceeds the limit.
Clearance between the roller and

rocker arm pin mm (in)
0.068 – 0.100
Standard values
(0.0027– 0.0039) LNW21BSH033101
Limit 0.2 (0.0079)

2. Install the rocker arm.
• Apply engine oil to the inner diameter of the
rocker arm, roller and rocker arm pin, and then
install to the rocker arm shaft.
1 2
LNW21BSH019301
Reassembly LNW21BSH019801
1. Install the camshaft bracket to one side of the

rocker arm shaft side. At this time, temporarily 3. Install the wave washer (3) between the rocker
tighten. After installing the rocker arm shaft arms.
assembly to the cylinder head, tighten.
4. Install the rocker arm bracket (5).
• Be careful of the direction of bracket assembly
to assemble to the rocker arm shaft (7).
5. Lastly, install the camshaft bracket to the opposite
side.

• Install the camshaft bracket (1) to the rocker
arm shaft (7). At this time, temporarily tighten
bolt indicated by the arrow. After installing the
rocker arm shaft assembly to the cylinder head,
tighten it. 1
2
5
4
3
2
1
6
MFW61BSH000401
Legend
1. Bridge cap
2. Bridge
7 LNW21BSH058101
Legend
1. Camshaft bracket • Loosen the rocker arm adjust screw and apply
2. Rocker arm engine oil to the rocker arm roller, and then
3. Wave washer install to the cylinder head.
4. Rocker arm • Slightly loosen the bolt indicated by the arrow to
5. Rocker arm bracket make installation easier.
6. Camshaft bracket
7. Rocker arm shaft
Installation
• If the bridge cap (1) is removed, apply engine
oil to the inside of the bridge cap, and assembly
to the bridge (2).
NOTE:
Be very careful not to drop the bridge cap into the
cylinder head rear-side gear case or front side oil return
hole.
LNW21BSH030201
• Apply engine oil to the threaded portions of the

nut and bolt.

• Temporarily tighten the rocker arm assembly
tightening bolts (2), and (3). Gradually tighten
the whole rocker arm assembly to become
level, in the order of nut (1) of the rocker arm
side.
Tightening torque
Bolt (3) 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)
Nut (1), bolts (2), (4) 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft)
1
2
3
1
2
4
LNW21BSH059201
Legend
1. Nut
2. Bolt
3. Bolt
4. Bolt
2. Adjust valve clearance.

Refer to "Functional inspection" in this section.
3. Install the cylinder head cover.

LNW71BMF002201
(a) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(c) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
Camshaft Assembly
Components
LNW71BLF001501
Legend
1. Bearing cap 3. Knock pin
2. Bearing 4. Camshaft gear
Removal NOTE:
Organize the removed bearings according to the
cylinders using tags, etc.
section.
3. Remove the camshaft bearing cap.
4. Remove the bearing upper.
6. Remove the bearing lower.

• Inspect the camshaft journal and cam for
wear and damage.
Replace if there are abnormalities.
LNW21BSH030301
Disassembly LNW21BSH020201
1. Remove the camshaft gear.

• Remove the camshaft gear installation bolt, 2. Inspect the clearance of the camshaft in the axis
sandwich wood piece in the pullers and remove direction.
the camshaft gear. • Insert a thickness gauge to measure the
clearance between the camshaft gear and
camshaft bracket in the axis direction.
• Replace the camshaft gear or camshaft if the
1
Clearance of the camshaft in the axis
direction mm (in)
0.05 – 0.170
Standard values
(0.0020 – 0.0067)
Limit 0.25 (0.0098)
LNW21BSH056201
Legend
1. Piece of wood
2. Remove the knock pin.
Inspection
1. Visually inspect the camshaft.
LNW21BSH020301
3. Inspect the cam lobe for wear.


• Measure the height of the cam lobe using a
micrometer.
• Replace the camshaft if the cam lobe height is
under the limit.
Cam lobe height mm (in)

Inlet Exhaust
Standard values 52.8 (2.08) 54.5 (2.15)
Limit 51.8 (2.04) 53.5 (2.11)
LNW21BSH020501
5. Inspect the camshaft for run-out.

• Place the camshaft in the V-block and use a
dial indicator to measure run-out.
• Use a dial indicator to measure the camshaft
central portion run-out. Replace the camshaft if
the run-out exceeds the limit.
Camshaft run-out mm (in)

Limit 0.05 (0.0020)
LNW21BSH020401
4. Inspect the camshaft journal for wear.

• Measure the diameter of the camshaft journal
and uneven wear using a micrometer.
• Replace the camshaft if the wear exceeds the
limit.
Outer diameter of the camshaft journal mm (in)

39.950 – 39.975
Standard values
(1.5728 – 1.5738)
Limit 39.850 (1.5689)
Disproportionate wear of the camshaft
journal mm (in)
Limit 0.05 (0.0020)
LNW21BSH020601
6. Measure the camshaft journal oil clearance.

a. Measure the inner diameter of the camshaft
bearing using the cylinder gauge.
b. Read the difference of the inner diameter of the
camshaft bearing and diameter of the camshaft
journal.
Replace the camshaft bearing if the measured
oil clearance exceeds the limit.
Clearance of journal mm (in)

0.025 – 0.087
Standard values
(0.001 – 0.0034)
Limit 0.15 (0.0059)
LNW21BSH020301
Installation
1. Rotate the crankshaft in the forward direction to
align the 1st cylinder piston to the compression top
dead center.
LNW21BSH054601
Reassembly
1. Install the knock pin. 1
2. Install the camshaft gear.
• Put the side of the camshaft gear center boss
that is projected to the camshaft side, and align 2
it to the knock pin. Then install the camshaft
gear.
NOTE:
When tightening the gear, be careful not to damage the
cam and journal. MFWB1BSH002601
2. Install the camshaft bearing lower.

• Apply engine oil to the camshaft bearing lower
and assembly to the cylinder head.

• Assemble the camshaft assembly so that the
"B" marks on the camshaft gear end and top
surface of the cylinder head are aligned.
LNW21BSH030901
LNW71BSH010601
section.
NOTE:
After tightening, check again that the "B" marks are 7. Install the cylinder head cover.
aligned. Refer to "Cylinder Head Cover" in this section.
4. Attach the bearing upper to the bearing cap.

5. Install the bearing cap.
• Apply engine oil to the bearing upper.
• Face the bearing cap front mark to the engine
front side, and assemble in numbered order to
the cylinder head.
LNW21BSH055801
• Apply engine oil to the threaded portion and

tighten the bearing cap at the specified torque.


LNW71BLF003301
(a) 27.5 N⋅m (2.8 kg⋅m / 20 lb⋅ft)

(b) 142 N⋅m (14.5 kg⋅m / 105 lb⋅ft)
Camshaft Position Sensor

Removal
1. Disconnect the camshaft position sensor
connector.
2. Remove the camshaft position sensor.
LNW71BSH007301
Installation
1. Install the camshaft position sensor and tighten at
the specified torque.
2. Connect the camshaft position sensor connector.

Cylinder Head
Components
1
4
2
17 5
6
7
3
8
9
10
11
16
12
15
13
14
MFW81BLF000301
Legend
1. Bridge cap 10. Idle gear C cover
2. Bridge 11. Idle gear C
3. Bridge guide 12. Glow plug
4. Split collar 13. Intake and exhaust valve
5. Spring upper seat 14. Cylinder head
6. Valve spring 15. A/C compressor bracket
7. Valve stem oil seal 16. Thermostat
8. Spring lower seat 17. Water outlet pipe
9. Valve guide
Removal 4. Remove the air intake duct.

1. Drain the coolant.
2. Remove the engine harness.
3. Remove the front exhaust pipe.

5. Remove the air charge pipe on the left and right of 8. Remove the oil separator together with the
the engine. bracket.
1
1 2
5 4
MFW71JSH001201 MFW71BSH003501
Legend Legend
1. Air charge pipe 1. Oil separator
2. Air intake duct 2. Rubber hose (blow-by gas OUT)
3. Oil separator bracket
4. Rubber hose (blow-by gas IN)
5. Oil drain hose
6. Disconnect the radiator upper hose.
7. Remove the water rubber hoses (2) (4), EGR
cooler duct (1), EGR cooler (3) and EGR valve (5).
9. Remove the water pipe assemblies (3), (7) and the
• Refer to "EGR Valve and EGR Cooler" in
oil pipes (1), (6).
Section 1F, Emission Control.
2 3
4
5
3
2
1
4
1
7 6 5
MFW71BSH003401
MFWA1FSH000101 Legend
1. Turbocharger feed oil pipe
Legend
2. Turbocharger
1. EGR cooler duct
3. Water pipe assembly (return)
2. Feed water rubber hose
4. Exhaust manifold
3. EGR cooler
5. Exhaust adaptor assembly
4. Return water rubber hose
6. Turbocharger return oil pipe
5. EGR valve
7. Water pipe assembly (feed)

14. Loosen the injector harness bracket bolts, remove
10. Remove the A/C compressor drive belt. the inside connector (2), and remove the harness
bracket (1).
• Loosen the tension pulley nut (1) and adjust
bolt (2), and remove the drive belt. NOTE:
The injector ID code identifies each injector.
Do not remove the injector ID codes from the injectors.
15. Remove the nozzle leak-off pipe (4).
2 3
MFW81BSH007601
Legend 2 4
1. Tension pulley nut
2. Adjust bolt
LNW71DSH003501
Legend
1. Harness bracket
11. Remove the A/C compressor.
2. Connector
• Remove the A/C compressor harness 3. Terminal nut
connector, and remove the compressor from 4. Leak-off pipe
the A/C compressor bracket to fasten to
appropriate position together with the hoses
using a wire, etc.
16. Disconnect the leak-off hose.
17. Disconnect the leak-off pipe (2).
1 2
MFW51ESH000301

Refer to "Cylinder Head Cover". MFWA1BSH000301
13. Loosen the injector terminal nut (3) and remove Legend
the terminal. 1. Injection pipe (C/R)
2. Leak-off pipe

25. Remove the glow plug.
18. Disconnect the water bypass hose (1) from the
cylinder head side.
• Remove the engine coolant temperature sensor
connector.
LNW21BSH055301
26. Remove the injection pipe clip (2), and remove the
MFW71BSH003701 injection pipe (1).
Legend
1. Water bypass hose
2. Engine coolant temperature sensor 1
19. Remove the cam position sensor connector and

sensor.
section.
22. Store the removed bridge and bridge cap so that
they can be returned to their original positions.
23. Remove the bridge.
2
NOTE:
Store the removed bridge and bridge cap so that they
can be returned to their original positions.
24. Remove the glow plug connector.
MFWA1BMH000101
Legend
1. Injection pipe
2. Injection pipe clip


• Remove the common rail pressure sensor NOTE:
connector. Store the removed injector with the cylinder number on
28. Remove the injector bracket. it.
Take sufficient care not to hit the injection hole.
29. When it is difficult to remove the injector, set an
injector remover (2) on the injector (3) leak-off pipe
installation section, and then pull the injector
upward using a sliding hammer (1).
Special Tool
Injector remover: 5-8840-2826-0
Sliding hammer: 5-8840-0019-0
NOTE:
• The injector ID code identifies the injectors. Do not
confuse between other injector ID code plates.
• When the injector assembly is replaced, use the
scan tool to register the ID code to the ECU.
For details on writing, refer to "Repair Instructions"
in Section 1A, Engine Control System.
• When a special tool is used to pull out the injector,
make sure that the injector sleeve does not come off MFW71BSH005301
while working on it.

• Evenly loosen the cylinder head bolts in the
order shown in the diagram.
1 NOTE:
(1) and (2) are tightened to the flywheel housing by
M10 bolts, so do not overlook them.
2
• Remove the cylinder head gasket.
NOTE:
Do not reuse the removed cylinder head gasket.
7 15 18 10
3 11 19 14 6 2
1
4 12 20 13 5
8 16 17 9
LNW46CMH000301
Legend
1. Sliding hammer
2. Injector remover LNW21BSH030401
3. Injector assembly

Disassembly 4. Remove the inlet cover outer.
1. Remove the exhaust adaptor (2) and turbocharger
(1).
3
2
1
LNW91BSH007801
Legend
MFW71BSH003901 1. Inlet cover outer
2. Gasket
3. Inlet cover
5. Remove the inlet cover.

• There is one bolt on the throttle valve assembly
installation section (arrow) in the inlet cover. Be
1 careful not to forget to remove it.
2
• Carefully remove the fluid gasket (1).
LNW91BSH008501
Legend
1. Cylinder head
2. Gasket
3. Exhaust manifold
4. Distance tube (spacer)
LNW91BSH008001
3. Remove the throttle valve assembly.

• Be careful not to lose the gasket.
Refer to "Intake Throttle Valve" in this section.

6. Remove the A/C compressor bracket. • As shown in the drawing, lightly tap the sealing
cup outer perimeter with the leading end of the
1 2 screwdriver, turn the sealing cup over and pull it
out using pliers.
MFWA1BSH000201
Legend
LNW21BSH054701
7. Remove the EGR cooler bracket. 11. Remove the idle gear C (1).
8. Remove the water outlet pipe.
9. Remove the thermostat.
LNW21BSH055601
Legend
LNW21BSH056501 1. Idle gear C
2. Idle gear shaft
10. Remove the idle gear C cover.

12. Remove the split collar.
13. Remove the spring upper seat.
14. Remove the valve spring.
• Compress the valve spring and remove the split
collar using a replacer.
Special Tool
Pivot: 5-8840-2808-0

• Remove the upper seat and valve springs. • Remove the oil seal using pliers.
Organize the removed valve springs in the
order of the cylinder number.
LNW21BSH056801
LNW21BSH031401
17. Remove the spring lower seat.
15. Remove the inlet valve and exhaust valve. 18. Remove the valve guide.
• Organize the removed valves according to the • Use the valve guide replacer to tap out the
cylinders using tags, etc. valve guide from the lower side of the cylinder
head.
Special Tool
Valve guide replacer: 5-8840-2628-0
LNW21BSH016801

LNW21BSH055701
19. Attach the injector sleeve remover to the bottom

surface of the head and tap to pull out the injector
sleeve (1).
Special Tool
Injector sleeve remover: 5-8840-2623-0

NOTE: • Attach a metal plate from the inside of the head
• Be careful not to damage the bottom surface of the to tap and remove.
head.
• Do not reuse the removed injector sleeve.
• Carefully remove any drill powder in the cylinder
head screws.
LNW21BSH056401
Inspection
1
1. Inspect the valve guide.
LNW21BSH056301
NOTE:
If there are scratches or abnormal wear on the inner
20. Remove the bridge guide. diameter of the valve stem or valve guide, replace it
• Electrically weld (1) the nut to the top of the together with the valve guide.
bridge guide, attach the sliding hammer to
remove the bridge guide. a. Measure the valve guide clearance.
• Measure the diameter of the valve stem
using the micrometer.
If the diameter of the valve stem is smaller
than the limit, replace the valve and valve
guide together.
1 Outer diameter of the valve stem mm (in)

Standard values Limit
7.946 – 7.961
Inlet valve 7.88 (0.3102)
(0.3128 – 0.3134)
7.921 – 7.936
Exhaust valve 7.80 (0.3071)
(0.3118 – 0.3124)
LNW21BSH058201
21. Remove the oil seal.


• Use a dial indicator to measure the contact
surface of the bridge cap and rocker arm.
• Replace the bridge cap if wear exceeds the
limit or if there is abnormal wear (band-shaped
wear).
Wear of the bridge cap mm (in)

Limit 0.1 (0.004)
LNW21BSH017301
• Use a dial indicator to measure the

clearance between the valve guide and
valve stem within a range of 10 mm(0.39 in)
from the valve guide.
• Replace the valve and valve guide together
as an assembly if the measured value
exceeds the limit.
LNW21BSH019401
Clearance between the valve guide

and valve stem mm (in) 3. Inspect the valve.
Standard values Limit Valve thickness
• Measure the thickness of the valve.
0.039 – 0.071 0.20
Inlet valve • Replace the valve and valve guide together as
(0.0015 – 0.0028) (0.0079)
an assembly if the measured value exceeds the
0.064 – 0.096 0.25 limit.
Exhaust valve
(0.0025 – 0.0038) (0.0098)
Valve thickness mm (in)
Inlet valve 1.71 (0.0673) 1.3 (0.051)
Exhaust valve 1.75 (0.0689) 1.3 (0.051)
BLW51BSH005801
2. Inspect the bridge cap for wear.

3
2
LNW21BSH017801 MFW51BSH003501
Legend
Valve seat 1. Contact length width
• Remove the carbon and water deposit on the 2. Valve depression
bottom surface of the cylinder head. 3. Contact surface angle
Install the valve to the cylinder head.
Use a depth gauge or a straight edge with steel
Valve seat surface
rule to measure the valve depression from the
cylinder head lower surface. • Measure the contact surface of the valve seat.
Replace the valve and insert if it exceeds the If the valve seat contact surface is improper,
limit. repair or replace together as an assembly with
the valve, valve guide and valve seat.
Valve depression mm (in)

Contact surface angle
Inlet 30°
0.73 – 1.10
Inlet 2.3 (0.091) Exhaust 45°
(0.0287 – 0.0433)
1.16 – 1.54
Exhaust 2.8 (0.110)
(0.0457 – 0.0606)
• Measure the valve contact width of the valve

seat. Repair or replace when there are
scratches on the seat contact surface, or it is
rough, or if the contact surface wear exceeds
the limit.
Valve seat contact width mm (in)

Inlet valve 2.7 (0.1063) 3.2 (0.13)
Exhaust valve 2.7 (0.1063) 3.0 (0.12)
LNW21BSH018101
Repair of the seat surface

• Remove the carbon from the valve seat insert
top surface.

• Use a seat cutter to minimize the scratches and
other uneven parts, and return the touching
width to the standard value.
LNW21BSH056101
LNW76BSH005501 • Add compound to the valve seat insert.

Legend • Insert the valve into the valve guide.
1. 119°45’ • Add compound to the valve seat surface and
gently tap the valve while turning it to check that
it is touching evenly around the entire
1
circumference.
NOTE:
After fitting, remove all applied compound.
LNW76BSH005401
Legend
1. 89°45’
NOTE:
Get rid of only the scratches and uneven portions, but
LNW21BSH031801
be careful not to over-cut.
Use an adjustable valve cutter pilot.
The valve cutter pilot should not be allowed to scrape Replacement of the valve seat insert
inside the valve guide. Removal of the valve seat insert
• Arc weld the entire inner circumference (1) of
the valve seat insert (2).
• Cool the valve seat insert for 2 to 3 minutes.
Cooling makes it easier to remove the valve
seat insert due to contraction.

• Remove the valve seat insert using a
screwdriver (3). At this time, be careful not to
damage the cylinder head.
1
2
3 2
LNW21BSH018601
Legend
1. Dolly block
LNW21BSH056001
2. Valve seat insert
Legend 3. Press
1. Arc welding
2. Valve seat insert
3. Screw driver 4. Inspect the cylinder head assembly.
• Completely remove the varnish-like matter and
soot on the metal surfaces. Use a metal brush
Installation of the valve seat insert
for the gasket installation surfaces. Be careful
• Be careful when placing the dolly block (1) not to scratch the seal surface.
(smaller outer diameter than the valve seat
• If the cylinder head seal surface is leaking,
insert) over the valve seat insert (2).
corroded or blown out, and the gasket is
• Use the press (3) to gradually apply pressure to defective, check the following possible causes.
the dolly block and push in the valve seat insert.
- Incorrect installation
NOTE: - Improper cylinder head tightening
Do not apply excessive pressure with the press. - Warping of the cylinder head bottom surface
Add compound to the valve seat surface and gently tap and cylinder block top surface
the valve while turning it to check that it is touching a. Screw surface damage caused by over-
evenly around the entire circumference. tightening, and stretched cylinder head bolts.
NOTE:
Replace dubious bolts.
b. Combustion chamber, glow plug holes.


• Inspect for cracks between the valve seat • As shown in the diagram, measure the four
and exhaust port of the cylinder head. sides and diagonal line with a simple
Replace the cylinder head if there is straight ruler and thickness gauge. Replace
damage or cracks. Perform a collar check if the limit is exceeded.
as necessary.
Strain on the installation surface of
the manifold and cover mm (in)
Limit 0.20 (0.0079)
LNW21BSH032401
c. Flatness of the cylinder head bottom surface

• As shown in the diagram, measure the four
sides and diagonal line with a simple
straight ruler and thickness gauge. Replace
if the limit is exceeded. LNW21BSH032601
Deformation on the bottom surface of e. Flatness of the exhaust manifold

the cylinder head mm (in) • Measure flatness using a simple straight
Standard values 0.05 (0.0020) or less ruler and thickness gauge. Replace the
exhaust manifold if it exceeds the limit.
Limit 0.20 (0.0079)
Deformation of the exhaust manifold mm (in)

Limit 0.5 (0.020)
LNW21BSH032501
d. Flatness of the installation surface of the

exhaust manifold and inlet cover

NOTE:
Be careful not to damage the lip section.
Special Tool
Oil seal installer: 5-8840-2627-0
LNW71BSH009001
5. Bridge
• There should be no strain in the bridge (1) and
bridge guide (2). LNW21BSH056401
• Measure the clearance between the bridge (1)
and bridge guide (2).
Clearance mm (in)
0.020 – 0.056 1 2
Assembly Standard 3
(0.00079 – 0.0022)
Limit for use 0.1 (0.0039)
MFW81BSH006201
Legend
1. Cylinder head
2. Oil seal
3. Oil seal installer
2. Install the bridge guide.

• Apply engine oil to the outer circumference of
LNW21BSH059101 the guide. Use a setting tool to tap the guide up
to finished depth of the cylinder head hole.
(Reference: The height of the bridge guide is
Reassembly approximately 37.5 mm(1.48 in) from the top
surface of the head.)
1. Install the oil seal.
• Install to the injection pipe insertion surface.
Special Tool
• Uniformly tap the seal so that it is not slanted.
Bridge guide setting tool: 5-8840-2626-0
1
b
MFW81BSH001401
Legend
1. a :37.5 mm (1.48in) 4
2. b :122.5 mm (4.823in)
3. Install the injector sleeve.

• Install the O-rings (1), (2) to the injector sleeve
and apply engine oil.
• Apply LOCTITE 290 to the tapered section (3) MFW61BMH000101
of the injector sleeve. Legend
• Apply engine oil (4) to the injector sleeve 1. O-ring (white paint)
contact surface of the cylinder head. 2. O-ring
3. LOCTITE application area
NOTE: 4. Engine oil application area
Check the combination of the O-rings.
Upper O-ring: With white paint • Install the injector sleeve (4) to the cylinder
Lower O-ring: Without paint head, and insert the guide sleeve (3) included
in the injector setting tool (5-8840-2624-0).
• Insert with the guide sleeve (3) so that the
injector sleeve securely attach to the bottom
surface of the cylinder head.
• Fasten the guide sleeve (3) with the injector
clamp (5) and injector clamp bolt (6).
• Insert a ball (2) (bearing steel ball 9.525 mm
(0.3750in)) into the guide sleeve (3) and attach
a punch bar (1), then hammer the ball (2)
through.
NOTE:
• Allow the cylinder head to float so that the ball
comes out from the bottom surface.
Special Tool
Injector sleeve setting tool: 5-8840-2624-0
2
6
5 3
LNW21BSH031601
4
The height from the upper surface of the

cylinder head to the end surface of the valve
guide.
End surface of the valve guide (a)

17.1 – 17.9 mm(0.673 – 0.705 in)
LNW21BMH001001
Legend NOTE:
1. Punch bar When replacing the valve guide, replace as a set with
2. Ball the valve.
3. Guide sleeve
4. Injector sleeve
5. Injector clamp
6. Injector clamp bolt
4. Install the valve guide.

• Use the valve guide replacer and valve guide
installer to tap the valve guide from the upper
surface side of the cylinder head. a
Special Tool
Valve guide replacer: 5-8840-2628-0
Valve guide installer: 5-8840-2930-0
LNW71BSH001701
5. Install the spring lower seat.

• Apply engine oil to outer circumference of the
valve guide and install the oil seal using the
valve stem seal setting tool.

NOTE:
After installing the valve stem oil seal, check that it is
Paint mark
securely inserted all the way in, and that the oil seal is
not inclined or that the garter spring will not come Inlet Blue
loose.
Exhaust Red
Special Tool
Valve stem seal installer: 5-8840-2625-0
LNW21BSH016701
LNW21BSH031901 Legend
1. Spring pitch
7. Install the inlet valve and exhaust valve. 2. Paint mark
• Apply engine oil to the valve stem and install
the valve. 9. Install the spring upper seat.
NOTE: 10. Install the split collar.
After assembling the valve, check that the assembly is • Using a replacer, compress the valve spring to
correct. install the split collar.
• After installation, lightly tap the top of the valve
stem with a rubber hammer to stabilize the split
collar.
Special Tool
Pivot: 5-8840-2808-0
NOTE:
Check that the split collar is securely in the valve stem
groove.
LNW21BSH018801
8. Install the valve spring.

• Install either the side with the paint mark (2) or
narrower spring pitch (2) to the lower side
(cylinder head side).
LNW21BSH031401 LNW21BSH022001
11. Install the thermostat. 13. Install the EGR cooler bracket and tighten the bolt
• Install the thermostat (1) to the position shown at the specified torque.
in the diagram.
Tightening torque
M12 104 N⋅m (10.6 kg⋅m/77 lb⋅ft)
M8 26 N⋅m (2.7 kg⋅m/20 lb⋅ft)
1
Install the A/C compressor bracket and tighten the
bolt at the specified torque.
1
LNW21BSH021901
Legend
1. Thermostat
12. Install the water outlet pipe.

• Tighten the water outlet pipe at its specified
torque.

1 2
MFWA1BSH000201 LNW91BSH007901
Legend
2. Front engine hanger • Tighten in the order of the numbers in the
diagram.

• Apply liquid gasket (ThreeBond 1207C) to Tightening torque 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
about 2.5 to 5.5 mm(0.10 to 0.22 in) width along
the inlet cover groove (1). Assembly it within 5
minutes after applying the liquid gasket.
6
2 1 7
3 5 4
LNW91BSH008201
LNW91BSH008101
16. Install the inlet cover outer.
• Install the gasket and inlet cover outer, and
3
2
1
LNW91BSH007801
Legend
2. Gasket
4
3. Inlet cover
3
2
• Tighten in the order the numbers in the 1
diagram.
LNW91BMH000301
Legend
Tightening torque 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft) 1. Installation rubber
2. Intake throttle assembly
3. Gasket
18. Install the exhaust gasket.

3 7 1 19. Install the exhaust manifold.
2
5 4 6
LNW91BSH008301
17. Install the throttle valve assembly and gasket, and

Refer to "Intake Throttle Valve" in this section.


• Install the distance tube (1), disc spring (2) and
nut (3) in that order to the stud on the cylinder
head.
5 3 4 6
1 2
1 2
3 7 8
LNW71BSH008901
MFW81BSH000601
20. Install the turbocharger assembly (1) and exhaust
adaptor (3).
Legend
• Install the turbocharger assembly (1) to the
1. Distance tube
exhaust manifold (5) through the gasket (6),
2. Disc spring
and tighten the nut at the specified torque.
3. Nut

• Tighten the exhaust manifold at the specified
torque in the order of numbers in diagram.
• Install the turbocharger (1) to the exhaust
adaptor (3) through the gasket (2), and tighten
Tightening torque at the specified torque.
Nuts (7),(8) 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
Bolts Tightening torque 33 N⋅m (3.4 kg⋅m/25 lb⋅ft)
34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
(1),(2),(3),(4),(5),(6)
• Tighten the mounting bolt (4) at the exhaust
NOTE: manifold side of the adaptor (3).
Since it will expand or contract due to the heat of the
manifold, do not over-tighten.

NOTE:
1 In the table below, there are three selections for the
piston protrusion amount on the head gasket, so be
2 careful.
3
4
• Calculate the average value (Ti) for the
protrusion amount of piston for each cylinder.
• Find the maximum value (Timax) of the
average value (Ti) for each cylinder.
• Select the gasket of the appropriate grade
6 using the Timax.
1
5
a
MFW71BSH004001
c
3
b
Installation
d
1. Install the cylinder head gasket.
• Select the cylinder head gasket.
• Clean the piston head and cylinder block top 2
surface.
• Measure the protrusion amount of piston using
a dial indicator. Perform the measurement in
two places on each cylinder. MFW81BSH001501
• The measuring positions of the piston head and Legend
reference points on the cylinder block side are 1. Cylinder block top surface
shown in the diagram below. 2. Piston head
3. Piston head
4. a :50 deg
5. b :20 deg
6. c :70mm (2.76in)
1 7. d :100mm (3.94in)
Protrusion amount of
Gasket
2 Identification the piston (Timax)
Grade
mm(in)
0.439 – 0.519
A No hole
(0.0173 – 0.0204)
0.519 – 0.589
B 1 hole
(0.0204 – 0.0232)
0.589 – 0.669)
C 2 holes
(0.0232 – 0.0263)
MFWB1BSH002601
Measurement
Piston head : Points (2) and (3)
points
Reference Cylinder block
Point (1)
points top surface :

• Set the side of the head gasket marked with the
part number facing upward, position and install
the cylinder head rear side gear case and
dowel together.
LNW21BSH002401
Legend
1. Grade identification hole
LNW21BSH015601
• Apply liquid gasket.

• As shown in the diagram, apply liquid gasket
• Gently install the cylinder head while aligning
(ThreeBond 1207C) to about 3 mm (0.12 in)
with the cylinder block dowel.
width to the aligning surface (mating surface)
(1) of the cylinder block and flywheel housing. NOTE:
• After applying the liquid gasket, install the When installing, be careful not to damage the head
cylinder head within 5 minutes. gasket.
LNW21BSH015501
LNW21BSH007901
Legend
1. Liquid gasket application position
• Apply molybdenum disulfide to the threaded

portion of the M14 head bolt and seat surface,
• Install the cylinder head gasket. and apply engine oil to the threaded portion of
the M10 head bolt and seat surface.

• Tighten the head bolts in the order shown in the
diagram using a torque wrench and angle
gauge.
1
Cylinder head tightening torque

1st time 98 N⋅m (10 kg⋅m/72 lb⋅ft)
M14 2
2nd time 147 N⋅m (15 kg⋅m/108 lb⋅ft)
(1 - 18)
3rd time 30° to 60°
M10
4th time 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
(19, 20)
Use a stud bolt for (16).
Special Tool
Angle gauge: 5-8840-0266-0 MFW81BSH002301
Legend
1. Bridge cap
2. Bridge
14 6 3 11 5. Insert the gasket into the injector (1) and install to

18 10 2 7 15 the cylinder head.
19
6. Apply engine oil to the threaded portion and seat
surface of the injector clamp bolt (2), and
20
temporarily tighten.
17 9 1 8 16
13 5 4 12
2 3
4
LNW21BSH030701
1
3. Apply engine oil to the bridge (2) for assembly.
NOTE:
5
Move it up and down to confirm that it moves smoothly.
4. Thinly apply engine oil to the bridge cap (1) inner 6

surface and install it.
NOTE:
Be very careful not to drop the bridge cap into the BLW71BSH020401
cylinder head rear-side gear case or front side oil return Legend
hole. 1. O-ring
2. Injector
4. Injector clamp
5. O-ring
6. Gasket
7. Install the idle gear C.


a. Assembly of the idle gear C. 4. Apply engine oil to the both surfaces of the
thrust collar, and molybdenum disulfide to
NOTE: the threaded portion of the bolt and seat
When disassembling the idle gear C, assembly it while surface. Assembly the bolt which is installed
paying attention to the following points because it is to the thrust collar.
difficult to position the idle gear C shaft. However, the bolt should be tightened at a
torque of 40 N⋅m (4.1 kg⋅m/30 lb⋅ft), and
1. Position the marked line on the crank pulley loosen by 30° – 90° after tightening.
(2) and the alignment mark on the front (Confirm that the idle gear C moves.)
cover (1) and set to compression top dead
center of the 1st cylinder.
1
1
2 3
2
4
MFWB1BSH002601
2. With the idle gear B assembled, insert the

idle gear C from above the cylinder head.
• Apply engine oil to the inner
circumference of the idle gear C bush
and the thrust bearing surface.
BLW71BMH000501
3. Apply engine oil to the outer circumference
of the shaft and pass from the cylinder head Legend
rear surface hole to the gear center hole. 1. Insertion Direction
2. Shaft
3. Thrust Collar
4. Bolt
5. Idle Gear C
6. Bush
b. Installation of the camshaft assembly.

1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.

2. Assembly the camshaft with the gear
installed to mesh with the idle gear C
installed to the cylinder head.
At this time, when the marked line on the 1
crank pulley and alignment mark on the front
cover are positioned compression top dead
center of the first cylinder, install so that the
alignment mark “B” on the camshaft gear
matches the top surface of the cylinder
head.
LNW81BSH005601
c. Tightening the idle gear C.

1. Manually rotate the camshaft gear in the left
direction (when looking from the engine
rear) (2), gently mesh the idle gear C to the
direction of the arrow (1) in the diagram, and
set the idle gear C shaft position.
LNW71BSH010601
NOTE:
Be careful as backlash can excessively build up if too
much force is applied when rotating the camshaft gear.
3. Set the cam bearing upper to the camshaft
cap, and apply engine oil to the bearing
inner circumference.
4. Assembly the #2, #3, #4 and #5 caps (1).
2
Apply engine oil to the threaded portion and seat 1

surface 1
Tightening torque
Cap bolts 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Cap nuts 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft) 2
NOTE:
Do not assemble the rocker arm. 3
BLW71BSH009801
Legend
(1) Lightly engage the idle gear C.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft gear
2. Idle gear C
3. Idle gear B

2. Hold down the camshaft gear by hand and
tighten the idle gear C bolt at the specified
torque.
Apply molybdenum disulfide to the threaded

portion and seat surface
Tightening torque
Idle gear C bolt 71 N⋅m (7.2 kg⋅m/52 lb⋅ft) a
NOTE:
When tightening, be careful that the idle gear C shaft
position does not move a lot.
3. After tightening the idle gear C, check the

backlash to ensure that it is within the
standard value below.
MFW81BSH000901
Between the idle gear C and camshaft

9. Installation of the camshaft assembly.
gear mm (in)
0.015 – 0.146 (0.00059 – 0.00575)
a. Set the cam bearing lower to the cylinder head.
Apply engine oil to the bearing inner
If the camshaft gear does not move with circumference.
rattling when manually moving it, there is the
b. Assembly the camshaft with the gear installed
possibility that that the backlash has
to mesh with the idle gear C installed to the
excessively built up. Check the backlash
cylinder head. At this time, when the marked
and readjust.
line on the crank pulley and alignment mark on
NOTE: the front cover are positioned compression top
If the backlash cannot be adjusted, assembly with the dead center of the first cylinder, install so that
service idle gear C shaft (8-97186-398-1). the alignment mark “B” on the camshaft gear
matches the top surface of the cylinder head.
4. Remove the cam cap and camshaft.
5. Use a flat-blade screwdriver (large size),
etc. to check the backlash of the idle gear C
while holding down the idle gear B.
Between the idle gear C and idle gear B mm (in)

0.015 – 0.217 (0.00059 – 0.00854)
6. Repeat Step b. 1 to 4.
7. Remove the camshaft cap end once, and
assembly with the rocker arm assembly.
8. Install the idle gear C cover.

• Apply liquid gasket (LOCTITE 262) to the outer
circumference of the idle gear C cover, and
then use the sealing cup setting tool to tap in to
the dimensions (a :1.5 to 2.5 mm(0.059 to LNW71BSH010601
0.098 in)) shown in the diagram.
Special Tool c. Set the cam bearing upper to the camshaft cap,
and apply engine oil to the bearing inner
Sealing cup installer: 5-8840-2222-0 circumference.

d. Assembly the #2, #3, #4 and #5 caps (1). • Tighten the injection pipe clip (2) at the
specified torque.
Apply engine oil to the threaded portion and seat

surface Tightening torque 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
Tightening torque
Cap bolts 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft)
Cap nuts 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft) 1
NOTE:
Do not assembly the rocker arm.
1
2
MFWA1DSH000101
13. Tighten the injector clamp bolt (temporarily

tightened earlier) at the specified torque.
LNW81BSH005601
14. Tighten the injection pipe (2) at the specified

10. Install the rocker arm shaft assembly. torque.
section.
Tightening torque
Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
Common rail side 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Tightening torque
Nuts side 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Bolts side 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
• Install the common rail pressure sensor

connector.
12. Install the injection pipe (1).
• Thinly apply engine oil to the outer
circumference of the injector side sleeve
nut and install it.
• Lightly tighten the sleeve nut with
spanner so that it is airtight to the
injector and common rail side.
1 2
MFWA1DSH000201 MFW71BSH004101
Legend
1. Injector side sleeve nut 18. Install the water bypass hose (1).
2. Common rail side sleeve nut
• Install the engine coolant temperature sensor
(2) connector to the thermostat housing.
15. Install the glow plug.
2
NOTE: 1
Do not over-tighten. There is the possibility of damage
by tightening beyond the standard.
16. Install the glow plug connector and tighten at the

specified torque.
Tightening torque 1.0 N⋅m (0.10 kg⋅m/14 lb⋅in)
17. Install the camshaft position sensor and tighten at

MFW71BSH003701
• After the installation of the camshaft position Legend
sensor, the connector is connected. 1. Water bypass hose
Refer to "Camshaft Position Sensor" in this 2. Engine coolant temperature sensor
section.
19. Install the leak-off pipe (2).

Leak-off pipe tightening torque

Common-rail side 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
Supply pump side 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
Cylinder head side 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
1 2
MFWA1BSH000301 LNW91DSH000801
23. Install the terminal nuts (3) to the injector (1).

20. Install the leak-off hose.
• Install the leak-off hose to the leak-off pipe and
fasten with the clips. Tightening torque 2 N⋅m (0.2 kg⋅m/17 lb⋅in)
21. Fit the new gasket onto the nozzle leak-off pipe,
and install leak-off pipe. NOTE:
• Alternately tighten the terminal nuts so that not only
1 side is tightened because this is an integrated
part.
• As the terminal stud can be damaged if the nut is
over-tightened, never over-tighten the nut.
1
MFW81BSH001701
LNW71DSH003601
22. Install the injector harness connector from the Legend

inside, and tighten the harness bracket at the 1. Injector
specified torque. 2. Harness
3. Terminal nut
Tightening torque 48 N⋅m (4.9 kg⋅m/35 lb⋅ft) 24. Install the cylinder head cover.

• Install the A/C compressor to the A/C 27. Install the water pipe (3), (7) and oil pipe (1), (6) to
compressor bracket, and tighten at the the turbocharger (2).
specified torque. Refer to "Turbocharger Assembly" in Section 1J,
Induction.
2 3
1
4
MFW51ESH000301 7 6 5
MFW71BSH003401
Legend
Tightening torque 1. Turbocharger feed oil pipe
A/C compressor 24 N⋅m (2.4 kg⋅m/17 lb⋅ft 2. Turbocharger
3. Water pipe (return)
• Install the A/C compressor harness connector. 4. Exhaust manifold
5. Exhaust manifold adaptor assembly
6. Turbocharger return oil pipe
26. Install the A/C compressor drive belt and adjust the
7. Water pipe (feed)
belt tension.
• Refer to "Drive Belt" in Section 1C, Engine
Cooling.
28. Install the oil separator (1) together with the
bracket (3).
Oil separator
• Install the rubber hoses (2), (4) and oil drain

hose (5) and fix them with the clips.
Oil separator bracket


30. Install the oil level gauge and guide tube.
1 31. Install the radiator upper hose.
2 Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
32. Install the charge air pipe on the left and right of
the engine to the intercooler.
3
33. Install the air duct to the turbocharger.
• Tighten the turbocharger inlet air duct
tightening clip (5) at its specified torque. Use a
new clip.
5 4
MFW71BSH003501
1 2
Legend
1. Oil separator
2. Rubber hose(blow-by gas OUT)
3. Oil separator bracket
4. Rubber hose(blow-by gas IN)
5. Oil drain hose
29. Install the EGR cooler (3), EGR duct (1), EGR
valve (5) and the water rubber hose (2), (4).
• Install the EGR cooler following the procedures.
Refer to "EGR Valve and EGR Cooler" in
Section 1F, Emission Control.
MFW71JSH001201
4
Legend
5
3 1. Charge air pipe
2. Air intake duct
2
1 34. Install the front exhaust pipe tighten it at the

specified torque.
Front exhaust pipe

35. Install the engine harness.

MFWA1FSH000101
Legend
1. EGR cooler duct
2. Water rubber hose(feed)
3. EGR cooler
4. Water rubber hose(return)
5. EGR valve

a
e
g
f
MFW71BMF000901
(a) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(d) 71 N⋅m (7.2 kg⋅m / 52 lb⋅ft)
(e) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(f) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(g) 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
147 N⋅m (15 kg⋅m / 108 lb⋅ft) → 30° to 60°
Flywheel
Components
MFW71BMF001001
Legend
1. Flywheel housing 4. Pilot bearing
2. Flywheel assembly 5. Crankshaft position (CKP) sensor
3. Washer
Removal
1. Remove the starter.
• Disconnect the starter ground cable.

• Disconnect the front frame harness connector • Refer to "Crankshaft Position Sensor" in this
near the transmission control box and remove section.
MFW71BSH004201
LNW21BSH011501

Refer to "Transmission ASM" in Section 5B,
• Remove the two bolts (upper and lower) Automatic transmission Smoother (MZW). Also,
attaching the starter, and remove the starter refer to "Transmission ASM" in Section 5C, Manual
from the clutch housing. Transmission (MZW).
• Fasten with a wire etc. to a position where it will 4. Remove the clutch pressure plate.
not interfere with the removal of the
• Insert the clutch aligner in the spline of the
transmission.
clutch disk.
• Remove the pressure plate mounting bolts in a
diagonal line order.
• Remove the pressure plate from the flywheel.
5. Remove the clutch disk.

• Remove the clutch disk from the flywheel along
with the clutch aligner.
• Install the crankshaft stopper to the flywheel
housing starter, and make sure the crankshaft
does not rotate.
NOTE:
Check that the stopper securely bites into the ring gear
and that it is installed.
Special Tool
LNW21BSH011601 Crankshaft stopper: 5-8840-2230-0
2. Remove the crankshaft position sensor (2) form

the flywheel housing (1).
• When removing the flywheel, remove to
prevent interference or damage.
• This is sensitive to shocks so do not throw or
drop.
NOTE:
Remove it before the flywheel, so as not to damage the
sensor.

• Remove the pilot bearing from the flywheel.
LNW21BSH007701
LNW21BSH029301
Legend
6. Remove the washer. 1. Washer
2. Pilot bearing
7. Remove the flywheel.
3. Flywheel
• Gradually loosen the flywheel mounting bolts in
the order shown in the drawing while making
sure that the flywheel does not rotate. 9. Remove the ring gear.
• Loosen all bolts, then remove the stopper, and • Attach a rod to the ring gear and remove it by
the flywheel. tapping with a hammer.
• For Smoother vehicles, after loosening the
flexible plate bolts, remove the washers and
flexible plate in that order.
1 4
6 7
3 2
8 5
LNW21BSH012001
MFW81BSH000501 Inspection
1. Visual inspection.
8. Remove the pilot bearing. • Inspect the flywheel friction surface for cracks,
wear, and damage. Repair or replace if there
are abnormalities.
• Inspect the ring gear tooth surfaces. Replace
the ring gear if it shows damage or is
significantly worn.
2. Measurement of friction surface.

• Measure the depth of the flywheel friction
surface.
• Repair the flywheel if the measured value is
within the standard value and limit value and if it
can be repaired by polishing or sanding.
• Replace the flywheel if the measured value
exceeds the limit.
Flywheel friction surface depth

Standard values 42.5 mm(1.673 in)
Depth :From pressure plate installation surface

to friction surface.
LNW21BSH012101

1
3. Install the washer.
M/T Specifications
• Align to the crankshaft knock pin, install the
flywheel, and tighten in the order shown in the
diagram.
• Apply molybdenum disulfide to the bolt
threaded portion and seat surface.
• Install the crankshaft stopper to the flywheel
housing starter installation section.
MFWB1BSH002501 Special Tool

Installation
1. Install the ring gear.
• Tap the ring gear onto the flywheel after Flywheel tightening torque
uniformly heating using a gas burner. 1st time 78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
Heating temperature should be less than
200°C(392°F). 2nd time 120° to 150°
• When shrink-fitting the ring gear and cooling,
apply a load of 68.6 kN (7,000 kg/15,435 lb)
and hold evenly.
NOTE:
• Install it with the chamfered side of the ring gear
facing the front.
• After shrink-fitting, check that the ring gear is airtight
against the flywheel.

• Tightening is the same as M/T specifications.
4
3
2
1 4 1
6 7
3 2
8 5
MFW81BSH000501
MFW81BSH006601
Legend
1. Flywheel
2. Flexible plate
3. Washer
4. Bolt
4. Tap in the pilot bearing until it touches the

crankshaft end surface.
5. Install the clutch disk.
• Install the clutch disk to the flywheel using the
clutch aligner.
6. Install the clutch pressure plate.

• Align the pressure plate installation hole to the
knock pin in the flywheel and install the
LNW21BSH007701
pressure plate to the flywheel.
• Tighten the pressure plate in a diagonal line
Smoother specifications order.
• Align to the crankshaft knock pin to install the
flywheel, flexible plate and washer.
NOTE:
When installing the flexible plate, align the flywheel
knock pin hole with the flexible plate positioning hole
(diameter 9 mm(0.35 in)). 7. Install the transmission assembly.
Automatic Transmission Smoother (MZW).
8. Install the crankshaft position sensor (2) to the

flywheel hosing (1).
section.


• Connect the front frame harness connector.
MFW71BSH004201
LNW21ESH001101
9. Install the starter to the clutch housing with a bolt,
LNW21ESH001001
• Install the starter ground cable.


a MT, Smoother
MFW71BMF001101
(a) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft) → 120° to 150°

(b) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Crankshaft Position Sensor

Removal
1. Disconnect the crankshaft position sensor harness
connector (1).
2. Remove the crankshaft position sensor (2).
• This is sensitive to shocks so do not throw or
drop.
MFW81ESH000501
Installation
1. Install the crankshaft position sensor (2) and
2. Connect the crankshaft position sensor harness

connector (1).
MFW81ESH000501
Front Cover
Components
1 2
10 4
12 11
5
13 6
7
8
MFW71BLF001801
Legend
1. Adjust plate 8. Front oil seal
2. Generator 9. Crankshaft pulley
3. Front cover 10. Water pump
4. Oil pan gasket 11. Fan belt
5. Oil pan 12. Water pump pulley
6. Rubber assembly 13. Fan assembly
7. Front slinger
Removal 3. Remove the water pump.

Refer to "Water Pump" in Section 1C, Engine
1. Remove the front oil seal.
Cooling.
Refer to "Crankshaft Front Oil Seal" in this section.
4. Remove the front cover.
Refer to "Oil Pan" in Section 1H, Engine
Lubrication.

• Remove the generator adjust plate. • Remove the oil cooler bypass valve from the
cylinder block.
MFW71BSH006601
LNW81BSH004801
• Remove the oil relief valve (arrow) and loosen

the front cover installation bolt to remove the Installation
front cover. 1. Install the oil cooler bypass valve.
• Insert the oil cooler bypass valve to the position
of the arrow on the cylinder block. At this time,
be careful not to mistake the insertion direction.
MFW71BSH006701
5. Remove the oil cooler bypass valve.

LNW81BSH004701

2. Install the front cover.
• Clean the cylinder block front side. Especially, 1 2
clean the liquid gasket that oozes out when the

(1)
crankcase is installed.
• Install the O-rings (two pieces) and apply liquid a
4
gasket (ThreeBond 1207B or 1207C) to the (2)
5
groove in the front cover installation surface.
3
b
2
(3)
Bead width 1.5 to 5 mm(0.059 to 0.20 in)
2
From aligning surface: c
Bead height
0.3 to 1.5 mm(0.012 to 0.060 in) (4)
d
minutes.
1
NOTE:
Apply the liquid gasket without applying it on the O-ring MFW81BSH001601
(1). Legend
1. a :35mm (1.38 in)
2. b :25mm (0.98 in)
3. c :65mm (2.56 in)
4. d :30mm (1.18 in)
3. Install the water pump.

1 Cooling.
4. Install the oil pan.
1 Refer to the "Oil Pan" in Section 1H, Engine
Lubrication.
5. Install the front oil seal.
Refer to "Crankshaft Front Oil Seal" in this
section.
LNW21BSH058701
Legend
1. O-ring
• Align to the cylinder block knock pin to install

the front cover.
NOTE:
At the same time as the front cover, install the water
pump (before the liquid gasket dries).
• The (*) bolt should be tightened together with

the generator adjust plate.
• Tighten the oil relief valve (5) at the specified
torque.


MFW81BLF003701
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Crankshaft Front Oil Seal

Components
3
2
1
MFW81BSF000101
Legend
1. Crankshaft pulley 3. Crankshaft front slinger
2. Crankshaft front oil seal
Removal • Fix it using wires, etc. in a place where it will not

interfere with the work.
1. Discharge the coolant.
• Disconnect the starter ground cable.
• Disconnect the front frame harness connector
LNW21BSH011601
3. Disconnect the air charge pipe connected to the

intercooler.
4. Remove the radiator upper hose at the engine
LNW21BSH011501
side.
5. Remove the coolant reserve tank hose at the
radiator side.
• Remove the two bolts (upper and lower) 6. Remove the radiator lower hose at the engine side.
attaching the starter, and remove the starter 7. Remove the brackets on the left and right sides of
from the clutch housing. the radiator (with fan guide) to remove the radiator.

8. Remove the fan assembly. • Be careful not to damage the front cover oil seal
• Remove the four installation nuts to remove the (3) installation section and shaft. Use a
fan assembly. screwdriver to pry only the oil seal to remove it.
9. Remove the drive belt.
LNW21BSH002801
LNW71CSH002001 Legend
1. Felt
2. Slinger
10. Remove the crankshaft pulley. 3. Oil seal
• Install the crankshaft stopper to the installation
section of the flywheel housing starter, and
loosen the pulley nut while making sure that the 12. Remove the crankshaft front slinger.
crankshaft does not rotate. • Pull out the slinger using a puller.
(It is easier to pull out by fastening the outer
NOTE: circumference of the puller with a clip band.)
Check that the stopper securely bites into the ring gear
and that it is installed. Special Tool
Special Tool Slinger puller: 5-8840-2360-0
LNW71BSH007601
LNW21BSH012301
Installation
11. Remove the crankshaft front oil seal (3). 1. Install the front slinger.

• Firmly fit the slinger (1) using the oil seal • Cover the sleeve (2) over the adaptor (1), and
installer kit. install the washer to the center bolt. Tighten
and then firmly fit in all the way to the end until
the sleeve (2) touches the adaptor (1).
4
1
2 5
3 6
LNW21BSH073201
Legend
LNW21BSH013301
1. Front slinger
2. Adaptor (front)
3. Fixing bolt
4. Sleeve (front) • After firmly fitting in the front slinger (3),
5. Washer (front) measure the dimension from the crankshaft
6. Center bolt end to the oil seal lip touching surface. Also
check for fluctuations in the front slinger (four
Special Tool directions).
Oil seal installer kit: 5-8840-2703-0

(Use the parts in the table below for the front oil seal.) Front Slinger press-fitting
measurement mm (in)
40.2 – 40.8
No Parts Oil Assembly Standard
Part Name Slinger (1.58 – 1.61)
. number seal
5-8840- NOTE:
1 Sleeve (Front) { {
2704-0 Be careful not to mistake the front slinger assembly
5-8840- direction and the front and rear. There is a right, four-
2 Adaptor (Front) { { thread screw cut at the rear side, and a left, four-thread
2705-0
screw cut at the front side. Always replace the slinger
5-8840- Adaptor ring
3 – { (3) and oil seal as a set.
2706-0 (front)
5-8840-
4 Washer (Front) { {
2707-0
5-8840-
5 Center bolt { {
2713-0
5-8840-
6 Fixing Bolt { {
2714-0
NOTE:
An engine sleeve (5-8840-2712-0) for engines before
‘93.5 models is included in oil seal installer kit, but it will
not be used with this engine.
• Insert the front slinger (3) to the leading end of

the adaptor (1) and install the adaptor (1) to the
crankshaft.

• Install the adaptor (1) to the crankshaft with the
fixing bolt.
a 1
MFW81BSH001001
Legend
LNW21BSH013101
1. Adaptor
2. Sleeve Legend
3. Slinger 1. Adaptor (front)
4. a :40.2 to 40.8 mm (1.58 to 1.61 in)
2. Install the front oil seal. • Thinly apply engine oil to the oil seal (1) lip
• Firmly fit the oil seal using the oil seal installer section, and set to the front adaptor.
kit.
NOTE:
Always apply oil to the lip section of the oil seal.
• Put the front adaptor ring (2) into the sleeve (3)
and set to the adaptor using the center bolt and
5 washer (4).
2 4
7
1 3 6
LNW21BSH073301
Legend
1. Oil seal
2. Adaptor (front)
3. Adaptor ring (front)
4. Fixing bolt
5. Sleeve (front)
6. Washer (front)
7. Center bolt

• Tighten until the sleeve (3) touches the adaptor
and firmly fit the front oil seal (1).
4 1
1 2 3 4
2
a
3
MFW81BSH001101
Legend
LNW21BSH013201
1. Adaptor ring
Legend 2. Sleeve
1. Oil seal 3. Adaptor
2. Adaptor ring 4. Front oil seal
3. Sleeve 5. a :30.7 to 31.3 mm(1.21 to 1.23 in)
4. Washer
3. Install the crankshaft pulley.

• Apply engine oil to the threaded portion of the
tightening bolt.
• Align to the crankshaft knock pin, and install the
crank pulley.
• Tighten in the order shown in the diagram.
1
LNW21BSH013301
3 4
• After firmly fitting the front oil seal (4), measure
the dimension from the crankshaft end surface
to the oil seal surface. Also check for
fluctuations in the oil seal (four directions). 2
Front oil seal press-fitting

measurement mm (in)
LNW71BSH007701
30.7 – 31.3
Assembly Standard
(1.21 – 1.23)

4. Install and adjust the drive belt.
Refer to "Drive Belt" in Section 1C, Engine
Cooling. 2
5. Install the fan assembly and tighten it at its
specified torque.
1

7
3
6
5
4
MFWA1CSH001501
Legend
1. Upper side nut
2. Stud bolt
3. Rubber
4. Lower side nut
5. Frame
6. Radiator side bracket
7. Washer
LNW71CSH002001
7. Install the radiator lower hose.

6. Install the radiator.
• Install the left and right bracket sections of the
radiator to the frame side bracket as shown in Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
the diagram.
8. Attach the coolant reserve tank hose.
9. Install the radiator upper hose.
Tightening torque
Lower side nut 85 N⋅m (8.7 kg⋅m/63 lb⋅ft) Tightening torque 5 N⋅m (0.5 kg⋅m/43 lb⋅in)
10. Install the air charge pipe to the intercooler.

11. Install the starter to the housing with a mounting
bolt, and tighten it at the specified torque.


LNW21BSH011601


MFW81BSF000201
(a) 200 N⋅m (20.4 kg⋅m / 148 lb⋅ft)

Crankshaft Rear Oil Seal

Components
5
4
3
2
1
2
7
MFW81BLF003801
Legend
1. Starter 5. Crankshaft rear slinger
2. Transmission assembly 6. Flywheel
3. Flywheel 7. Flexible plate
4. Crankshaft rear oil seal
Removal 4. Remove the crankshaft position sensor from the

flywheel hosing.
Refer to "Flywheel" in this section.
Also, refer to "Transmission ASM" in Section 6. Remove the rear oil seal.
3. Remove the pressure plate and clutch disk.

• Be careful not to damage the flywheel housing • Firmly fit the slinger using the oil seal installer
oil seal installation section and shaft. Use a kit.
screwdriver to pry only the oil seal to remove it.
3
1 3
2
2
5
6 4
LNW21BSH073401
LNW21BSH002801
Legend
Legend 1. Rear slinger
1. Felt 2. Fixing bolt
2. Slinger 3. Center bolt
3. Oil seal 4. Sleeve (rear)
5. Collar (rear)
6. Adaptor (rear)
7. Remove the rear slinger.
• Pull out the slinger using a puller. Special Tool
(It is easier to pull out by fastening the outer
Oil seal installer kit: 5-8840-2703-0
circumference of the puller with a clip band.)
Special Tool
Parts Oil
Slinger puller: 5-8840-2360-0 No. Part Name Slinger
number seal
5-8840-
1 Sleeve (rear) { {
2708-0
5-8840-
2 Adaptor (Rear) { {
2709-0
5-8840-
3 Collar (Rear) { {
2710-0
5-8840- Adaptor Ring
4 – {
2711-0 (Rear)
5-8840-
5 Center bolt { {
2713-0
5-8840-
6 Fixing Bolt { {
2714-0
NOTE:
An engine sleeve (5-8840-2712-0) for engines before
MFW81BSH000701 '93.5 models is included in the oil seal installer kit, but it
will not be used with this engine.
Installation
1. Install the rear slinger.

• Insert the slinger to the leading end of the rear • After firmly fitting in the slinger, measure the
adaptor (3), install the collar (1) to the fixing bolt dimension from the crankshaft end to the oil
(3), and install the adaptor to the crankshaft. seal lip touching surface. Also check for
fluctuations in the slinger (four directions).
Slinger press-fitting measurement (rear)

mm (in)
1
17.0 – 17.6
Assembly Standard
(0.669 – 0.693)
2
NOTE:
Be careful not to mistake the slinger assembly direction
and the front and rear. There is a right, four-thread
screw cut at the rear side, and a left, four-thread screw
cut at the front side. Always replace the slinger and oil
3
seal as a set.
LNW21BSH014501
Legend
1
1. Collar
2. Fixing bolt
3. Adaptor 2
3
4
5
• Cover the slinger over the adaptor and tighten
the center bolt all the way to the end until the
sleeve touches the adaptor and firmly fit the 6
slinger.
7
LNW21BSH014301
Legend
1. Crankshaft
2. Adaptor
3. 17.0 to 17.6 mm (0.669 to 0.693 in)
4. 10.7 to 10.9 mm (0.421 to 0.429 in)
5. Slinger
6. Sleeve
7. Collar
2. Install the rear oil seal.
LNW21BSH014701

• Firmly fit the oil seal using the oil seal installer • Thinly apply engine oil to the oil seal lip section,
kit. and set the rear oil seal to the rear adaptor.
NOTE:
Always apply oil to the lip section of the oil seal.
• Put the rear adaptor ring (2) into the sleeve (1)
and set to the adaptor and install the center
1 2 3 bolt.
7 6 5 4
LNW21BSH073501
Legend
1. Adaptor (rear)
2. Fixing bolt 2
3. Center bolt
4. Sleeve (rear)
5. Collar (rear) LNW21BSH014601
6. Adaptor ring (rear)
7. Oil seal Legend
1. Sleeve
2. Adaptor ring
• Install the collar (1) to the fixing bolt (2), and

install the adaptor (3) to the crankshaft.
• Tighten the center bolt all the way to the end
until the sleeve touches the adaptor, and firmly
fit the oil seal.
LNW21BSH014501
Legend
1. Collar LNW21BSH014701
2. Fixing bolt
3. Adaptor

• After firmly fitting the oil seal, measure the
dimension from the crankshaft end surface to
the oil seal surface. Also check for fluctuations
in the oil seal (four directions).
Oil seal press-fitting measurement (rear)

mm (in)
Assembly Standard 7.5 – 8.1(0.30 – 0.32)
1
2
7
3
6
5
LNW21BSH014801
Legend
1. Crankshaft
2. Oil seal
3. 7.5 to 8.1 mm (0.30 to 0.32 in)
4. Collar
5. Adaptor ring
6. Sleeve
7. Adaptor

Refer to "Flywheel" in this section.
4. Install the crankshaft position sensor to the
flywheel housing.
5. Install the clutch disk and pressure plate.
6. Install the starter.
Piston and Connecting Rod

Components
1 2
2
3
6
4
MFW71BLF000601
Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Piston pin
4. Bearing
Removal 4. Remove the camshaft assembly.

Refer to the "Oil Pan" in Section 1H, Engine Refer to "Cylinder Head" in this section.
Lubrication.
6. Remove the connecting rod cap.
Refer to "Cylinder Head Cover" in this section. NOTE:
3. Remove the rocker arm shaft assembly. Organize the removed bearings according to the
Refer to "Rocker Arm Shaft Assembly" in this cylinders using tags, etc.
section.

Disassembly
1. Remove the piston ring.
• Remove the piston ring using the ring pliers.
NOTE:
When reusing the piston rings, organize them
according to the order of the cylinders so that other
cylinder pistons and piston rings do not get mistaken.
LNW21BSH004901
7. Remove the piston and connecting rod.

• Remove carbon from the top of the
cylinder liner using a scraper.
• Pull out the piston and connecting rod out to the
cylinder head side.
NOTE: LNW21BSH005101
When pushing out the connecting rod, be careful not to

damage the oil jet and cylinder liner.
2. Remove the snap ring.
3. Remove the piston pin (1).
NOTE:
Organize the disassembled piston pin, piston
and connecting rods according to the cylinders.
LNW21BSH005001
1
8. Remove the connecting rod bearing.
NOTE:
When reusing the bearing, organize them MFW41BSH016101
according to the order of the cylinders so that
other cylinder bearings do not get mistaken.
4. Remove the connecting rods from the pistons.
5. Piston.

• Carefully clean carbon from the piston heads
and piston ring grooves.
Piston outer diameter mm (in)
NOTE: 114.944 – 114.979
Do not use a wire brush to clean the pistons. Standard values
(4.5254 – 4.5267)
Visually inspect the pistons for cracks, seizure or other
excessive wear. If there is an abnormality, replace the
piston.
Clearance between the piston and the
cylinder liner mm (in)
Inspection
0.052 – 0.106
1. Measure the gap between the piston and the inner Standard values
(0.0020 – 0.0042)
diameter of the cylinder liner.
Inner diameter of cylinder liner
NOTE:
• Use the cylinder bore gauge to measure the
liner inner diameter in the thrust direction and • The dimensions above are of the piston and the
the radial direction at the specified position. liner for service replacement.
• Measuring position (From top surface of the • If the measurement reveals that the clearance
cylinder block) between the pistons and the cylinder liners exceed
1) 20 mm(0.79 in), 2) 110 mm(4.33 in), 3) 190 the standard values, replace the pistons or cylinder
mm(7.48 in) liners.
• Find the liner inner diameter according to the
average value of the six locations actually
measured.
Inner diameter of cylinder liner

115.031 – 115.050 mm(4.5288 – 4.5295 in)
2
LNW21BSH009101
3
2. Replace the piston

• There is only 1 type of grade of the piston and
the inner diameter of the cylinder liner. There is
no need to select the grade.
However, when replacing the cylinder liner,
there are 2 types of liner outer diameters (1x,
LNW21BSH009001
3x), so it is necessary to select for the cylinder
blocks (1, 2, and 3).
• Refer to section "Cylinder Block" for
Piston outer diameter replacement of the cylinder liner.
• Use a micrometer to measure the piston pin of
NOTE:
the specified position and the outer diameter of
Grades A, B, and C are marked on the top of the piston
the piston at the perpendicular direction.
when shipped from the factory.
• Measuring position (From top surface of the
piston) 85 mm(3.35 in).

• Use a thickness gauge to measure the ring
gap.
LNW46ASH004501
Legend
LNW61BSH000901
1. Front mark
3. Inspect the piston ring.

Measurement of the piston ring gap (remove the • Replace the piston ring if the measured value
carbon from the ring gap) exceeds the limit.
• Insert the piston ring into the cylinder liner.
• Push the ring into the lower end of the cylinder Piston ring gap mm(in)
liner using the piston.
Piston ring Standard values Limit
0.27 – 0.46 1.20
No.1 Compression ring
(0.0106 – 0.0181) (0.047)
0.37 – 0.61 1.20
(0.0146 – 0.0240) (0.047)
0.27 – 0.56 1.20
Oil ring
(0.0106 – 0.0220) (0.047)
Measure the clearance between the piston ring

groove and the piston ring.
• Remove all carbon in the piston ring groove.
• Insert the piston ring into the piston ring groove,
and measure the gap with the thickness gauge.
• If the clearance between the piston ring groove
and the piston ring exceeds the standard value,
replace the piston or piston ring.
LNW21BSH009301
NOTE:
The No.1 compression ring cannot be measured
because of the half keystone ring.
Clearance of the piston ring and ring groove mm(in)

Piston ring: Standard values Limit
No.1 Compression ring — —
0.015 – 0.055 0.15
(0.0006 – 0.0022) (0.0059)
0.03 – 0.07 0.15
Oil ring
(0.0012 – 0.0028) (0.0059)
LNW21BSH009601
• Check that the piston pin will pass through with

a light thumb pressure when the piston is at
room temperature.
• Replace the piston or the piston pin if they are
loose or rattle at room temperature.
LNW21BSH009501
4. Inspect the piston pin.

• Visually inspect the piston pin for cracks,
scratches or other damages, and replace it as
necessary.
diameter of the piston pin. Replace the piston
pin if the measured value exceeds the limit.
Piston pin outer diameter mm (in)

39.995 – 40.000 LNW21BSH009701
Standard values
(1.5746 – 1.5748)
Limit 39.970(1.5736)
• Measure the inner diameter of the connecting
rod small end bush. If the clearance between
the bush inner diameter and pin outer diameter,
replace the bush or the connecting rod
assembly, and pin.
Clearance of connecting rod small end and

piston pin outer diameter mm (in)
0.012 – 0.027
Standard values
(0.00047– 0.00106)
Limit 0.05(0.0020)
5. Measure the clearance between the piston and the 7. Measure the bearing oil clearance.
piston pin. • Use the following method to measure the oil
• Apply engine oil to the piston pin. Then, clearance between the connecting rod bearing
manually push it into the piston hole and rotate and crank pin.
it. If the pin rotates smoothly without any - Remove the connecting rod caps. Set the
looseness, the clearance is normal. If there is removed caps in the order of the cylinder
looseness, measure the clearance. Replace the number.
piston and piston pin if the clearance exceeds
- Clean the bearing and crankshaft pin.
the limit.
- Inspect the bearing. Replace the bearings in
sets if there is damage or excessive wear.
Clearance between piston and piston pin mm (in)
• Place the plastigage on the crankshaft pin.
0.009 – 0.022 • Install the bearing cap, and tighten the bolt at its
Standard values
(0.00035 – 0.00087) specified torque.
Limit 0.04(0.0016) Apply molybdenum disulfide to the threaded
portion and seat surface.
6. Measure the connecting rod alignment.
• Use the connecting rod aligner to measure the Tightening torque
twisting of the large end hole and small end 1st time 39 N⋅m (4.0 kg⋅m/29 lb⋅ft)
hole, and the degree of parallelization. Make
replacements if the measured value exceeds 2nd time 60°
the limit. 3rd time 30°
NOTE:
Connecting rod alignment Do not rotate the crankshaft.
for 100 mm (3.94 in) mm (in)
Twisting 0.05(0.0020) 0.20(0.0079)
Degree of
0.05(0.0020) 0.20(0.0079)
parallelization

• Select the bearing by carefully considering the
grade of the big end diameter of the connecting
rod for installation.
1
1
2 3
LNW21BSH010501
- Remove the cap. LNW71BSH009101
- Measure the widest width area of the Legend

plastigage to find the oil clearance. Replace 1. Rear mark
the bearings in sets if the clearance exceeds 2. Diameter grade mark of big end hole
the limit. 3. Cylinder number
Crank pin oil clearance mm(in)

Bearing selection table
0.037 – 0.076
Standard values Large end Bearing
(0.0015 – 0.0030) Oil clearance
hole diameter Identification
Limit 0.10(0.0039) mm (in)
Grade color
0.037 – 0.076
- Remove the plastigage from the bearing and A Green
(0.0015 – 0.0030)
crank pin.
0.037 – 0.076
B Yellow
(0.0015 – 0.0030)
LNW21BSH010601
8. Select the connecting rod bearing.

• Select the bearing from the table when
installing a new one or replacing a bearing in
use.
LNW21BSH010801 MFW81BSH007401
Legend Legend
1. Grade identification color 1. Front mark
2. Convex mark
Reassembly 3. Apply an adequate amount of engine oil to the

1. Install the piston. piston pin. Then, push it into the piston and
2. Install the connecting rod. connecting rod small end.
• Assemble so that the piston head front mark (1) 4. Install the snap ring using long-nose pliers.
and the connecting rod cast mark (convex) (2)
face same directions. NOTE:
Check that the snap ring is securely installed in the ring
• Install the snap ring at one side using the long-
groove. Check that the connecting rod slides smoothly.
nose pliers.
MFW61BSH001601 LNW71BSH007401
5. Install the piston ring using the ring pliers.

• Install the oil ring so that the coil expander joint
is 180° in the opposite direction.

• The compression ring is installed with the "2T" • Thoroughly apply engine oil to the piston ring,
or the "T1" mark facing upward, and install in ring groove and piston side surface.
the order of No.2 and No.1 compression rings. • Shift the piston ring joint in intervals of 120°, as
shown in the drawing, assigning (1) for the ring
No.1, (3) for the ring No.2, and (2) for the oil
ring.
• Face the piston front mark towards the front,
and insert the piston into the cylinder liner using
1 the setting tool.
NOTE:
2
• When pushing in the piston, firmly attach the setting
tool to the cylinder liner and push in. If the
adherence is inadequate, the ring can be damaged
3 when pushed.
• When pushing the piston, be careful not to touch the
oil jet against the connecting rod.
• Be careful not to damage the inner surface of the
liner when inserting the piston.
MFW61BSH000101 • Set the crankshaft pin to top dead center with each
cylinder, when inserting piston/connecting rod.
Legend
1. Compression ring No.1 • When inserting piston/connecting rod if the crank
2. Compression ring No.2 pin is set to the bottom dead center, the oil jet might
3. Oil ring hit connecting rod and it might break.
NOTE: Special Tool

Check that there is no gap at the position of the arrow Piston installer: 5-8840-9018-0
in the diagram when the oil ring coil expander is
installed.
2
1
4
MFW71BSH002601
Legend
1. No.1 compression ring gap
LNW21BSH011201
2. No.2 compression ring gap
3. Oil ring gap
4. Front mark
Installation
1. Install the connecting rod bearing.
• Install the bearing to the connecting rod, and 3. Install the connecting rod cap.
apply engine oil to the bearing. • Install the bearing to the connecting rod cap
2. Install the piston and connecting rod assembly. and apply engine oil.

• Align the cap and the connecting rod number
markings (1, 2, 3, 4) and install the cap.
1
1
2 3
LNW21BSH011401
LNW71BSH009101
Legend Refer to "Cylinder Head" in this section.
1. Front and back side discrimination boss
2. Diameter grade of large end hole mark
3. Cylinder number
section.
• Apply molybdenum disulfide to the threaded 7. Install the cylinder head cover.
portion of the mounting bolts and seat surface. Refer to "Cylinder Head Cover" in this section.
Tighten at the specified torques. 8. Install the oil pan.
Refer to the "Oil Pan" in Section 1H, Engine
Lubrication.
Tightening torque
2nd time 60°
3rd time 30°
Special Tool
Angle gauge: 5-8840-0266-0
NOTE:
• Set the crank pin to the bottom dead center when
tighten connrod cap. (Because it doesn’t hit the
tightening tool to the oil jet.)
• Check that the crankshaft turns smoothly.

MFW71BMF000101
(a) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) → 60°→ 30°

Crankshaft
Components
1
3
LNW81BLF002201
Legend
1. Upper bearing 5. Lower bearing
2. Thrust bearing upper 6. Thrust bearing lower
3. Gear 7. Crankcase
4. Crankshaft
Removal 4. Remove the oil pan.

1. Remove the engine assembly from the vehicle.
Lubrication.
Refer to "Engine Assembly" in this section.
5. Remove the water pump.
Cooling.
3. Remove the supply pump.
6. Remove the front cover.
Refer to "Supply Pump" in Section 1D, Engine
Refer to "Front Cover" in this section.
Fuel.
7. Remove the timing gear train.
Refer to "Timing Gear Train" in this section.

8. Remove the crankshaft front oil seal. 16. Remove the thrust bearing upper.
Refer to "Crankshaft Front Oil Seal" in this section. 17. Remove the upper bearing.
9. Remove the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal" in this section.
10. Remove the oil pump.
Refer to "Oil Pump" in Section 1H, Engine
Lubrication.
Refer to "Piston and Connecting Rod" in this
section.
12. Remove the crankcase.
• Gradually loosen the crankcase installation bolt
in the order shown in the drawing, and use the
three replacer holes (at the arrows in the
diagram) to remove it.
3 7 11 15 16 12 8 LNW21BSH023801
1
4
Disassembly
18 22 26 25 21
1. Remove the gear.
• Use the gear puller to remove it.
19 23 27 24 20
Special Tool
Puller; Crankshaft gear: 8-94396-818-0
2 6 10
14 17 13 9 5
LNW21BSH023601
13. Remove the thrust bearing lower.

14. Remove the crankshaft lower bearing.
LNW21BSH023901
Inspection
1. Thrust clearance.
• As shown in the diagram, set a dial indicator
and measure the crankshaft thrust clearance.
LNW21BSH023701
• Replace the thrust bearing in sets if the thrust
clearance exceeds the limit.
15. Remove the crankshaft.

Play in the crankshaft axis direction mm (in)

Standard values 0.040 – 0.205(0.0016 – 0.0081)
NOTE:
Measure the thrust clearance prior to disassembly.
LNW21BSH024101
• As shown in the diagram, place the plastigage

on the crankshaft journal.
• Set the lower bearing to the original position of
the crankcase.
LNW21BSH024001
2. Main bearing clearance.

• Remove the crankcase.
The removed main bearing should be lined in
the order of the number.
• Remove the crankshaft. Remove the main
bearing.
• Clean the crankshaft journal and upper and
lower bearings.
• Inspect the bearings for damage and excess
wear.
If damage and excess wear is found during the

inspection, replace the bearings in sets.
LNW21BSH024201
• Set the upper bearing and crankshaft to the
cylinder block. Install the crankshaft to be level.
• Install the crankcase and tighten the bolt at the
NOTE:
specified torque.
Turn the crankshaft approximately 30° to stabilize the
bearing.

• Use a torque wrench and angle gauge to NOTE:
tighten the crankcase in the order shown in the After tightening the crankcase, do not turn
diagram. the crankshaft.
• Loosen the bolts and gently remove the

crankcase.
• Measure the maximum width portion of
the plastic gauge crushed by tightening
the crankcase to determine clearance.
Journal oil clearance mm (in)

Standard values
0.039 – 0.070
No.1,2,4,5
(0.0015 – 0.0028)
0.053 – 0.084
No.3
(0.0021 – 0.0033)
LNW21BSH024301
25 21 17 13 12 16 20
27
24
10 6 2 3 7
9 5 1 4 8
26 22 18
14 11 15 19 23 LNW21BSH024401
LNW21BSH022601
• Replace all sets of main bearings or the
crankshaft if the oil clearance exceeds the limit.
Tightening torque • Remove the plastigage from the bearing and
1st time 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) crankshaft.
M14
2nd time 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) Inspection of the crankshaft.
(1 to 10)
3rd time 30° to 60° • Inspect the crankshaft journal and crank pin
M10 surface for wear and damage. Inspect the oil
4th time 37 N⋅m (3.8 kg⋅m/27 lb⋅ft) seal installation surface for excess wear and
(11 to 27)
damage.
• Tighten the (1) to (10) bolts (M14) in the • Inspect the oil port for clogging.
tightening direction. Check that they are 3. Crankshaft run-out.
tightened at a torque beyond 167 N⋅m (17 kg⋅m/ Carefully set the crankshaft to the V-block. Slowly
123 lb⋅ft). rotate the crankshaft to measure run-out. Replace
the crankshaft if the crankshaft run-out exceeds
Special Tool the limit.
Angle gauge: 5-8840-0266-0

Crankshaft run-out mm (in) Crankshaft outer diameter mm (in)

Standard values 0.05(0.0020) or less Standard values
81.905 – 81.925
Journal #1, #2, #3, #4, #5
(3.2246 – 3.2254)
81.891 – 81.911
Journal #3
(3.2241 – 3.2248)
72.902 – 72.922
Pin
(2.8702 – 2.8709)
NOTE:
Repairs must not be done because TUFFTRIDE (soft
nitriding) is implemented to increase the strength of the
crankshaft.
Inspection of the TUFFTRIDE layer of the
crankshaft
1. Use an organic detergent to thoroughly clean the
crankshaft. Completely remove the oil from the test
locations.
2. Prepare a solution of copper chloride ammonium
LNW21BSH054801
of 5 to 10% (diluted with diluting water).
3. Use an oil drop to apply the solution to the test
locations. Maintain the inspection surface at a
4. Measure the journal and crank pin diameter and complete level so that the solution does not flow.
uneven wear.
• Use a micrometer to measure the journal and
pin outer diameters to calculate difference of
the maximum and minimum. Measure in 4
sections on the journal and on the pin. 2
1
LNW21BSH038001
Legend
1. Drip prohibited area
2. Test liquid drop section
3. Pin or journal moving surface
LNW21BSH024601
NOTE:
Do not allow the solution to approach the oil port.
Determination
• Wait 30 to 40 seconds.
• If the color does not change after 30 or 40
seconds, the crankshaft can be used. If the color
changes (test surface turns copper-colored)
(indicating a residual layer of TUFFTRIDE),
replace the crankshaft.

CAUTION:
• The inspection liquid is highly corrosive, so when 1 2
finished, wipe it away with a cloth immediately and 3
clean with water or steam. 4
• Do not let any inspection liquid get in your eyes, on
your hands or cloths. If some of the liquid gets in
your eyes, wash them immediately with large
volumes of fresh water and seek medical
treatment.
Selection of the crankshaft bearing

• Refer to the bearing selection table to install a new
crankshaft bearing or to replace one in use.
5
• Be careful of the journal hole inner diameter grade
of the cylinder block and the crankshaft journal
diameter grade in selecting a new bearing. 6
• The journal numbers are #1 to #5 from the left in
LNW21BSH024901
the direction that the characters are read.
Legend
1. Upper bearing
2. Oil hole
3. Grade identification color
4. Oil groove
5. Lower bearing
LNW21BSH024701
LNW21BSH024801
NOTE:
Be careful not to mistake the bearing shape when
installing.

Grade combination Oil clearance mm (in)
Cylinder block Crank journal Bearing identification
#1,2,4,5 #3
Grade Grade color
0.041 – 0.068 0.055 – 0.082
1 1 Black
(0.00161 – 0.00268) (0.00217 – 0.00323)
0.039 – 0.065 0.053 – 0.079
1 2 Brown
(0.00154 – 0.00256) (0.00209 – 0.00311)
0.043 – 0.070 0.057 – 0.084
2 1 Blue
(0.00169 – 0.00276) (0.00224 – 0.00331)
0.041 – 0.067 0.055 – 0.081
2 2 Black
(0.00161 – 0.00264) (0.00217 – 0.00319)
Reassembly Installation
1. Install the gear. 1. Install the crankshaft upper bearing.
• Warm the gear to 170 to 250°C(338 to 482°F), • Install the upper bearing to the cylinder block
and align the gear side groove with the pin and apply oil.
position at the backside of the crankshaft and
install them. NOTE:
• When installing, face the alignment mark "S" (1) When replacing the crankshaft bearing, select the
of the gear edge surface towards the outside grade upon referring to the selection of the crankshaft
and insert at once up to the rim. When it is bearing grade. Do not apply oil to the cylinder block
cooling, use the installer to tap into until it bearing installation surface or the outer circumference
touches the end. of the bearing.
Special Tool
Installer; crankshaft gear: 8-94396-819-0
MFW81BSH006901
2. Install the thrust bearing upper.

LNW21BSH025101
• Install the thrust bearing upper to the cylinder
Legend block No.5 journal section front side. When
1. Alignment mark “S” doing so, it is acceptable to use grease to
adhere the bearing upper to the cylinder block.
However, wipe away any excess grease.
NOTE:
Install so that the oil groove of the thrust bearing
touches the crankshaft.

• Install so that the oil groove of the thrust
bearing touches the crankshaft.
LNW21BSH025301
LNW21BSH025501
3. Install the crankshaft.
• Apply engine oil to the crankshaft journal and
gently place it on the cylinder block. 6. Install the crankcase.
• Push the installed crankshaft against the rear • Apply liquid gasket (ThreeBond 1207C) to the
side, and insert the thrust bearing upper to the crankcase in a width of approx. 3 to 4 mm(0.12
cylinder block No.5 journal section rear side. to 0.16 in).
NOTE: minutes.
Install so that the oil groove of the thrust bearing
touches the crankshaft.
MFW81BSH006801
4. Install the crankshaft lower bearing.

5. Install the thrust bearing lower.
• Install the thrust bearing lower to the crankcase
No. 5 journal rear side.

• Gently place the crankcase on the cylinder
block.
20
20
16
16
152
148
142.5
132
136
3~4mm
142.5
2~3mm
136
152
180
38
16
20
20
LNW21BMF000401
• Apply molybdenum disulfide to the threaded

portion of the M14 bolt and seat surface, and
tighten at the specified torque in the numbered 25 21 17 13 12 16 20
order in the diagram. 27
24
• Do not apply engine oil to the M10 bolt.
10 6 2 3 7
Tightening torque 9 5 1 4 8
M14
2nd time 132 N⋅m (13.5 kg⋅m/98 lb⋅ft)
(1 to 10)
3rd time 30° to 60°
26 22 18
M10 14 11 15 19 23
4th time 37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
(11 to 27)
LNW21BSH022601
• Tighten the (1) to (10) bolts (M14) in the
tightening direction. Check that they are
tightened at a torque beyond 142 N⋅m (15 kg⋅m/ 7. Install the piston and connecting rod.
105 lb⋅ft). Refer to "Piston and Connecting Rod" in this
section.
Special Tool 8. Install the oil pump.
Refer to "Oil Pump" in Section 1H, Engine
Angle gauge: 5-8840-0266-0
Lubrication.
NOTE: 9. Install the timing gear train.
Check that the crankshaft turns smoothly. Refer to "Timing Gear Train" in this section.

10. Install the crankshaft rear oil seal.
Refer to "Crankshaft Rear Oil Seal" in this
section.
12. Install the crankshaft front oil seal.
Refer to "Crankshaft Front Oil Seal" in this section.
Cooling.
Lubrication.
15. Install the supply pump.
Refer to "Supply Pump" in Section 1D, Engine
Fuel.
17. Install the engine assembly to the vehicle.

LNW71BLF002201
(a) M14; 98 N⋅m (10 kg⋅m / 72 lb⋅ft) → 132 N⋅m (13.5 kg⋅m / 98 lb⋅ft) → 30° to 60°
M10; 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
Cylinder Block
Components
LNW81BLF002101
Legend
1. Cylinder liner 2. Cylinder block
Removal 5. Remove the water pump.

1. Remove the engine assembly from the vehicle.
Cooling.
Refer to "Engine Assembly" in this section. 6. Remove the front cover.
2. Remove the cylinder head. Refer to "Front Cover" in this section.
Refer to "Cylinder Head" in this section. 7. Remove the timing gear train.
3. Remove the supply pump. Refer to "Timing Gear Train" in this section.
Refer to "Fuel Supply Pump" in Section 1D, Engine 8. Remove the oil pump.
Fuel. Refer to "Oil Pump" in Section 1H, Engine
4. Remove the oil pan. Lubrication.
Refer to the "Oil Pan" in Section 1H, Engine 9. Remove the piston and connecting rod.
Lubrication. Refer to "Piston and Connecting Rod" in this
section.

10. Remove the crankshaft. 5. Measurement of cylinder liner wear
Refer to "Crankshaft" in this section. • Inspect the inner surface of the liner for
11. Remove the piston oil jet. scratches or damage.
• For the liner inner diameter, measure the
maximum wear (much wear in rotation
direction) of approximately 15 to 20 mm(0.59 to
0.79 in) position from the liner surface with the
cylinder block installed. Replace the liner if that
exceeds the use limit.
LNW21BSH026401
12. Remove the cylinder liner.
Inspection
BLW51BSH005401
1. Gently remove foreign materials such as water
deposit adhering to the top surface of the cylinder
block. Inner diameter of cylinder liner mm (in)
• Be careful not to damage the cylinder block.
115.031 – 115.050
2. Gently remove the liquid gasket on the crankcase Standard values
(4.5288 – 4.5295)
installation surface.
3. Clean the cylinder block. Limit 115.20(4.5283)
4. Visually inspect the cylinder block.
NOTE:
• Perform the collar check and water pressure (or
There is only one type of replacement cylinder liner
air pressure) test, and replace the cylinder
bore (inner diameter). There is no need to select the
block if cracks or other damage is found.
grade.
6. Measure the flatness.

• Pull out the cylinder liner and remove all water
deposit on the top of the cylinder block.
• Use a simple straight ruler and thickness gauge
to measure the four sides of the cylinder block
top surface and two locations in a diagonal line.
• Replace the cylinder block if the measured
value exceeds the limit.
Deformation on the cylinder block top

surface mm (in)
Standard values 0.05(0.0020) or less
Limit 0.20(0.0079)
LNW81BSH004501
Cylinder block inner diameter, liner grade (reference)

mm (in)
Grade (1,2) (1X) (3) (3X)
Cylinder 118.001 – 118.020 118.021 – 118.030
block Inner (4.64570 – (4.64649 –
diameter 4.64645) 4.64684)
Lining 117.991 – 118.000 118.001 – 118.010
outer (4.64531 – (4.64570 –
diameter 4.64566) 4.64605)
(Reference)
When replacing the liner, replenishment with
the "liner set" can be performed by replenishing
the liner with piston grade that matches the
LNW21BSH026901
inner diameter of the liner, per cylinder, if the
liner outer diameter grade is specified.
Installation 2. Install the cylinder liner.
• Install straight into the cylinder block.
1. Selection of the cylinder liner grade
• Do not tap or apply excessive force when
• The cylinder block inner diameter grades are
inserting the liner.
marked at the arrows in the diagram of the
cylinder block. Select the liner depending on NOTE:
the outer diameter grade of that. Thoroughly clean the cylinder block and cylinder liner
• Matching grades for cylinder block and liner and install them after air-blowing.
outer diameter
Cylinder block (marked) 1,2 3

Lining outer diameter 1X 3X
LNW21BSH027101
3. Protrusion amount of the cylinder liner.

Use a dial indicator to measure the protrusion
amount of cylinder liner.
The difference of protrusion amounts of adjacent
LNW81BSH004401 cylinder liner should not exceed 0.03 mm(0.0012
in).
Projection amount of the cylinder liner mm (in)

Standard values 0.05 – 0.10(0.0020 – 0.0039)

NOTE: 7. Install the oil pump.
After replacing the cylinder liner, always measure the Refer to "Oil Pump" in Section 1H, Engine
protrusion amount of the cylinder liner. Lubrication.
8. Install the timing gear train.
Refer to "Timing Gear Train" in this section.
Cooling.
Lubrication.
Refer to "Fuel Supply Pump" in Section 1D, Engine
Fuel.
14. Install the engine assembly to the vehicle.
LNW21BSH026801
4. Install the piston oil jet.

• Align the oil jet knock pin to the cylinder block
pin hole and tighten with a check valve.
NOTE:
Be careful not to deform or damage the oil jet nozzle.
LNW21BSH065701

Refer to "Crankshaft" in this section.
6. Install the piston and connecting rod.
Refer to "Piston and Connecting Rod" in this
section.

LNW71BSF000801
(a) 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)

MEMO
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Engine Cooling (4HK1) 1C-1
ENGINE
Engine Cooling
(4HK1)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1C-2
Functional and Operational Description . . . . . . 1C-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1C-6
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1C-9
Phenomenon:The Engine has Overheated. . . 1C-10
Phenomenon:The Engine has Overcooled. . . 1C-11
Primary Specifications. . . . . . . . . . . . . . . . . . . 1C-11
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-13
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-17
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Engine Coolant Temperature Sensor . . . . . . . . . 1C-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-23
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-25
Engine Coolant Replacement Guidelines . . . . 1C-26
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-29
List of Tightening Torques . . . . . . . . . . . . . . . . 1C-31
1C-2 Engine Cooling (4HK1)
Cooling System
Maintenance Precautions Functional and Operational Description
WARNING: Coolant System
Do not loosen or remove the radiator cap when the The coolant system is a force-circulation system, and
coolant is hot. Steam and boiling water can burst out its main components are a water pump, thermostat and
from the radiator possibly causing burns or heat related radiator. Oil in Smoother system is cooled by the
injuries. When opening the radiator cap, place a thick coolant in the radiator.
cloth over the cap when the coolant is cooled, and turn
it gradually to release the pressure before opening it.
9 10
4
5
6
3
2 11
8
17
1
12
16
13
14
18
15
LNW71CLF001101
Legend
1. Radiator 10. EGR cooler
2. Radiator cap 11. Turbo charger
3. Reserve tank 12. Water jacket
4. Air removal plug 13. Cylinder block drain plug
5. Water outlet pipe 14. Oil cooler
6. Thermostat (2 units) 15. Heater core
7. Engine temperature sensor 16. Water pump
8. Bypass pathway 17. Cooling fan
9. EGR cooler 18. Drain plug

Water pump
The water pump is a centrifugal impeller type pump. It
is driven by the engine fan belt.
Since the water pump cannot be disassembled, replace
the water pump assembly when there is an
abnormality.
2
3
6
5
MFW81CMF000101
Legend
1. Fan center 4. Seal unit
2. Water pump pulley 5. Impeller
3. Liquid gasket application groove 6. Bearing

Thermostat
The thermostat is a wax pellet type and there is a total
of two used. One is used (bottom bypass type) for an
opening valve temperature of 82°C(180°F), and the
other is used for an opening valve temperature of
85°C(185°F). This structure enables fine water
temperature adjustments. The thermostat is installed in
the thermostat housing.
2 2
5
5
4 4
3
3
LNW21CMF001301
Legend
1. Jiggle valve 4. Gasket
2. Open valve temperature marking 5. Piston
3. Valve

Radiator
The radiator is a tube type with a corrugated fin. To
raise the boiling point of the coolant, a radiator cap with
an open valve pressure of 93 - 122 kPa (0.9 - 1.2 kg/
cm2 /13 - 17 psi) is installed.
MFW71CSH000101

Functional Inspection
Engine coolant level detection
• Inspect the coolant level in the reserve tank (1). If
the level is within its MAX (upper limit) and MIN
(lower limit), it is the appropriate amount. Note that
if there is insufficient coolant, remove the reserve
tank cap and pour in a mixture of water and engine
coolant at the appropriate proportion and fill the
tank to the MAX line. (Refer to Coolant section.)
Vehicles 19.0 L
Coolant
(4.18 lmp⋅gal)
Standard Amount
(Within MIN – MAX level)
value
Replacement
Every 2 years
period
LNW41CSH000101
1 Coolant concentration inspection

1. Engine coolant concentration.
• Because the freezing temperature of engine
coolant differs according to the concentration of
2
the coolant, change the concentration
3 according to minimum temperature.
• Do not use anything other than engine coolant
specified by Isuzu and water.
• If the mixing ratio of the engine coolant is higher
than 60%, it overheats easily. If it is less than
30%, it will not be sufficient to prevent
corrosion.
When it is used at the temperature of -30°C (-
22°F) or below, make the concentration to 55%.
MFW81CSH000501
Legend
1. Reserve tank Coolant
Region where used
2. MAX Concentration
3. MIN General regions, regions where the
lowest temperature is -12°C (10.4°F) 30%
or above
Coolant Leaks Inspection
• Add 200 kPa (2.0 kg/cm2 /28.4 psi) pressure using Cold regions, regions where the
the radiator cap tester to inspect for leaks in the lowest temperature is -30°C (-22°F) 50%
following locations. Also, inspect the radiator hose or above
and heater hose for damage or wear. Check that Regions where the lowest
hose clamps are not loose. temperature is -30°C (-22°F) or 55%
below
Inspection locations
• Radiator assembly, Water pump assembly, CAUTION:
Radiator hose, Heater hose. • For the coolant, make sure to use the products
specified (recommended) by Isuzu.
• If the coolant specified (recommended) by Isuzu is
not used, the engine, radiator or heater core may be
damaged.

• Never use the coolant which contains borate or • After measuring the temperature and relative
silicate. The engine, radiator or heater core may density, find the concentration from the table
corrode, causing a water leakage. below.
2. Measurements of engine coolant concentration.

Hydrometry 1.100
• Use an antifreeze hydrometer to measure the 1.090
specific gravity and coolant temperature. 1.080 50%
1.070
SPECIFIC GRAVITY
CAUTION:
If you remove the cap when it is hot, be careful 1.060
because the coolant will burst out. 1.050 30%
• Use a container that is deeper than the length
1.040
of the hydrometer. 1.030
1.020
1.010
1.000
2
0 10 20 30 40 50 60 70
TEMPERATURE
MFW91CSH001001
1 Coolant Scope Method

• Measure the concentration using a coolant
scope.
Engine Cooling Water Replacement Procedure

NOTE:
Replace the coolant every two years. Wash the radiator
cap, radiator and coolant passage at the same time.
LNW41CSH000201 1. Check that the engine is cool.

Legend
WARNING:
1. Radiator
Do not loosen or remove the radiator cap when the
2. Density gauge
coolant is hot. Steam and boiling water can burst out
from the radiator possibly causing burns or heat related
injuries. When opening the radiator cap, place a thick
• The temperature of the coolant should be within cloth over the cap when the coolant is cooled, and turn
0 - 50°C (32 - 122°F) for measurement. it gradually to release the pressure before opening it.
2. Remove the radiator cap.

3. Open the coolant drain plug of the radiator, loosen
the air removal plug of the water outlet pipe and
drain the coolant.
4. Tighten the drain plug.
5. Fill tap water in the radiator until it is completely
full, and then tighten the air removal plug.
Air removal plug
6. Inspect and clean the radiator cap. If the cap is

defective, replace it.
7. Install the radiator cap firmly.
8. Fill tap water in the reserve tank to its "MAX" line.
9. Close the cap of the reserve tank.

10. Start the engine, and idle the engine for 20
minutes. Stop the engine, and drain tap water after
it is completely cooled down.
11. Fill the coolant in the radiator until it is completely
full.
• However, remove the air removal plug of the
water outlet pipe when filling the coolant. After
filling the coolant, tighten the air removal plug.
Air removal plug

13. Fill the coolant in the reserve tank to its "MAX" line.
15. Start the engine.
16. Let the engine idle for 2 to 3 minutes at a normal
idling speed, and then stop it.
17. After confirming that the coolant is cooled down,
open the radiator cap and pour in more coolant if
the level has dropped.
18. After firmly closing the radiator cap, warm up the
engine at approximately 2000 r/min.
19. After the water temperature gauge indicator has
passed the center, idle the engine for about 5
minutes at a normal idling speed, then stop the
engine and let the vehicle stand.
necessary. If the coolant level is excessively low,
check for the coolant leakage.
21. Firmly close the radiator cap.
22. Fill the coolant in the reserve tank again to its
"MAX" line.

Failure Symptom List
• The engine has overheated.
• The engine has overcooled.

Phenomenon:The Engine has Overheated.

The engine has overheated Coolant is insufficient Refill
Defective thermostat Replace the thermostat
Defective water pump Replace the water pump
Radiator clogging Clean or replace
Defective radiator cap Replace the radiator cap
Insufficient engine oil or improper Refill or replace engine oil
engine oil was used
Defective cylinder head gasket Replace the cylinder head gasket
Looseness of fan belt Adjust or replace
Exhaust system clogging Clean or replace
Excessive fuel injection amount Diagnose engine control system

Phenomenon:The Engine has Overcooled.

The engine has overcooled. Defective thermostat Replacement
Coolant system method Force circulation method

Radiator Tube with corrugated fins
Heat dissipation capacity kW (Kcal/h) 127.2 (109,400)
Heat dissipation surface
m2(ft2) 17.65 (189.98)
area
Front surface area m2(ft2) 0.364 (3.92)
Dry mass kg(lb) M/T vehicles:18.3(40.4) / Smoother vehicles:18.5(40.8)
Radiator cap
Open valve pressure kPa (kg/cm2 /psi) 93 - 122 (0.9 - 1.2 / 13 - 17)
Coolant capacity L (lmp⋅gal) 3.2 (0.70)
Water pump Centrifugal impeller method
Pulley ratio 1.190
Thermostat Wax pellet type
Open valve temperature °C (°F) 85(185) (With jiggle valve)/82(180) (without jiggle valve)
Full-open temperature
°C (°F) 100(212) (With jiggle valve)/95(203) (without jiggle valve)
(More than 8mm/0.315in)
Coolant total capacity
L (lmp⋅gal) 19.0 (4.18)
[reference values]
Water Pump
Components
7
6
5
LNW71CMF000901
Legend
1. Radiator lower hose 5. Water pump pulley
2. Fan guide 6. Fan belt
3. Fan assembly 7. Water pump assembly
4. Set plate

Removal 5. Loosen the adjust plate lock nut (3) and generator
tightening bolt (2).
1. Drain the engine coolant.
Loosen the generator adjust bolt (1) to remove the
fan belt.
MFW71CSH000201 1 2
Legend MFW71CSH001601
1. Radiator drain Plug
Legend
1. Adjust bolt
2. Remove the radiator lower hose at the radiator
2. Generator tightening bolt
side.
3. Adjust plate lock nut
3. Remove the fan guide from below.
4. Remove the four fan assembly tightening nuts (2)
to remove the fan assembly (1). At that time, 6. Remove the set plate (3) and water pump pulley
loosen the water pump pulley (3) and set plate (2).
collective-fastening bolts (5). 7. Insert a screwdriver into the position shown in the
drawing to remove the water pump assembly by
prying it out.
1 3
2 1
MFW81CSH000601
3
Legend
1. Fan assembly LNW71CSH002401
2. Fan assembly tightening nut (four pieces) Legend
3. Water pump pulley 1. Water pump assembly
4. Set plate 2. Water pump pulley
5. Set plate collective-fastening bolt 3. Set plate

Inspection • Apply liquid gasket (ThreeBond 1207B) to
about 3 to 5 mm(0.12 to 0.20 in) width in the
1. External inspection.
groove of the water pump installation surface.
• Inspect the pump body for cracks and damage.
• Install the water pump by aligning to the front
• Inspect the impeller for cracks and corrosion. cover stud.
• Inspect for water leaks from the seal unit. • After applying the liquid gasket, Install within 5
• When you find a problem, replace with the minutes.
water pump assembly. • See the drawing for the position to apply the
liquid gasket.
1 2 3
b c
LNW21CSH000901
a
2. Inspection of the bearing unit.
• Rotate the fan while pushing the fan center to
the radius direction and inspect for any notable
MFW81CSH000401
rattling or abnormal sounds.
• When you find a problem, replace with the Legend
water pump assembly. 1. OK
2. OK
3. NG
4. a:0.5 to 1.5 mm(0.020 to 0.06 in)
5. b:3 to 5 mm(0.12 to 0.20 in)
6. c:1 mm(0.04 in) More than
LNW21CSH001001
Installation
1. Install the water pump assembly.

2. Temporarily tighten the bolt until the water pump
pulley (1) is seated together with the set plate (2)
on the water pump assembly.
2
1 2
MFW71CSH001601
Legend
1. Adjust bolt
LNW71CSH002501
Legend 3. Adjust plate lock nut
1. Water pump pulley
2. Set plate
5. After adjusting the fan belt, tighten the temporarily
tightened water pump pulley and set plate at the
3. Install the fan belt, and tighten the generator adjust specified torques.
bolts to adjust the tension of the belt.
• Refer to "Drive Belt" in this section.
4. After adjusting the fan belt, tighten the generator at
6. Install the fan assembly (1) and tighten it at the
specified torque.
Tightening torque
Adjust plate lock Tightening torque 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
nut (3)
Generator tightening
126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
bolt (2)
1 3
2
MFW81CSH000601
Legend
1. Fan assembly
2. Fan assembly tightening nut (four pieces)
4. Set plate
5. Set plate collective-fastening bolt

9. Refill the engine coolant.


MFW71CLF000301
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m / 93 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Thermostat
Components
LNW41CMF000201
Legend
1. Radiator upper hose 3. Thermostat
2. Water outlet pipe 4. Gasket
Removal
1. Discharge coolant. Prepare a container for
discharge and use it for filling when installing the
thermostat. The amount of coolant to be
discharged should not be enough to avoid coolant
spilling from the thermostat housing.
2. Remove the radiator upper hose at the radiator
side.
4. Remove the thermostat.
5. Remove the gasket from the thermostat.
Inspection
1. Inspect the water outlet pipe for corrosion, etc.
2. Inspect the thermostat.
• Inspect the thermostat pellet, spring, shaft, jiggle
valve and crimped sections for damage.
• Place the thermostat in water, and raise the water
temperature while thoroughly stirring it.

• Measure the temperatures when the valve starts 2. Install the water outlet pipe.
opening and when it is fully opened.
Refer to “Primary Specifications” for open valve
temperature and full-open temperature. Tightening torque 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
LNW21CSH003401
Installation
1. Install the gasket (1) to the thermostat, and install
to the position in the drawing.
MFW71CSH000401
• There are two types of thermostats (1) with
different shapes. Make sure to install them to 4. Fill the coolant stored when discharged, and check
the positions shown in the diagram. that the coolant is at the specified level.
• Securely insert so that the thermostat gasket
does not ride up outside of the cylinder head
side housing.
1
MFW71CSH000301
1 2
Legend
1. Reserve tank
LNW21CSH000201
Legend
1. Thermostat
2. Cylinder head
Engine Coolant Temperature Sensor

Removal Example of how to measure the thermistor
characteristics
1. Disconnect wiring connector.
2. Remove the engine coolant temperature sensor.
Inspection
ECM thermo sensor is a thermistor type whose
characteristics is that the electrical resistance
decreases as the temperature rises.
1 2
MFW71KSH000201
1 2
Resistance value at a certain temperature
(approximate value)
– 20°C (– 4°F) Approx. 15.48kΩ
3
0°C (32°F) Approx. 5.79kΩ
MFW71CSH000601 20°C (68°F) Approx. 2.45kΩ
Legend 40°C (104°F) Approx. 1.148kΩ
1. Indicates the wiring
2. Indicates the wiring 60°C (140°F) Approx. 0.5865kΩ
3. ECM thermistor 80°C (176°F) Approx. 0.3222kΩ
100°C (212°F) Approx. 0.1884kΩ
1. Place the temperature sensor section of the

sensor into water. Inspect whether the changes in
resistance value correspond to the values in the
thermistor characteristics graph while changing the
water temperature.
NOTE:
Be careful not to allow water to get into the terminal
section. Wipe off the water droplets on the sensor after
the inspection.
Thermistor characteristic
30
20
10
7.0 1
)
5.0
Resistance value(k
3.0
2.0
1.0
0.7
0.5 2
0.3 MFW81CSH000101
0.2 Legend
0.1
1. Engine coolant temperature sensor
-20/-4 0/32 20/68 40/104 60/140 80/176 100/212 120/248 2. Loctite application area
Engine coolant temperature( )
2. Install the wiring connector.
LNW91CMH000201
• If any abnormality is found in the inspection

results, replace it with a normal one.
Installation
1. Apply LOCTITE 262 or 962 to the engine coolant
temperature sensor threaded portion and tighten at

Radiator
Components
2 3
4
5
MFW81CLF000101
Legend
1. Coolant reserve tank hose 5. Fan guide
2. Air removal plug 6. Intercooler
3. Radiator upper hose 7. Radiator lower hose
4. Radiator
Removal
1. Loosen the radiator drain plug (1), and completely
drain the coolant.
• After draining, securely tighten the drain plug
(1).

7. Be careful not to damage the radiator core with the
fan blades. Remove the bracket tightening nuts on
the left and right sides of the radiator, remove the
radiator stay and then the radiator.
MFW71CSH000201
2. Remove the intercooler air change pipe.

3. Remove the radiator upper hose at the radiator
side.
4. Remove the radiator lower hose at the radiator
side.
5. Remove the coolant reserve tank hose from the
radiator side.
• Remove the oil cooler hose for Smoother only.
A small amount of oil will come out when
removing it, so collect it using a tray.
MFW81CMH000201
Inspection
Radiator cap
1. Use the radiator cap tester to inspect the open
valve pressure. Replace the radiator cap if the
open valve pressure is not at the standard value.
2 kPa(kg/cm2/psi)
Positive pressure ;
3 Cap operating 93 – 122 (0.9 – 122/13 – 17)
pressure Negative pressure ;
Min 4.9 (0.05/0.7)
4
MFW71CSH001501
Legend
1. Radiator stay
2. Intercooler
3. Radiator
4. Oil hose
6. Remove the fan guide from below.


• Adhering matter which easily comes off with a
splash of tap water should be washed off
sufficiently in advance.
NOTE:
Do not use a high-pressure washer or brush.
3. Prepare a mild detergent.

• Use a type which contains approx. 8% of
surface acting agent.
NOTE:
Do not use anything other than a mild detergent. Use of
any product other than a mild detergent may cause
corrosion.
4. Spray the mild detergent onto both sides of the

fins, and leave them as is for 10 minutes.
LNW21BSH000201
5. Rinse off the mild detergent using a high-pressure
washer.
2. Inspect the condition of the negative pressure • Start washing from the engine side of the
valve in the center of the cap valve seat side. If the radiator.
valve seat is not operating smoothly because of
rust or foreign matter, clean or replace the radiator NOTE:
cap. • Apply the high-pressure water in a direction
perpendicular to the fins.
Radiator core • Do not bring the high-pressure water too close to
1. Deformed radiator fins can cause inefficient heat the fins.
dissipation. So, repair the fins, or it can lead to • Be careful not to deform the fins.
overheating. When repairing, take sufficient care
not to damage the base of the fins.
• Remove filth or other foreign materials.
CAUTION:
Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts. 1
Cleaning the radiator

1. Clean the inside of the radiator and coolant path
with tap water. Clean away all scales and rust.
Cleaning
Washing inside the radiator and the water passage.
Wash the inside of the radiator and coolant path with
water.
Wash away all scales and rust.
MFWA1CSH001101
Washing the radiator core Legend
CAUTION: 1. Radiator
radiator, intercooler and surrounding parts when they 6. After washing is finished, inspect the fins to
are still installed on the vehicle. confirm that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again.
1. Seal the hose connecting section with a cap or
fabric tape. NOTE:
2. Sufficiently wet the front and back surfaces of the If some dirt is still left, fine black particles attached on
radiator. the fins can be seen.

7. Rinse off the detergent constituents on the fins and 5. Install the radiator upper hose.
resin parts using the tap water.
8. Remove the seal on the hose connecting section.
9. Clean and dry the hose connecting section
sufficiently.
6. Install the charge air pipe to the intercooler.
Installation 8. Tighten the air removal plug.
1. Be careful not to damage the radiator core with the
fan blades. Install the left and right brackets of the
radiator to the stud bolt as shown in the diagram. Tightening torque 23.5 N⋅m (2.4 kg⋅m/17 lb⋅in)
Tightening torque
Lower side nut 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
7
3
6
5
4
MFWA1CSH001501
Legend
1. Upper side nut
2. Stud bolt
3. Rubber
4. Lower side nut
5. Frame
6. Radiator side bracket
7. Washer

3. Install the coolant reserve tank hose to the
radiator.
• For Smoother, install the oil hose, too.


Engine Coolant Replacement Guidelines
NOTE: 18. After firmly closing the radiator cap, warm up the
Replace the coolant every two years. Wash the engine at approximately 2,000 r/min.
radiator cap, radiator and coolant passage at the same 19. After the water temperature gauge indicator has
time. passed the center, idle the engine for about 5
minutes at a normal idling speed, then stop the
1. Check that the engine is cool. engine and let the vehicle stand.
WARNING: 20. After confirming that the coolant is cooled down,
Do not loosen or remove the radiator cap when the open the radiator cap and pour in more coolant if
coolant is hot. necessary.
Steam and boiling water can burst out from the radiator If the coolant is excessively low, check for the
possibly causing burns or heat related injuries. coolant leakage.
When opening the radiator cap, place a thick cloth over 21. Firmly close the radiator cap.
the cap when the coolant is cooled, and turn it 22. Fill the coolant in the reserve tank again to its
gradually to release the pressure before opening it. “MAX” line.
3. Open the coolant drain plug of the radiator, loosen
the air removal plug of the water outlet pipe and 1
drain the coolant.
4. Tighten the drain plug.
5. Fill tap water in the radiator until it is completely
full, and then tighten the air removal plug. 2
3
Tightening torque
Air removal plug 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
6. Inspect and clean the radiator cap. If the cap is

defective, replace it.
8. Fill tap water in the reserve tank to its “MAX” line. MFW81CSH000501
9. Close the cap of the reserve tank. Legend
10. Start the engine, and idle the engine for 20 1. Reserve tank
minutes. Stop the engine, and drain tap water after 2. MAX
it is completely cooled down. 3. MIN
• However, remove the air removal plug of the
water outlet pipe when filling the coolant. After
filling the coolant, tighten the air removal plug.
Tightening torque
Air removal plug 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
11. Fill the coolant in the radiator until it is completely

full.
13. Fill the coolant in the reserve tank to its “MAX” line.
16. Let the engine idle for 2 to 3 minutes at a normal
idling speed, and then stop it.
the level has dropped.
Drive Belt
Components
(50A,60A specifications)
1 2
3
4
5
6
13
7
12
11 9
10
4 9
MFW71CMF000101
Legend
1. A/C compressor 8. Tension pulley
2. Adjust plate lock nut 9. Generator drive belt
3. Adjust plate 10. Crank pulley
4. A/C drive belt 11. Generator tightening bolt
5. Water pump pulley (fan pulley) 12. Generator
6. Tension pulley lock nut 13. Adjust bolt
7. Tension pulley adjust bolt

(90A specification)
3 4 6
2
8
5
10
17
11
18
12
7 5 8 16
13
15
14
MFW81CMF000201
Legend
1. A/C compressor 10. Idle pulley (for A/C compressor)
2. Tension pulley (for refrigerator compressor) 11. Tension pulley (for A/C compressor)
3. Tension adjust bolt (for refrigerator compressor) 12. Tension adjust bolt (for A/C compressor)
4. Tension pulley lock nut (for refrigerator 13. For tension pulley lock nut (for A/C compressor)
compressor) 14. Crank pulley
5. Generator drive belt 15. Tension pulley (for generator drive belt)
6. Water pump pulley (fan pulley) 16. Tension pulley lock nut (for generator drive belt)
7. A/C drive belt 17. Tension adjust bolt (for generator drive belt)
8. Drive belt of refrigerator compressor 18. Generator
9. Refrigerator compressor
Inspection
Inspect the drive belt for wear and damage. Replace it
if necessary.
Also inspect belt tension. Adjust the tension if
necessary.

Inspection guidelines Belt tension adjustment value
Press on the specified position on the belt with 98 N (10 Frequency
kg/22 lb) of pressure to inspect the amount of belt flex. Amount of
of
Belt types flex
vibrations
mm(in)
(Hz)
a
1 Generator 4.9 - 5.9
New belt 208 - 232
2 50, 60A
Reused 6.9 - 7.7
belt (0.27-0.30)
Generator 5.4 - 6.6
New belt 190 - 212
90A
Reused 7.5 - 8.5
belt (0.30-0.33)
19.6 - 23.6
New belt 59 - 73
(0.77-0.93)
A/C drive belt
b 1 Reused 24.1 - 27.5
51 - 59
belt (0.95-1.08)
2
Adjustment
When adjusting the tension of the drive belt, do so for
both the generator drive belt and the A/C drive belt.
NOTE:
After adjusting the generator drive belt, adjust the A/C
drive belt.
LNW71EMH000201
50A,60A specification generator drive belt
Legend adjustment
1 A/C drive belt 1. Loosen the A/C drive belt tension pulley lock nut
2 Generator drive belt and adjust bolt to free the belts.
(a) 50A ,60A specifications 2. Loosen the adjust plate lock nut and generator
(b) 90A specification tightening bolt.
3. Turn the adjust bolt to adjust the generator drive
belt.
Reference
4. After adjusting, tighten the adjust plate lock nut
NOTE:
and generator tightening bolt at their specified
• A V-ribbed belt is used for the generator drive belt, torques.
which requires a more accurate tension
adjustment than conventional V belts.
Therefore, use a sonic tension meter to check that Tightening torque
the measured frequency of vibrations is within the
Lock nut 76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
adjustment value.
Perform adjustment if the value is improper. Generator
126 N⋅m (12.8 kg⋅m/93 lb⋅ft)
If the tension is improper, the belt life will be tightening bolt
reduced, or the belt can squeak.
• After the adjustment, securely tighten each bolt. 90A specification generator drive belt adjustment
1. Loosen the A/C drive belt tension pulley lock nut
and adjust bolt to free the belts.
2. Loosen the generator drive belt tension pulley lock
nut.
3. Turn the generator drive belt tension pulley adjust
bolt to adjust generator drive belt.

4. After adjusting the generator drive belt, tighten the
generator drive belt tension pulley lock nut at its
specified torque.
Tightening torque
Lock nut 41 N⋅m (4.2 kg⋅m/ 30 lb⋅ft)
Adjusting the A/C drive belt

1. Loosen the tension pulley lock nut.
2. Turn the tension pulley adjust bolt to adjust the
belt.
3. After adjusting, tighten the lock nut at the specified
torque.
Tightening torque
Adjusting the drive belt of the compressor for the

refrigerator
1. Loosen the tension pulley lock nut.
2. Turn the tension pulley adjust bolt to adjust the
belt.
3. After adjusting, tighten the lock nut at the specified
torque.
Tightening torque

50,60A specifications
c
MFW71CSF000101
(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m / 93 lb⋅ft)
90A specification
b
c
LNW71CSF000401
(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
MEMO
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Engine Fuel (4HK1) 1D-1
ENGINE
Engine Fuel
(4HK1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-41
Maintenance Precautions . . . . . . . . . . . . . . . . . 1D-2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-41
Description of Function and Operation . . . . . . . 1D-2 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-43
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1D-6 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-43
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1D-7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-43
Phenomenon: Starting is Difficult . . . . . . . . . . . 1D-8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-44
Phenomenon: Hunching when idling. . . . . . . . . 1D-9 Tightening Torque Table . . . . . . . . . . . . . . . . . 1D-45
Phenomenon: Insufficient output. . . . . . . . . . . 1D-10 Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-46
Phenomenon: Engine does not stop . . . . . . . . 1D-11 Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-46
Phenomenon: Exhaust Gas is Blue or Black . 1D-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-46
Primary Specifications. . . . . . . . . . . . . . . . . . . 1D-12 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-46
Fuel Filter Element . . . . . . . . . . . . . . . . . . . . . . . 1D-13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-47
Maintenance Precautions . . . . . . . . . . . . . . . . 1D-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . 1D-15
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Water Sedimenter Switch. . . . . . . . . . . . . . . . . . 1D-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
List of Tightening Torques . . . . . . . . . . . . . . . . 1D-24
Common Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-27
Fuel Pressure Sensor (Common Rail) . . . . . . . . 1D-31
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-32
Pressure Limiter (Common Rail) . . . . . . . . . . . . 1D-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-33
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-33
Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . 1D-34
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-35
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-36
Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . 1D-40
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Fuel Rail Pressure (FRP) Regulator . . . . . . . . . 1D-41
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1D-41
1D-2 Engine Fuel (4HK1)
Fuel System
Maintenance Precautions Working procedures
Including the inside of the injector, the holes and gaps • When the fuel pipe, injection pipe, injector, supply
that are the fuel paths for the fuel system have an pump, and common rail have been removed,
extremely precise finish. Therefore, because there is quickly apply a seal to the fuel opening.
the possibility of damage if foreign material becomes • Store the eyebolt and gasket in a clean parts box
mixed in, cover the cap after removing parts, etc. to with a cover so that foreign material does not
prevent the entry of foreign material. attach to them.
The injector ID plate is specific to that injector. Do not • Leaking fuel is the cause of fires. Therefore, after
confuse other injector ID code plates. completing the work, wipe away any leaked fuel,
When the injector assembly is replaced, use the scan and check for fuel leaks after starting the engine.
tool to write the ID code to the ECM. For details on
writing, refer to "Repair Instructions" in Section 1A,
Engine Control System.
The fuel moisture removal agent has a nature of
absorbing moisture into diesel oil and is the cause of
rust. Therefore, do not use moisture removal agents in
the fuel tank.

Fuel system diagram
5
3
6
1 2 4
7
11
10 9
MFW81DSF000101
Legend
1. Common rail (Fuel rail) 7. Breather valve
2. Pressure limiter 8. Fuel feed pipe
3. Leak-off pipe 9. Fuel filter (with sedimenter)
4. Injector 10. Recirculation valve
5. Fuel return pipe 11. Supply pump
6. Fuel tank

Common rail
RTW76CLF000601
Legend
1. Pressure limiter 2. Fuel pressure sensor

Supply pump
3
MFWB1DLF000401
Legend
1. Fuel temperature sensor 3. High pressure pipe
2. Fuel rail pressure (FRP) regulator / Suction 4. Camshaft key
control valve (SCV)

Injector Fuel filter
1
1 2
8
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00
7 3
6 4 6
3
5 4
5
MFW71DMH000201 MFW61DMH000101
Legend Legend
1. ID plate 1. Priming pump
2. Terminal stud 2. Element
3. Injector drive section 3. Drain plug
4. Injector assembly 4. Float
5. Gasket (cone type) 5. Switch connector
6. O-ring 6. Case
7. Fuel outlet port 7. Body assembly
8. Recirculation valve

Air removal • Install a plastic hose, etc. to the end of the drain
1. Loosen the air removal plug of the fuel filter. plug.
2. Operate the priming pump to feed the fuel by • Prepare a container at the end of the vinyl hose
pressure. Confirm that the fuel containing air attached to the drain plug.
bubbles comes out from the air removal plug. • Loosen the drain plug.
3. When there is no more air bubble coming out, • Press the priming pump several times to discharge
tighten the air removal plug. the water.
• After discharging, tighten the drain plug.
• Press the priming pump several times to check
that no fuel is leaking.
• Check that the warning light is extinguished.
4. After tightening the plug, operate the priming pump
for about 150 times (until it gets heavy enough). NOTE:
5. Wipe off the leaked fuel. • The discharged water contains fuel. Therefore,
6. Start the engine. follow processing regulations established by your
heck that there is no fuel leakage. If the engine local area when discarding the water.
does not start, repeat the procedures from step 1. • If fuel sticks to the vehicle body, etc. wipe it clean.
MFW81DMH000101
Legend
1. Priming pump
2. Air removal plug (with a rubber cap)
Moisture removal
If more than the specified amount of water builds up in
the sedimenter, the warning light will turn on. In such
cases, use the following procedures to remove the
water.

• Starting is difficult
• Hunching when idling
• Insufficient output
• Engine does not stop
• Exhaust gas is blue or black

Phenomenon: Starting is Difficult

Starting is difficult Fuel tank is empty Refill the fuel
Clogging of the fuel tank breather Clean the fuel tank breather
Air entering into the fuel Remove the air in the fuel system
Clogging of or damage to the fuel line. Repair or replace the fuel line
Loose fuel line connection
Feed pump problem Replace the supply pump
Regulating valve is open Replace the regulating valve
Locking of the injector nozzle Replace the injector

Phenomenon: Hunching when idling

Hunching when idling Fuel is frozen Slowly warm up the engine and raise
the engine return fuel temperature
Air mixture in the fuel system Remove the air in the fuel system
Leak or clogging of fuel system Repair or replace the fuel system
Water mixture in the fuel system Replace the fuel
Injector opening valve pressure drop, Replace the injector
atomizing problem
Feed pump malfunction Replace the supply pump

Phenomenon: Insufficient output

Insufficient output Clogging of the fuel tank breather Clean the fuel tank breather
Air mixture in the fuel system Remove the air in the fuel system
Leak or clogging of fuel system Repair or replace the fuel system
Water mixture in the fuel system Replace the fuel
Clogging of the fuel filter element Replace the element (excluding when
fuel is frozen)
Engine control problem Diagnose engine control system

Phenomenon: Engine does not stop

Engine does not stop Engine control system problem Diagnose engine control system

Phenomenon: Exhaust Gas is Blue or Black

Exhaust gas is blue or black. Injector opening valve pressure drop, Replace the injector
atomizing problem
Fuel system
Item Specifications
Fuel system Electronically controlled fuel injection system
(common rail type)
Fuel Filter Element

Maintenance Precautions
• Replace the fuel filter element every 30,000 km
(18,000 mile) or once every 9 months. 1
2
Removal
3
1. Drain the fuel in the element case
a. Loosen the drain plug at the bottom of the
4
element case.
b. Loosen the air removal plug on the filter body to
remove the fuel.
5
2. Disconnect the switch connector from the element
case.
3. Use a socket wrench [“a” section width across flat:
29 mm(1.14 in)] or a general-purpose filter wrench
to remove the element case.
6
NOTE: 9
Check that the float in the element case moves
smoothly.
• Refer to “Water sedimenter switch inspection” for
alarm switch inspection. 7
8
4. Pull the element downward to remove the O-ring
around the outer surface of the filter body. a
5. If foreign material has accumulated on inner

BLW61DMH000101
surface of the filter body, wipe it with a clean cloth.
Legend
NOTE: 1. Cap
Do not use an air blower to remove the foreign 2. Air removal plug
material. If you do, that foreign material can be blown 3. Filter body
into the path on the clean side and cause failure of the 4. O-ring
supply pump. 5. Fuel filter element
6. Element case
7. O-ring
8. Drain plug
9. Switch connector
Installation
1. Insert the O-ring into the groove on the outer
circumference of the filter body. Do not let the O-
ring get damaged by the threaded portion of the
body.
2. Apply clean fuel to the gaskets inside and outside
of the element, and insert the element until it
reaches the end.
NOTE:
Do not allow foreign material to get into the four holes
on the clean side next to the inner side gasket.

• Make sure to use a genuine Isuzu fuel filter, and
replace the O-ring at the same time.
• Please abandon exchanged filters, and process
it by a regulated method.
4. Install the element case, and tighten at the
specified torque.
Tightening torque 33 Nm (3.4 kg⋅m/25 lb⋅ft)
5. Tighten the drain plug of the element case and

connect the switch connector.
1 Tightening torque 0.4 Nm (0.04 kg⋅m/3.5 lb⋅in)

2
6. Remove the air in the fuel system.

• Refer to “Air removal” in Fuel System.
7 7. Start the engine and confirm that the “Warning
light” is turned off.
6
4
5
MFWA1DLH000101
Legend
1. Socket mounting position
2. Float
3. Gasket (outside)
4. Gasket (inside)
5. Hole on the clean side
6. Element kit
7. O-ring groove
3. Apply clean fuel to the inner circumference of the

element case or to the O-ring, and tighten until it
reaches the body while preventing the O-ring from
being caught.
If the element insertion does not reach the case,
the element is not completely inserted. Press while
turning the element again.
WARNING:
Be careful so as not to pinch the O-ring when installing
the element case. If the O-ring gets stuck, fuel may leak
to cause fire.
Fuel Filter Assembly

Components
2
1
3
MFW81DMF000401
Legend
1. Fuel filter assembly 4. Fuel return hose
2. Air removal plug 5. Water sedimenter switch connector
3. Fuel feed pipe (from the fuel tank)
Removal Installation
1. Remove the filler cap. 1. Install the fuel filter assembly.
2. Disconnect the switch connector. 2. Install the fuel filter installation bolt.
3. Disconnect the feed hose and return hose from the
fuel filter.
• Plug the hoses so that fuel does not spill.
At this time, do not let foreign material get
inside. Do not use rusted bolts etc. 3. Install the feed hose and the return hose.
4. Install the switch connector.
CAUTION: 5. Remove the air in the fuel system.
Make sure that foreign material does not enter the fuel Refer to "Fuel System" in this section.
feed hose (engine side) when it is removed, as this
may cause the supply pump to fail. (Inserting a rusty
bolt, etc. is strictly prohibited)
4. Remove the fuel filter installation bolt.

5. Remove the fuel filter assembly.
Water Sedimenter Switch

Inspection
1. Remove the fuel filter case and turn it upside
down. When the float rises, check that there is
continuity between the switch connector terminals.
2. Turn the engine control switch ON, disconnect the
engine harness connector from the water
sedimenter switch connector and connect between
the engine harness connector terminals. Check
that the warning light of the sedimenter light.
• If any abnormality is found in the inspection
results, replace the fuel filter case, or repair
defective connections or open circuits between
the circuits.
2
5
4 3
MFW61DMH000201
Legend
1. Fuel filter assembly
2. Drain plug
3. Lead switch terminal
5. Water sedimenter switch connector
Injector
Components
6 7
1 8
4
11
10 13
12
14
MFWB1DLF000201
Legend
1. Injector terminal 8. Gasket
2. Injector harness bracket 9. Injector clamp
3. Noise cover 10. Injector clamp bolt
4. Cylinder head cover 11. Leak-off pipe
5. EGR cooler duct 12. Injector
6. EGR valve 13. Injection pipe
7. Gasket 14. Injection pipe clip
Including the inside of the injector, the holes and gaps Removal
that are the fuel paths for the fuel system have an
1. Disconnect the EGR valve connector and injector
extremely precise finish. Therefore, because there is
connector.
the possibility of damage if foreign material becomes
mixed in, cover the cap after removing parts, etc. to 2. Remove the EGR cooler duct (2) and EGR valve
prevent the entry of foreign material. (1).

• Use packing tape, etc. to cover the EGR case 7. Disconnect the injector leak off pipe (3).
side opening to prevent foreign material from
entering.
2
1 2
1
4 3
MFW81DSH000201
Legend
LNW91DSH001201
1. Terminal nut
2. Harness bracket
3. Remove the noise cover. 3. Leak-off pipe
4. Harness connector
8. Remove the injection pipe clip (2) to remove the

injection pipe (1).
1
1
2 2
MFWB1BSH002701
Legend
1. Noise cover
MFWA1DSH000101
4. Remove the cylinder head cover. 9. Loosen the injector clamp tightening bolt.
5. Remove the injector terminal nut (1). 10. When it is difficult to remove the injector, set a
special tool injector remover:5-8840-2826-0 (2) on
NOTE: the injector (3) leak off pipe installation. Pull the
ID codes are unique to each injector. Put a injector clamp upward using a sliding hammer:5-
corresponding number tag on each QR plate when 8840-0019-0 (1).
storing injectors to avoid mix-up.
NOTE:
6. Loosen the injector harness bracket bolts, and When a special tool is used to pull out the injector,
remove the inside connector (4) to remove the make sure that the injector sleeve does not fall out
harness bracket (2). while working on it.

Installation
NOTE:
• When injector replaced, fuel injector ID codes is
written in ECM with scan tool.
1
1. Install a new gasket and O-rings and install to the
cylinder head with the injector clamp sandwiched
2 as shown in the drawing.
• Apply engine oil to the threaded portion of the
clamp bolt and seat surface, and temporarily
tighten.
2 3
3 4
LNW46CMH000301
BLW71BSH020401
• Store the removed injector with the cylinder Legend

number on it. Be very careful not to bump the 1. O-ring
injection hole. 2. Injector
CAUTION: 4. Injector clamp
Absolutely never touch the injector solenoids because 5. O-ring
that can hinder their performance or cause damage. 6. Gasket
2. Install the injection pipe and fasten with the clips to

the position shown in the drawing.
circumference of the injector side sleeve nut
and assemble it.
• Lightly tighten the sleeve nut with spanner so
that it is attached airtight to the injector and
common rail side.
• Tighten the injection pipe clip at the specified
torque.
LNW91BSH004401
1 5. Install the injector leak off pipe sandwiching the

new gasket and tighten it at the specified torque.
MFWA1DSH000101
Legend
1. Injection pipe
2. Injection pipe Clip
3. Tighten the injector clamp bolt that was temporarily

tightened earlier at the specified torque. MFW81BSH001701
Tightening torque 30 N⋅m (3.1 kg⋅m/22 lb⋅ft) 6. Record the fuel injector ID codes of the new
injector.
4. Tighten the injection pipe at the specified torque. • Only when injector are replaced, it does.
a. Records 24 figures of fuel injector ID plate. The
correct order for the fuel injector ID codes of the
Tightening torque following illustration is as follow:
Common rail side 25 N⋅m (2.5 kg⋅m/18 lb⋅ft) 64 DA A5 05 2F 4C 0F 36 FA 17 25 8C
2 1
64DA A505
2F4C 0F36
FA17 25 00
0000 8C
1 2
LNW76ESH002601
Legend
1. Fuel injector ID plate
MFWA1DSH000201
2. Fuel injector ID codes
Legend 3. Fuel injector
1. Injector side sleeve nut
2. Common rail side sleeve nut

7. Install the injector harness connector from the
inside and tighten the harness bracket at the 1
specified torque.
MFW81DSH000401
Legend
1. Terminal nut
2. Injector
3. Harness
9. Install the gasket to the cylinder head cover, and

LNW71DSH003701 tighten at the specified torque.
8. Install the terminal nut to the injector and tighten it

Tightening torque 2 N⋅m (0.2 kg⋅m/17 lb⋅in) 10. Tighten the noise cover at the specified torque.
CAUTION:
If the nut is over-tightened, the terminal stud can be Tightening torque 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
damaged. Never over-tighten.
2
MFWB1BSH002701
Legend
1. Noise cover

11. Paint out fuel injector ID codes of the cylinder that
replaced injector among the fuel injector ID codes
written in the code label.
• Only when injector are replaced, it does. 1 2
• Injector ID code label is on the surface of the
noise cover.
1 SAMPLE
2 64 FB 00
4HK1
00 0A 00 04 F4 F0 00 01 94
64 0B 08 10 2B 28 1E 26 17 16 31 7C
3 64
64
CB
21
1A
17
00 2F
16 2B
3C
3A
29
2D
3DFF
4A 14
27
25
5A
65
F0
66
4 LNW91DSH001201
14. Connect the engine harness connectors.

5 • Check that there is a clicking sound when
attaching the connector joints to securely
connect them.
LNW81ASH000101
Legend Programming Fuel Injector ID Codes
1. Cylinder #1 fuel injector ID code NOTE:
2. Cylinder #2 fuel injector ID code
• When injector replaced, fuel injector ID codes is
written in ECM with scan tool.
5. Injector ID code label 1. Install a scan tool.
12. Install the gasket to the EGR valve (1), and tighten 2. Turn ON the ignition, with the engine OFF.
at the specified torque. 3. Select Diagnostics > Appropriate Vehicle
identification > appropriate engine model >
Programming > Injector Programming.
Tightening torque 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft) 4. In order to get programming approval, the on
screen displays a message to user. Get
13. Install the gasket to the EGR cooler duct (2), and programming approval from the TIS 2000 using
tighten at the specified torque. the following procedure.
a. Cannot a scan tool to the terminal that installed
TIS 2000 with the latest software and the
Tightening torque hardware key is plugged into port.
EGR valve side 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft) b. Turn ON the scan tool and keep at title screen.
Cylinder head side 104 N⋅m (10.6 kg⋅m/77 lb⋅ft) c. Launch the TIS application.
EGR cooler side 28 N⋅m (29 kg⋅m/21 lb⋅ft) d. Select the Security Access at the main screen.
e. Highlight the Tech 2 on the Diagnostic Tool
Selection screen and click Next.
f. Click Close on the Security Access Enabled
screen.
g. Turn OFF the scan tool.
h. Disconnect the scan tool from the engine OFF.
5. Install a scan tool to the vehicle.
6. Turn ON the ignition, with the engine OFF.
7. Select Diagnostics > appropriate vehicle
Programming > Injector Programming.

8. Verify the fuel injector ID code, input 24 digits of
replaced fuel injector ID code.
9. After complete the programming, turn OFF the
ignition for 30 seconds.
10. Start the engine and let idle.
11. Inspect for a proper engine running condition and
for no DTC’s. Refer to Diagnostic System Check -
Engine Controls if needed.

d
a c
e
n
f
m
i
g
h
j
MFWB1DLF000301
(a) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)

(b) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(c) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(e) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(f) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(g) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(h) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
(i) 24 N⋅m (2.4 kg⋅m / 17 lb⋅in)
(j) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(k) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(l) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(m) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(n) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
Common Rail
Components
6 8
7
4
1 2
10
MFWA1DLF000301
Legend
1. Oil cooler 6. EGR valve
2. Common rail (Fuel rail) bracket 7. EGR valve gasket
3. Common rail (Fuel rail) 8. EGR cooler duct
4. Injection pipe 9. Fuel leak-off pipe
5. Injection pipe clip 10. Fuel pipe (high pressure)
Including the inside of the injector, the holes and gaps

that are the fuel paths for the fuel system have an 2. Disconnect the fuel pressure sensor connector and
extremely precise finish. Therefore, because there is EGR valve connector.
the possibility of damage if foreign material becomes
3. Disconnect the fuel leak off hose from the leak-off
mixed in, cover the cap after removing parts, etc. to
pipe.
prevent the entry of foreign material.
• Put a cover over the removed fuel hose and
fasten it facing upward using a wire.
Removal 4. Remove the EGR cooler duct (2) and EGR valve
1. Remove the air intake hose. (1).

• Use packing tape, etc. to cover the EGR case 7. Remove the harness bracket.
side opening to prevent foreign material from
entering. 1 2 3
1 2
MFWA1DSH000401
Legend
LNW91DSH001201
1. M6 bolt
2. Harness bracket
5. Remove the oil level gauge and guide tube. 3. M8 bolt
6. Remove the injection pipe clip (2) and remove the
injection pipe (1).
8. Remove the fuel pipe (1).
1 9. Remove the clip, and remove the fuel leak-off pipe
(2).
1 2
MFWA1DSH000101
Legend
1. Injection pipe
2. Injection pipe clip MFWA1BSH000301
Legend
1. Fuel pipe (High pressure)
2. Fuel leak-off pipe
10. Remove the common rail (2) and the common rail
bracket (1).
• Do not hold the flow damper, pressure limiter
and fuel pressure sensor. Make sure to hold the
common rail.

• Be careful not to damage the pressure sensor
connector.
1 2
3
LNW91DSH002201
Legend
LNW91DSH002101
1. Inlet cover
Legend 2. Oil cooler
1. Common rail (Fuel rail) bracket 3. Common rail (Fuel rail) bracket
2. Common rail (Fuel rail)
2. Install the common rail (2) and tighten it at the

11. Remove the common rail bracket (3). specified torque.
1 2
3
LNW91DSH002201
Legend
1. Inlet cover
2. Oil cooler
3. Common rail (Fuel rail) bracket LNW91DSH002101
Legend
1. Common rail (Fuel rail) bracket
Installation 2. Common rail (Fuel rail)
1. Install the common rail bracket (3) and tighten it at



3. Install the fuel leak-off pipe (2), and then tighten • Thinly apply engine oil to the outer
the eyebolt and clip at their specified torque. circumference of the injector side sleeve nut
and assembly it.
Fuel leak off pipe tightening torque

1
Eye bolt (3) 20 N⋅m(2.0 kg⋅m/14 lb⋅ft)
Eye bolt (4) 10 N⋅m(1.0 kg⋅m/87 lb⋅in)
Cylinder head 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Clip 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
4. Install the fuel pipe (1) and tighten the sleeve nut at
2
NOTE:
The fuel pipe (1) has directionality. Install the common
rail side with the yellow color of the processed surface
side of the sleeve nut, and the green should be MFWA1DSH000101
installed at the supply pump side. Legend

1. Injection pipe
2. Injection pipe clip
1 2 3 4
1 2
MFWA1DSH000301
Legend
1. Fuel pipe (High pressure) MFWA1DSH000201
2. Fuel leak-off pipe Legend

3. Eye bolt 1. Injector side
4. Eye bolt 2. Common rail (Fuel rail) side
5. Install the injection pipe and injection pipe clip, and 6. Install the harness bracket.
tighten them at the specified torques.
Harness bracket tightening torque

Tightening torque
M6 bolt 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
M8 bolt 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Injector side 30 N⋅m (3.1kg⋅m/22 lb⋅ft)
Injection pipe clip 8 N⋅m (0.8 kg⋅m/69 lb⋅in)

11. Check that there is a clicking sound when
1 2 3 connecting each connector with the engine
harness to securely connect them.
12. Install the air intake duct.
1 2
MFWA1DSH000401
Legend
1. M6 bolt
2. Harness bracket
3. M8 bolt MFWA1BSH001101
Legend
1. Rubber hose
2. Intake duct
7. Install the oil level gauge and guide tube.
8. Temporarily install the gasket to the EGR valve (1).
9. Insert the gasket into the EGR cooler duct (2),
install it so that the both ends are firmly attached,
• Tighten the EGR valve at the specified torque.
1 2
LNW91DSH001201
10. Install the fuel leak hose to the leak off pipe and
fasten with the clips.

a
c
b d
n e
f
g
p
p
o
h
m
p q
j
MFWA1DLF000401
(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)

(b) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(c) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 172 N⋅m (17.5 kg⋅m / 127 lb⋅ft)
(f) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(h) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(i) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(j) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(k) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(l) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(m) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(n) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(o) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(p) 23.5 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(q) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
Fuel Pressure Sensor (Common Rail)

Components
RTW76CLF000601
Legend
1. Pressure limiter 2. Fuel pressure sensor
Maintenance Precautions • After replacing each sensor, check that the DTC
code is extinguished and the operations are
Precautions for Maintenance
normal with the scan tool.
• Add a cleaning agent to the steam cleaner and
thoroughly clean the sensor and common rail
areas. Removal
• Completely remove the moisture with an air Fuel pressure sensor
blower.
1. Disconnect the harness connector of the fuel
• Start work after checking that all foreign material pressure sensor.
has been removed.
• After starting the engine, check to be sure that
there is no fuel leaking.

2. Remove the fuel pressure sensor.
1
1
3 2
3 2
RTW76CSH000101
RTW76CSH000101
Legend
Legend 1. Common rail (Fuel rail)
1. Common rail (Fuel rail) 2. Fuel pressure sensor
2. Fuel pressure sensor 3. Pressure limiter
3. Pressure limiter
2. Connect the fuel pressure sensor harness
connector.
Installation
Fuel pressure sensor
1. Install the fuel pressure sensor.
• Apply grease to the threaded portion of the
sensor and install it.
• Install so that this does not interfere with the
connector terminals.
NOTE:
• Do not remove the protective cap right until
assembling the sensor.
• Be careful not to allow water or foreign material to
get into the connector.
• Do not allow foreign material to adhere to the
threaded portion. Also, thoroughly check that there
is no foreign material in the installation section.
Pressure Limiter (Common Rail)

Removal
• Remove the pressure limiter.
NOTE:
• Do not reuse the removed sensor or gasket.
1
• When removing the gasket, be careful not to
damage the seat surface.
1
3 2
RTW76CSH000101
Legend
2. Pressure sensor
3. Pressure limiter
3 2
RTW76CSH000101
Legend
2. Fuel pressure sensor
3. Pressure limiter
Installation
• Install the pressure limiter.
NOTE:
• Before installation, thoroughly check that there is
no foreign material in the installation section.
• Tighten using a 19 mm (0.75 in) width across flat
section.
Fuel Supply Pump

Components
1 2
MFWA1DMF000101
Legend
1. Fuel pipe (High pressure) 4. Supply pump bracket
2. Fuel leak-off pipe 5. Oil level gauge guide tube
3. Air compressor 6. Supply pump
Including the inside of the injector, the holes and gaps

that are the fuel paths for the fuel system have an
extremely precise finish. For that reason, the sensitivity
to foreign material is high. Since foreign material can
lead to trouble on the road, take every precaution to
prevent foreign material from getting inside.

Removal • Remove the fuel return hose (2) that is located
between the supply pump and fuel filter.
1. Remove the intake duct (2) that is located between
the intercooler and intake throttle valve.
1 2
MFW71DSH000901
MFWA1BSH001101
Legend 7. Remove the fuel leak-off pipe (1).

1. Rubber hose
2. Intake duct
2. Remove the oil separator together with the

bracket.
3. Remove the oil level gauge guide tube.
4. Remove the fuel pipe (1) (between the supply

pump and common rail).
MFWA1DSH000601
1 8. Remove the fuel temperature sensor.

9. Remove the supply pump and bracket.
• Remove the coupling and O-ring.
MFWA1DSH000501
5. Disconnect the fuel temperature sensor connector

and suction control valve connector from the
supply pump.
6. Remove the fuel feed hose (1).
MFW81DSH000601 LNW71DSH001501
Legend
10. Remove the coupling from the supply pump. 1. Supply pump
2. O-ring
• Tighten the two bolts in the coupling screw
holes and after applying a turn stopper, remove
the nut.
• Put the puller on the two tightened bolts of the
coupling and remove the coupling. Installation
1. Install the O-ring (2) to the supply pump (1) with
the three mounting bolts and tighten to the supply
pump bracket (3) at the specified torque.
• Be careful of the O-ring protruding.
LNW71DSH001401
11. Remove the three bolts to remove the supply

pump bracket (3).
• Remove the O-ring (2).
LNW71DSH001501
Legend
1. Supply pump
2. O-ring

2. Install the alignment coupling to the supply pump 4. Install the fuel temperature sensor.
shaft key and tighten the nut at the specified 5. Install the fuel leak-off pipe (1).
torque.
• Tighten two bolts to the coupling screw holes as
a turn stopper. Tightening torque
Tightening torque 64 N⋅m (6.5 kg⋅m/47 lb⋅ft) Supply pump side 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
Cylinder head side 12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Clip bracket side 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
LNW71DSH001401
MFWA1DSH000601
3. Install the O-ring to the supply pump and bracket,
and install to the air compressor via the coupling.
6. Install the fuel feed hose (1).
NOTE: • Install the fuel return hose (2).
There is no need to align the position of the supply
pump claw.
MFW71DSH000901
7. Connect the fuel temperature sensor connector

and suction control valve connector to the supply
pump.
MFW81DSH000601

8. Install the fuel pipe (1) (between the supply pump Supply Pump Relearn
and common rail). 1. Install a scan tool.
Tightening torque 44 N⋅m (4.5 kg⋅m/33 lb⋅ft) 3. Command the Fuel Supply Pump Learn Resetting
with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter
with the scan tool. Confirm the scan tool indicates
Not Learned.
5. Start the engine and let idle until engine coolant
temperature reads 70°C (158°F) or higher while
observing the Fuel Supply Pump Status parameter
with a scan tool. The scan tool parameter changes
status Not Learned > Learned.
1
MFWA1DSH000501
9. Install the oil separator together with the bracket.
10. Install the oil level gauge guide tube.

11. Install the intake duct (2) between the intercooler
and intake throttle valve.
1 2
MFWA1BSH001101
Legend
1. Rubber hose
2. Intake duct

a b
g
e
MFWA1DLF000501
(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)
(c) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(d) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(e) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) Common rail side
10 N⋅m (1.0 kg⋅m / 87 lb⋅in) Supply pump side
(f) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(g) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(h) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
Fuel Temperature Sensor

Removal
1. Remove the supply pump.
• Refer to "Fuel Supply Pump" in this section.
2. Remove the fuel temperature sensor (1).
LNW81DSH000201
Installation
1. Install the fuel temperature sensor.

• Refer to "Fuel Supply Pump" in this section.
Fuel Rail Pressure (FRP) Regulator

Component Parts
2 3
1
MFWB1DMF000401
Legend
1. Bolt 3. O-ring
2. Fuel rail pressure (FRP) regulator / Suction 4. Supply pump
control valve (SCV)
Maintenance Precautions Installation

• Add cleaning agent to the steam cleaner and 1. Install the O-ring to the supply pump.
thoroughly clean the sensor and supply pump 2. Install the FRP regulator to the supply pump, and
areas. temporarily tighten two bolts.
• Completely remove the moisture with an air
blower. NOTE:
• Start work after checking that all foreign matter has • Be careful so as not to pinch the O-ring during
been removed. installation.
• After starting the engine, check to be sure that • Temporarily tighten by hand until the FRP regulator
there is no fuel leaking. adheres the supply pump.
• After replacing valves, use a scan tool to check
3. Tighten the FRP regulator to the specified torque.
that the trouble code is cleared and that operations
are normal.
Removal
4. Connect the connector to the FRP regulator.
1. Disconnect the connector from the FRP regulator.
2. Remove the FRP regulator.
3. Remove the O-ring from the FRP regulator.

Supply Pump Relearn
1. Install a scan tool.
3. Command the Fuel Supply Pump Learn Resetting
with the scan tool.
4. Observe the Fuel Supply Pump Status Parameter
with the scan tool. Confirm the scan tool indicates
Not Learned.
status Not Learned > Learned.
Fuel Tank
Component Parts
2 4
1
7
8
MFW81DMF001001
Legend
1. Fuel return hose 6. Filler cap
2. Fuel feed hose 7. Drain plug
3. Outlet breather hose 8. Fuel tank
4. Fuel tank bracket 9. Fuel tank unit
5. Fuel tank band
Removal 8. Remove the fuel tank attachment band, and

remove the frame side end of the band.
1. Disconnect the negative terminal of the battery
cable. 9. Extract the fuel tank to the outside.
2. Loosen the fuel filler cap. NOTE:
3. Drain the fuel from the drain plug. If the fuel tank cannot be extracted, remove the
4. After draining the fuel, tighten the drain plug to the bracket, and extract the fuel tank from the bottom.
specified torque strength.
Drain plug
Tightening torque
73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
5. Remove the fuel tank unit connector.

6. Remove the fuel feed hose.
7. Remove the fuel return hose.
• Plug the hose so that fuel does not leak, and tie
it to the frame side pointing upwards.
1
2
1
3
2
4 3
MFW81DSH001401 MFW81BSH001801
Legend Legend
1. Fuel tank unit 1. Band
2. Fuel tank 2. Bracket
3. Band 3. Inside nut
4. Outside nut
3. Install the fuel return hose.

Installation
4. Install the fuel feed hose.
1. Install the fuel tank temporarily.
• Insert the hose more than 25 mm (0.9843 in)
NOTE: into the pipe.
• When removing the fuel tank, if the bracket was 5. Connect the fuel tank unit connector.
removed, install the bracket to the frame at the 6. Fill the fuel tank with fuel, and tighten the fuel filler
specified torque strength. cap.
• When supporting the fuel tank in the bracket, make 7. Connect the negative terminal of the battery cable.
sure the rubber section stuck to the fuel tank is 8. After starting the engine, check all of the hose
firmly supported in the bracket. connection sections to make sure there are no fuel
Bracket leaks.
Bracket tightening torque

47.1 N⋅m (4.8 kg⋅m/35 lb⋅ft)
2. Install the band to the fuel tank, and tighten the

nuts to the specified torque strength.
Band nut
Tightening torque
Inside nut 17.7 N⋅m (1.8 kg⋅m/13 lb⋅ft)
Outside nut 20.6 N⋅m (2.1 kg⋅m/15.2 lb⋅ft)

Tightening Torque Table
b
c
MFW81DMF001101
(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
Fuel Tank Unit

Component Parts
MFWA1DMF000601
Legend
1. Fuel tank unit 2. Fuel tank
Removal 2. Check that the low fuel level warning light lights up
when the float is at the "E" position.
1. Disconnect the wiring connector from the fuel tank
If any abnormality is found in the inspection
unit.
results, replace the meter with a normal one.
2. Remove the installment screw, and remove the
fuel tank unit.
NOTE:
• When removing and replacing the fuel tank unit,
make sure there is no interference around the
perimeter, and be sure not to distort the shape of the
arm.
• After removing the fuel tank unit, cover it to ensure
debris does not enter the tank.
Inspection
The fuel tank unit changes the internal resistance by
the float position (the fuel level height) and operates the
fuel meter indicator.
1. While moving the float from "E" to "F", inspect the
resistance value between the connector terminals.
F point 3/4 point 1/2 point 1/4 point E point SE point

Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 53.5 114.1 171.6 233.0 295.8 303.4
mm (in)
flange (2.11) (4.49) (6.76) (9.17) (11.65)) (11.94)
182.0 143.0 102.0 60.5 19.0 13.8
Tank capacity L (lmp⋅gal)
(40.0) (31.5) (22.4) (13.3) (4.2) (3.0)
Resistance value (Ω)
6.0 28 50 86 141 150
(Between terminal 2 and 3)
3 2 1
h1
h2
F
h3
h4
3/4
h5
h6
1/2
1/4
SE
MFW81ELF000601
Installation
Follow the disassemble procedure in reverse order to
reassemble.
1. Install the fuel tank unit.
2. Connect the wiring connector to the fuel tank unit.
MEMO
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Engine Electrical (4HK1) 1E-1
ENGINE
Engine Electrical
(4HK1)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1E-2
Description of Function and Operation . . . . . . . 1E-2
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1E-5
Phenomenon: The starter does not work even
when the engine control switch is turned ON . . 1E-6
Phenomenon: The pinion advances
but does not mesh with the ring gear . . . . . . . . 1E-7
Phenomenon: The pinion meshes and
the motor turns, but the engine does not crank. 1E-8
Phenomenon: The pinion meshes,
but the engine does not crank. . . . . . . . . . . . . . 1E-9
Phenomenon: After the engine starts, the
starter does not stop even if the engine
control switch is turned OFF . . . . . . . . . . . . . . 1E-10
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-10
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-13
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-14
Inspection and Repair . . . . . . . . . . . . . . . . . . . 1E-15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-21
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-22
Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-23
Charging System . . . . . . . . . . . . . . . . . . . . . . . . 1E-24
Maintenance Precautions . . . . . . . . . . . . . . . . 1E-24
Description of Function and Operation . . . . . . 1E-24
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 1E-26
Primary Specifications. . . . . . . . . . . . . . . . . . . 1E-26
Functional Inspection: . . . . . . . . . . . . . . . . . . . 1E-27
Failure Symptom List . . . . . . . . . . . . . . . . . . . 1E-28
Phenomenon: Does not charge at all . . . . . . . 1E-29
Phenomenon: Charge is insufficient . . . . . . . . 1E-30
Phenomenon: Overcharged . . . . . . . . . . . . . . 1E-31
Phenomenon: Charged current is unstable. . . 1E-32
Phenomenon: Abnormal sound in generator . 1E-33
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-34
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-41
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-43
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-45
List of Tightening Torques . . . . . . . . . . . . . . . . 1E-46
1E-2 Engine Electrical (4HK1)
Starting System
Maintenance Precautions Starter
When performing maintenance on the electrical The starter is a magnetic shift type starter and is an
system, check that the engine control switch and outer gearing mesh method reduction starter.
lighting switch are off, and always disconnect the When the engine control switch is turned ON, the
battery negative terminal before working. plunger is drawn in, the contact point of the magnetic
switch closes and the armature rotates. At the same
time, the pinion is pushed to the front via the shift lever
Description of Function and Operation to mesh with the ring gear. When the ring gear rotates,
Starter circuit the crankshaft is turned to start the engine. After the
engine starts, the plunger returns, the pinion separates
The starting system is composed of the batteries, from the ring gear, and the armature stops rotating
starter, engine control switch, inhibitor switch (A/T when the engine control switch is turned OFF. When
vehicles only) and starter relay. Each of these main the engine rotation increases faster than the pinion, the
components are wired as shown in the starter circuit pinion will be caused to turn in reverse, but because
diagram. the pinion is idling by the one-way clutch operation, it
does not drive the armature.
4 5
ST
8
3
B
2
10
1
9
MFW51EMF000101
Legend
1. Pinion clutch 6. B terminal
2. Ring gear 7. Starter relay
3. Shift lever 8. Engine control switch
4. Magnetic switch 9. Batteries
5. S terminal 10. Armature

Starter motor
24V 4.5kW
3
4
5
6
2
1
MFW51EMF000201
Legend
1. Brush 5. Clutch
2. Yoke 6. Pinion
3. Magnetic switch 7. Armature
4. Torsion spring
Output characteristics
S25-511
P T1 N TV
Performance diagram
kW Nm r/min V
P
4.8 118 6000 24
TV
4.0 98 5000 20
3.2 78 4000 16
2.4 59 3000 12
T1
1.6 39 2000 8
N
0.8 20 1000 4
0 0 0 0
0 100 200 300 400 500 600 700 800 900 1000 1100
I (A)
MFW81ESF000101

Engine control switch
IG1 B2
ACC ST
B1
IG2
MFW71ESF000201
Starting circuit diagram
Engine control switch
Conne
ctor nu B-130
Ter mber
min
Engine al n
um
Te ber 4 5 6 1 2 3
control rm
ina
switch key ls
Batteries ign
position B1 ACC IG1 IG1 ST B2
When you extract

the key
OFF
ACC
When you
insert the key
ON
START
ECM
Slow blow fuse 6 F-20
40A
Slow blow fuse 5
30A
Slow blow fuse 2 Starter

Starter relay F-24
60A
Starter cut relay

ECM
Fusible
link
B S
ECM main
F-33
Magnetic switch
Starter motor
MFW81ELF000201

• The pinion advances but does not mesh with the
ring gear.
• The pinion meshes and the motor turns, but the
engine does not crank.
• The pinion meshes, but the engine does not crank.
• After the engine starts, the starter does not stop
even if the engine control switch is turned OFF.

Phenomenon: The starter does not work even when the engine control switch is turned ON

The starter does not work even when Complete battery discharge Replace the battery
the engine control switch is turned ON Wiring circuit open circuit, improper Repair
connection
Defective contact of the engine control Repair or replace
switch contact point, or improper
tightening of the terminal
Defective contact of the starter relay or Repair or replace
defective contact of the insertion
terminals
Magnetic switch coil short circuit or Replacement
open circuit

Phenomenon: The pinion advances but does not mesh with the ring gear

The pinion advances but does not mesh Insufficient battery charge Recharge the battery
with the ring gear Wear of the pinion or ring gear teeth Replace the pinion or the ring gear
Dust adhesion on pinion shaft Repair

Phenomenon: The pinion meshes and the motor turns, but the engine does not crank

The pinion meshes and the motor turns, Slipping of the clutch Replace the clutch or the starter motor
but the engine does not crank Damage of the deceleration gear Replace the gear or the starter motor

Phenomenon: The pinion meshes, but the engine does not crank

The pinion meshes, but the engine Insufficient battery charge Recharge the battery
does not crank Insufficient tightening of the wiring Repair
circuit terminal
Armature or field coil short Replace the starter motor
Dirty or damaged commutator Repair or replace the starter motor
Deterioration of the brush spring or Replace the brush spring or brush
wear of the brush
Bearing lock Replace the bearing or the starter motor
Defective contact of the magnetic Replace the magnetic switch
switch contact point

Phenomenon: After the engine starts, the starter does not stop even if the engine control
switch is turned OFF

After the engine starts, the starter does Improper return of the engine control Replace the engine control switch
not stop even if the engine control switch contact point
switch is turned OFF Improper return of the starter relay Replace the starter relay
contact point
Magnetic switch coil short circuit Replace the magnetic switch
Model (Hitachi, Ltd.) S25-505G , S25-511

Rating
Voltage V 24
Output kW 4.5
Time second 30
Number of pinion teeth 11
Rotational direction Counterclockwise
(When seen from the pinion side)
Mass (Approx.) kg (lb) 7.5 (16.5)
No-Load characteristic
Voltage / Current V-A 23 / 120 or less
Speed r/min 3,500 or more
Load characteristic
Voltage / Current V-A 14.3 / 400 or less
Torque N⋅m (kg⋅m / lb⋅ft) 25 (2.5 / 18) or more
Speed r/min 1,000 or more
Locking characteristic
Voltage / Current V-A 10 / 1,200 or less
Torque N⋅m (kg⋅m / lb⋅ft) 47 (4.8 / 35) or more
Starter Motor
Components
LNW21EMH000101
Legend
1. Starter ground cable
2. Starter assembly
3. Starter terminal
4 5
2
1 6
7
34
33
32
31
30
29
28 8
27
26 9
25
24
23
22
21
19 20
10
12
13 11
14
15
16
17
18
LNW76DLF000301
Legend
1. Plunger 18. Ball bearing
2. Dust cover 19. Bearing retainer
3. Magnetic switch 20. Clip
4. Terminal cover 21. Pinion stopper
5. Torsion spring 22. Pinion
6. Shift lever 23. Cushion spring
7. Dust cover 24. Sleeve cover
8. Gear case 25. Stopper washer
9. Through bolt 26. Pinion shaft
10. Rear cover 27. Ball bearing
11. Drain pipe 28. Clutch
12. Brush holder 29. Ball bearing
13. O-ring 30. Return spring
14. Yoke 31. Stopper
15. O-ring 32. Clip
16. Ball bearing 33. Ball bearing
17. Armature 34. Bearing holder

Removal • Remove the magnetic switch B terminal (1)
harness.
1. Remove the starter ground cable.
• Remove the nut attaching the starter ground
cable to remove the ground cable.
1
• Disconnect the front frame harness connector 2
LNW21ESH001401
Legend
1. B terminal
2. S terminal
LNW21ESH001001
3. Remove the starter assembly.
• Remove the two bolts on the top and bottom,
and remove the starter from the clutch housing.
LNW21ESH001101
LNW21ESH001001
2. Remove the harness terminal.
• Remove the magnetic switch S terminal (2)
harness.

Disassembly 3. Remove the torsion spring from the magnetic
switch.
1. Disconnect the lead wire at the magnetic switch.
RTW46DSH002801
RTW46DSH002601
4. Remove the through bolt.

2. Remove the magnetic switch bolts, then remove
the switch from the shift lever. 5. Remove the screw.
6. Remove the rear cover.
RTW46DSH002701
RTW46DSH002901

7. Remove the four brushes from the brush holders. 16. Disassemble the pinion assembly.
MFW81ESH000301 RTW46DSH003401
Legend
1. Brush
Inspection and Repair
Make the necessary adjustments, repairs, and part
replacement if excessive wear or damage is discovered
8. Remove the yoke along with the armature and the during inspection.
brush holder from the gear case.
9. Remove the brush holder from yoke and armature. Armature
10. Remove the armature from yoke. 1. Measure the commutator runout.
Replace the commutator if the measured runout
exceeds the specified limit.
Commutator Runout mm(in)

Standard 0.05 (0.002)
Limit 0.20 (0.0079)
RTW46DSH003201
11. Remove the bearing retainer.

12. Remove the pinion assembly.
13. Remove the dust cover.
14. Remove the shift lever.
15. Remove the stopper clip.
RTW46DSH003501

2. Check the commutator mica segments for If the measured outside diameter is less than the
excessive wear. specified limit, the commutator must be replaced.
3. Measure the mica segment depth.
Mica Segment Depth mm(in)

Standard 0.5 – 0.8 (0.020 – 0.031)
Limit 0.2 (0.0079)
If the mica segment depth is less than the standard

but more than the limit, the commutator may be
reground.
If the mica segment depth is less than the limit, the
commutator must be replaced.
1 2 HCW51ESH000901
5. Use a circuit tester to check the armature for

grounding.
4
a. Hold one probe of the circuit tester against the
commutator segment.
b. Hold the other circuit tester probe against the
armature core.
5 If the circuit tester indicates continuity, the
armature is grounded.
The armature must be replaced.
RTW56DSH000701
Legend
1. Insulator
2. 0.5 to 0.8 mm (0.020 to 0.031 in)
3. Commutator Segments
4. Correct
5. Incorrect
4. Measure the commutator outside diameter.
Commutator Outside Diameter mm(in)

Standard 36.5 (1.44)
Limit 35.5 (1.40)
RTW46DSH003601
6. Use the circuit tester to check the armature for

continuity.
a. Hold the circuit tester probes against two
commutator segments.

b. Repair Step 1 at different segments of the b. Hold the other circuit tester probe against the
armature core. field winding brush.
There should be continuity between all There should be continuity.
segments of the commutator. If there is no continuity, the yoke must be
If there is not, the armature must be replaced. replaced.
RTW46DSH003701 RTW46DSH003901
Yoke Brush and Brush Holder

1. Use a circuit tester to check the field winding 1. Use a vernier caliper to measure the brush length
ground. (four brushes).
a. Hold one circuit tester probe against the field Replace the brushes as a set if one or more of
winding end or brush. brush lengths is less than the specified limit.
b. Hold the other circuit tester probe against the
bare surface of the yoke body. Brush Length mm(in)
There should be no continuity. If there is
Standard 15.5 (0.61)
continuity, the field coil is grounded. The yoke
must be replaced. Limit 12 (0.47)
RTW46DSH003801
RTW46DSH004001
2. Use the circuit tester to check the field winding

continuity.
a. Hold one circuit tester probe against the M
terminal lead wire.

2. Use a circuit tester to check the brush holder Bearing
insulation. Inspect the bearings for excessive wear and damage.
Touch one probe to the holder plate and the other Replace the bearings if necessary.
probe to the positive brush holder.
There should be no continuity.
RTW46DSH004401
RTW46DSH004101
Reassembly
Inspect the brushes for excessive wear.
If the negative brushes have excessive wear, the 1. Attach the torsion spring to the hole in the
entire brush holder assembly must be replaced. magnetic switch as illustrated.
If the positive brushes have excessive wear, the 2. Insert the shift lever into the plunger hole of the
entire yoke must be replaced. magnetic switch.
Overrunning Clutch
1. Inspect the overrunning clutch gear teeth for
excessive wear and damage.
Replace the overrunning clutch if necessary.
2. Rotate the pinion clockwise.
It should turn smoothly.
3. Try to rotate the pinion in the opposite direction.
The pinion should lock.
RTW46DSH005601
3. Install the magnetic switch assembly in the gear

case.
4. Install the dust cover.
Dust Cover Bolt

LNW61DSH002701 Tightening torque 10.6 N⋅m (1.08 kg⋅m/78 lb⋅in)

7. Install the brush holder with aligning the
peripheries of the yoke and the brush holder.
RTW46DSH005701
RTW46DSH004501
5. Apply a coat of grease to the reduction gear and

install the pinion assembly to the armature shaft.
8. Install the through bolts in the rear cover and
tighten them to the specified torque.
Through bolt
Tightening torque 8.1 N⋅m (0.83 kg⋅m/69.7 lb⋅in)
LNW61DSH002801
6. Install the brushes into the brush holder with

raising the spring end of the brush spring.
NOTE:
Take care not to damage the commutator face. LNW61DSH002901
9. Connect the lead wire in the magnetic switch and

tighten the terminal nut to the specified torque.
Through bolt
Tightening torque 8.6 N⋅m (0.88 kg⋅m/74.9 lb⋅in)

NOTE:
The following tests must be performed with the starter
motor fully assembled.
The yoke lead wire must be disconnected from the M
terminal.
To prevent coil burning, complete each test as quickly
as possible (within 3 to 5 seconds).
Temporarily connect the solenoid switch
between the clutch and the housing and run the
following test.
Complete each test within 3 to 5 seconds.
a. Pull-in Test
• Connect the battery negative terminal with
the solenoid switch body and the M terminal.
When current is applied to the S terminal
from the battery positive terminal, the pinion
should flutter.
RTW46DSH002601
Inspection After Reassembly S
1. Use a vernier caliper to measure the pinion shaft

thrust play.
The pinion shaft thrust play is equal to the pinion
shaft end and pinion stopper clearance.
Pinion shaft thrust play(a) mm (in)

0.3 – 1.0 (0.012 – 0.039)
RTW46DSH004601
a
b. Hold-in Maintenance Test

• Disconnect the lead at the M terminal.
The pinion should continue to flutter.
MFW81ESH000201
2. Magnetic Switch
RTW46DSH005901
c. Return Test Tightening torque

• Disconnect the battery positive lead at the S 1 - 1.5 N⋅m (10 - 15 kg⋅cm / 8.7 - 13.1 lb⋅in)
terminal.
The pinion should return to its home
• Tighten the B terminal (1) at the specified
position.
torque.
S
Tightening torque
7.5 - 10 N⋅m (75 - 100 kg⋅cm / 65 - 87 lb⋅in)
1
2
RTW46DSH004701
Installation
1. Install the starter assembly.
• Install the starter to the clutch housing with a LNW21ESH001401
bolt, and tighten at the specified torque. Legend
1. B terminal
2. S terminal
Tightening torque 127 N⋅m(12.9 kg⋅m / 94 lb⋅ft)
3. Install the starter ground cable.

LNW21ESH001001
LNW21ESH001501
2. Install the harness terminal.
• Tighten the S terminal (2) at the specified
torque.

a b
c
d
MFW71EMF000201
(a) 7.5 - 10 N⋅m (75 - 100 kg⋅cm / 65 - 87 lb⋅in)

(b) 1 - 1.5 N⋅m (10 - 15 kg⋅cm / 8.7 - 13.1 lb⋅in)
(c) 127 N⋅m (12.9 kg⋅m / 94 lb⋅ft)
(d) 127 N⋅m (12.9 kg⋅m / 94 lb⋅ft)
Starter Switch
Removal
1. Remove the steering cowl (1).
• Remove four screws to remove the cowl. 1
MFW76BSH000601
Inspection
MFW76BSH000401
Inspect the continuity between the engine control
switch connector terminals.
If any abnormality is found in the inspection results,
2. Remove the immobilizer control unit (1). repair or replace it.
B2 ST IG2
+B
UNIT
KEYLESS 10mA
BUZZER 10mA
IG1 ACC B1
ENGINE CONTROL SWITCH KEYSWITCH
REMINDER
KEY B1 ACC IG1 IG2 ST B2 W W

PUT OFF
LOCK
ACC
PUT ON
1 ON
START
MFW76BSH000501
MFW81ESH000401
3. Remove the steering engine control switch (1). Installation

• Disconnect the connector. Installation is in the reverse order of the removal.
• As a share bolt (of a type with a head that can
be twisted off after it is tightened) is used for the
tightening bolt, use an extractor, reverse tap,
etc., to remove it.
Charging System
Maintenance Precautions • When charging from external equipment in such
cases as quick charge, disconnect the battery
When handling the generator, pay attention to the
terminal before working.
following points.
• Do not directly pour steam cleaner, water, etc.
• If the battery poles are reversely connected, the
diode of the generator will be damaged. • After the wiring, tighten B and E terminals at the
following tightening torques.
• Never disconnect the battery terminal and the
wiring of the charging circuit when the engine is
running. 50A , 60A , 90A specifications
• Make sure to connect each terminal wiring B terminal 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
according to the terminal symbol.
E terminal 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
• Do not perform a megger test on semiconductor
devices.
• When inspecting the equipment, make sure to Description of Function and Operation
disconnect the battery negative terminal.
Multi-function IC regulator
• Do not open and close the battery relay switch
• Trouble diagnosis function
when the engine is running.
Trouble diagnosis is added to light the charge
warning light when the feed coil circuit is open and
there is excessive voltage.
50A and 60A specifications
2 3
1 4
11
10
8
7 6
MFW71EMF000301
Legend
1. Regulator 7. Rotor
2. Field coil 8. Rear bracket
3. Stator 9. Rectifier
4. Ball bearing 10. B terminal
5. Pulley 11. Ball bearing
6. Front bracket

90A specification
3
2
1
4
11
5
10
8
6
7
MFW71EMF000401
Legend
6. Front bracket

Circuit Diagram
50A, 60A, 90A specifications
1
2
7 L
B S L
P
3
F
6
MIC
4
E
E
MFW71EMF000101
Legend
1. Charge warning light (LED) 5. Generator
2. Engine control switch 6. Field coil
3. Batteries 7. Stator coil
4. IC regulator
Nominal output V-A 24 - 50 24 - 60 24 - 90

Rated speed r/min 5,000 5,000 5,000
Regulator type IC Type
Adjusted voltage V 28 - 29
Mass kg (lb) 9.8 (21.6) 9.8 (21.6) 18.0 (39.7)

General on-board inspection
The charging system indicates a problem in operations
using the charge warning light. If the warning light lights
up when the engine control switch is ON and turns off
after the engine is started, operations are normal. If the
warning light indicates an abnormality, or it is thought
that there is an insufficient battery charge or
overcharge, perform trouble diagnosis according to the
failure symptom list.

• Charge is insufficient
• Overcharged
• Charged current is unstable
• Abnormal sound in generator

Phenomenon: Does not charge at all

Does not charge at all Defective battery Replace the battery
Open circuit, short circuit and Repair
disconnection of connecting section of
wiring or current meter
Open circuit in each coil, ground short Replace the generator
circuit, or damaged diode of the
generator
Defective regulator Replace the regulator
Regulator terminal contact problem Repair

Phenomenon: Charge is insufficient

Charge is insufficient Defective battery Replace the battery
Open circuit, short circuit and Repair
disconnection of connecting sections of
wiring
Loose generator drive belt Adjust belt tension
Stator coil layer short Replace the stator coil
Diode failure Replace the diode
Improper terminal contact Repair
Regulator terminal defective contact Repair

Phenomenon: Overcharged

Overcharged Defective regulator Repair

Phenomenon: Charged current is unstable

Charged current is unstable Intermittent contact of wiring, or open Repair
circuit
Loose generator drive belt Adjust belt tension
Short circuit in stator coil, or near open Repair
circuit
Improper terminal contact Repair
Regulator terminal defective contact Repair

Phenomenon: Abnormal sound in generator

Abnormal sound in generator Belt tension is loose Adjust belt tension
Defective bearing Replace the bearing
Contact of rotor core and stator core Repair
Diode failure Replace the diode
Short circuit in stator coil, or near open Replace the stator coil
circuit
Generator
Components
1
2
3
4
5
6
7
8
9
10
11
12
13
24
23
22
21
20
19 18
17 16
15
14
MFW61ELF000101
Legend
1. Pulley nut 13. Nuts (for tightening the cover)
2. Pulley 14. Rear cover
3. Fan 15. Screws (for installing the regulator)
4. Through bolts 16. Screws (for tightening the regulator)
5. Collar 17. Clamp
6. Front bracket 18. Regulator
7. Front bearing 19. Nut (for installing the rectifier)
8. Retainer 20. Rectifier
9. Screws (for tightening the retainer) 21. Screws (for installing the field coil)
10. Collar 22. Rear bracket
11. Rotor assembly 23. Stator
12. Rear bearing 24. Field coil

90A specification
1
2 3
4
5
6
7 8
9
10
11
12
13
14
23
15
26
25
17
24
23
22
21
20 19
18
16
MFW61ELF000201
Legend
1. Pulley nut 14. Rear bearing
2. Spring washer 15. Nuts (for tightening the cover)
3. Washer 16. Rear cover
4. Pulley 17. Screws (for installing the regulator)
5. Fan 18. Screws (for tightening the regulator)
6. Through bolts 19. Clamp
7. Collar 20. Regulator
8. Front bracket 21. Nut (for installing the rectifier)
9. Front bearing 22. Rectifier
10. Retainer 23. Screws (for installing the field coil)
11. Screws (for tightening the retainer) 24. Rear bracket
12. Woodruff key 25. Stator
13. Rotor assembly 26. Field coil
Removal
1. Remove the A/C drive belt.

• After loosening the tension pulley nut (1), • Disconnect the A/C compressor harness
loosen the adjust bolt (2) and remove the drive connector, and remove the compressor from
belt (3). the A/C compressor bracket to fasten to any
50A and 60A specifications position together with the hoses using a wire,
etc.
1
2
MFW71ESH000101
90A specification MFW51ESH000301
3. Disconnect the generator harness.

1
2 3 • Disconnect the B terminal cable and harness
connector from the generator.
4. Remove the fan belt.
• Loosen the nut (2) and generator tightening bolt
(3).
• Loosen the AC generator adjust bolt (1) and
remove the belt.
4 50A and 60A specifications
5
2
6
1
MFW71ESH000201
Legend
1. Tension pulley (Refrigerated vehicles)
2. Adjust bolt
3. Tension pulley nut
4. Tension pulley (Other than refrigerated vehicles)
5. Adjust bolt
6. Tension pulley nut 3

MFW71ESH000301
• After loosening the tension pulley (3) nut (2),

loosen the adjust bolt (1) and remove the belt.

90A specification 90A specification
1
1
3 2
2
MFW71ESH000401 MFW71ESH000601
5. Remove the tension pulley Disassembly

(90A specifications). Disassembly Procedures
• Remove three bolts and remove the tension NOTE:
pulley. Place alignment marks to the front bracket and rear
6. Remove the generator. bracket before disassembly to make it easy to
• Remove the nuts at two locations, pull out the reassemble.
bolts, and remove the generator.
1. Remove the through bolts.
• Remove three through bolts (50A, 60A).
1 2
• Remove four through bolts (90A).
2. Remove the rear side cover.
• Remove three nuts.
• Remove two nuts of B terminal (90A).
3
MFW71ESH000501
Legend
1. Adjust bolt
2. Adjust plate lock nut
• After loosening the bolt (1) and generator

tightening bolt (2), pull out each bolt to remove
the generator.

50A and 60A specifications NOTE:
Be careful not to damage the stator coil.
1 5. Remove the pulley nut with an impact wrench.
6. Remove the spring washer and flat washer (90A).
7. Remove the pulley.
8. Remove the fan.
9. Remove the woodruff key (90A).
B 10. Remove the collar.
11. Remove the rotor from the front bracket assembly.
E
• Use a press, etc. when removing.
• Do not use a vise because the rotor will be
2
deformed when it is fixed with a vise.
4 3 12. Remove the collar from the rotor (50A, 60A).
14. Remove the front bearing.
MFW61ESH000501
• When the front bearing has to be removed,
Legend remove the retainer mounting screw and use an
1. Connector appropriate socket to push out the bearing.
2. B terminal
3. Nuts NOTE:
4. Cover Do not remove it unless it is necessary. Do not reuse
the removed bearing.
90A specification
15. Remove the stator.
1
• Disconnect the stator coil lead wire at four
locations to remove the stator from the rectifier.
• Disconnect the stator coil lead wire at seven
locations to remove the stator from the rectifier
(90A).
NOTE:
Use a soldering iron to remove it quickly (within 5
seconds) so as not to overheat the rectifier and
damage the diode.
2 16. Remove the field coil terminal lead wire.

4
• Remove the screws (M4) that are connected to
the rectifier at two locations.
3
• Remove the soldering at one location that is
connected to the IC regulator.
MFW61ESH000701
Legend NOTE:
1. Nuts Use a soldering iron to remove it quickly (within 5
2. B terminal seconds) so as not to overheat the IC regulator and
3. Cover damage the semiconductor.
4. Nuts
• Disconnect the IC regulator side lead wire from
the clamp.
17. Remove the mounting screw for the IC regulator.
3. Remove the collar of B terminal (90A).
18. Remove the IC regulator.
4. Separate the front side and rear side. 19. Remove the nut (at one location) that fixes the
• Use a dryer, etc. to warm the bearing room rectifier.
before separating them.
• Separate them with a press using the hole that
the through bolt is removed.

20. Remove the rectifier. 21. Remove three mounting screws for the field coil.
50A and 60A specifications 22. Remove four mounting screws for the field coil
(90A).
2 23. Remove the field coil.
1
24. Remove the rear bearing.
• When the rear bearing has to be removed, use
7 a press to remove it.
NOTE:
Do not remove it unless it is necessary. Do not reuse
3
the removed bearing.
6 Inspection method
4 1. Inspect the stator.
• Visually inspect for damage, loose connection
or discoloration of wiring.
5
• Inspect the continuity between the two stator
coil lead wires using a circuit tester.
MFW61ESH000801
If there is no continuity, replace the stator.
Legend
1. Screws
2. Soldering section
3. IC regulator
4. Rectifier 1
5. Nut
6. Screws
7. Clamp
90A specification
7
MFW61ESH000301
3
Legend
1. Stator coil lead
6
4
• Inspect the continuity between the stator coil

lead wire and the core using a circuit tester.
5
If there is continuity, replace the stator.
MFW61ESH000901
Legend
1. Screws
2. Soldering section
3. IC regulator
4. Rectifier
5. Nut
6. Screws
7. Clamp
4. Inspect the rectifier assembly.

• Inspect the continuity between four diode
terminals of the positive diode using a circuit
1 tester.
If there is continuity in both directions, the
positive diode is shorted, so replace the rectifier
assembly. If there is no continuity in both
direction, the positive diode is open, so replace
the rectifier assembly.
• Inspect the continuity between four diode
terminals of the negative diode using a circuit
tester.
If there is continuity in both directions, the
2
negative diode is shorted, so replace the
rectifier assembly. If there is no continuity in
both direction, the negative diode is open, so
MFW61ESH000201 replace the rectifier assembly.
Legend
1. Core
2. Stator coil lead
1
2. Inspect the rotor. 3
• Inspect the bearing for abnormal noise,

looseness or grease leakage (if the amount is
small, just wipe it off), and replace it if an
abnormality is detected. For abnormal noise
and looseness, it is easier to inspect when it is
firmly fitted in the shaft rather than when it is
2
separated.
3. Inspect the field coil assembly.
• Measure the resistance between both ends of
the terminal section using a circuit tester.
If the value is not within the standard value, MFW61ESH000601
replace the field coil assembly. Legend

1. Positive heat sink
2. A part of negative heat sink
3. Diode terminals
MFW61ESH000101
Legend
1. Terminal

3. Tightening torque for each section
Tightening torque N⋅m(kg⋅m/lb⋅ ft)

Pulley nut (50A, 60A
137 (14 / 101)
specifications)
(90A specification) 245 (25 / 181)
Through (50A specification) 6 (6.0 / 4)
bolt (60A, 90A
14 (1.4 / 10)
specifications)
Bearing retainer 5 (0.5 / 4)
Field coil (50A, 60A
3 (0.3 / 2)
assembly specifications)
( 90A specification) 5 (0.5 / 4)
Rectifier 3 (0.3 / 2)
MFW61ESH000401
IC regulator 3 (0.3 / 2)
IC regulator and
2 (0.2 / 1)
Rectifier mounting screw
5. Inspect the front bearing.
Cover 3 (0.3 / 2)
• Inspect the bearing for abnormal noise,
looseness or grease leakage (if the amount is B terminal nut 11 (1.1 / 8)
small, just wipe it off), and replace it if an
abnormality is detected. For abnormal noise NOTE:
and looseness, it is easier to inspect when the Be careful not to tighten excessively.
bearing is firmly fitted in the bracket rather than
when it is separated. 4. Reassembly of rear bracket, stator assembly and
6. Inspect the IC regulator. front bracket rotor assembly
• IC regulators cannot be inspected by a circuit • Since the rear bearing and the rear bracket
tester. have to be fitted tightly, heat the bearing box
After reassembling the generator, test the section of the rear bracket to 50 to 60°C (122 to
generator and inspect that the IC regulator is 140°F) before assembly.
controlling the generator voltage. • After reassembling the generator, turn the
pulley by hand and confirm that the rotor
rotates smoothly.
Reassembly
Reassembly can be performed in the reverse order of
the disassembly. Only the important points are
described here. Also, be careful of the following points.
1. Bearing is filled with grease and sealed, so there is
no need to apply grease.
NOTE:
Never apply oil to the bearing of the rotor shaft with a
resin band.
If oil is attached to the bearing box section of the rear
bracket, completely wipe it off because it will cause the
rear bearing to turn together.
2. Use a high temperature solder (melting point

230°C / 440°F specification).
Perform soldering quickly (within approx. 5
seconds) using a 180 to 270 watt soldering
iron so that the rectifier will not be
overheated.

Generator bench test
5
4
8
(3W less than) 6
MFW81EMF000101
Legend
1. Load resistance 5. Switch1
2. Generator 6. Switch2
3. Voltage meter 7. Battery (24V)
4. Current meter 8. Light (24V)
• Confirm that the light turns off before the speed

1. Adjusted voltage inspection reaches approximately 1,300 r/min.
Pay attention to the voltage. If the voltage
• Perform the wiring as shown in the diagram.
exceeds 30V without being controlled, failures
Use a current meter with the rated current of
in IC regulator could be considered.
150A, and a voltage meter with the rated
If the voltage does not exceed the battery
voltage of 30V.
voltage, the generator is not generating power.
Use a variable type with the rated current of
Inspect the generator again.
150A or higher for the load resistance.
If the light does not turn off, inspect the
• Close the switch 1. Open the switch 2. generator again.
At this time, the light turns on.
• Increase the generator rotation speed to
If it does not turn on, inspect the L terminal
approximately 5,000 r/min and read the current
voltage.
meter.
If the voltage is close to the battery voltage,
If it is 5A or lower, read the voltage meter. This
inspect the generator.
value is the adjusted voltage.
If the voltage is low, there is an open circuit in
If the voltage does not exceed the battery
the light or the light circuit.
voltage, the generator is not generating power.
If the current meter reading is 5A or higher,
continue charging until it is 5A or lower, or
replace the battery with a fully charged one.
If the adjusted voltage is not within the standard
value, replace the regulator.

2. Output current test 90A specification
Output current test is performed to inspect whether
Rotation 2,500 5,000
the generator can output as rated.
Speed r/min r/min
• After inspecting the adjusted voltage, decrease
the generator rotation speed and stop it. Output Voltage 27 V
characteristics
• Close the switch 1. Confirm that the light turns 80 A or 90 A or
(When heated) Current
on. more more
• Maximize the load resistance value (the current Field coil resistance
is minimized), and close the switch 2. 8.8 - 9.5 Ω
(At 20°C / At 68°F)
• Increase the generator rotation speed and
IC regulator
adjust the load resistance so that the output 28 - 29 V
Adjusted voltage
current is maximized while keeping the
generator speed at 5,000 r/min. Rotation direction(when seen
Clockwise
While keeping this condition, run the generator from the pulley side)
for 15 minutes to increase the generator
temperature.
After 15 minutes, set the generator rotation Installation
speed to the maintenance standard value
1. Install the generator.
(2,500 or 5,000 r/min). While keeping this
speed, adjust the load resistance so that the • Install the generator to the bracket and adjust
output current is maximized. If the current plate and temporarily tighten.
meter reading is within the maintenance
standard value, generator is normal. NOTE:
If it is below the maintenance standard value, • Insert the lower side mounting bolt (3) from the
follow the procedures in "Inspection Method" to front, and tighten it with a nut at the rear side as
inspect the generator again. shown in the diagram.
3. Maintenance standard values • Tighten the generator after adjusting the fan belt.
50A specification
Speed r/min r/min
2
Output Voltage 27 V
characteristics
42 A or 50 A or
(When heated) Current
more more
Field coil resistance 1
8.3 - 9.1 Ω
(At 20°C / At 68°F)
IC regulator
28 - 29 V
Adjusted voltage
3
Rotation direction(when seen
Clockwise
from the pulley side)
60A specification
Speed r/min r/min MFW71CSH001701
Output Voltage 27 V Legend

characteristics 1. Bolt
42 A or 50 A or
(When heated) Current 2. Adjust plate lock nut
more more
Field coil resistance
8.3 - 9.1 Ω
(At 20°C / At 68°F)
IC regulator • Temporarily tighten the mounting bolt to the
28 - 29 V
Adjusted voltage lower and upper generator brackets.
Rotation direction(when seen
Clockwise
from the pulley side)

NOTE: Belt tension adjustment value
• Insert the lower side mounting bolt (2) from the Frequency
front, and tighten it with a nut at the rear side as Amount of
of
shown in the diagram. Belt types flex
vibrations
mm(in)
(Hz)
90A specification
Generator 4.9 - 5.9
New belt 208 - 232
1 drive belt (0.19-0.23)
a ; 50, 60A
Reused 6.9 - 7.7
belt (0.27-0.30)
Generator 5.4 - 6.6
New belt 190 - 212
b ; 90A
Reused 7.5 - 8.5
belt (0.30-0.33)
19.6 - 23.6
New belt 59 - 73
(0.77-0.93)
A/C drive belt
2 Reused 24.1 - 27.5
51 - 59
belt (0.95-1.08)
NOTE:
3
MFWB1ESH000101 • A V-ribbed belt is used for the generator drive belt,
which requires more accurate tension adjustment
Legend than conventional V belt. Therefore, use a sonic
1. Adjust bolt tension meter to check that the measured frequency
2. Generator tightening bolt of vibrations is within the adjustment value. Perform
3. Lower generator bracket adjustment if the value is improper.
Improper tension causes the belt life to shorten or
the belt to squeak.
2. Install the tension pulley (90A specifications). • After the adjustment, securely tighten each bolt.
• Temporarily install the fan belt to each pulley
(crank, water pump, and generator) and tighten
the tension pulley with three bolts so that the
belt contacts the backside of the tension pulley.
Tightening torque 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
NOTE:
• Consider the 5th re-tightening of the tension pulley
fixing bolt as the recommended time for
replacement.
• Be careful as the threaded portion may be damaged
or loose if it is reused continuously.
3. Install the fan belt.

• Install the fan belt and adjust belt tension.
• Refer to "Drive Belt" in Section 1C, Cooling
System.
Adjust it so that the amount of flex is within the
proper values as shown in the following table when
the arrow section in the engine layout diagram is
pressed with a pressure of 98 N(10 kg / 22lb).
a
1
b 1
MFW51ESH000301
6. Connect the A/C compressor harness connector.

7. Install the A/C drive belt.
Inspection
Inspect the drive belt for wear or damage and replace it
LNW71EMH000201 with a new one as necessary.
Legend Also inspect the belt tension. Adjust the tension if
1. A/C drive belt necessary.
2. Generator drive belt
4. Connect the generator harness.

• Connect the harness connector (one pole) and
B terminal cable to the generator.
5. Install the A/C compressor, and tighten at the
specified torque.
Tightening torque 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
NOTE:
• Tighten the two backside mounting bolts of the
compressor first and tighten the two front side bolts.

c
MFW71CSF000101
(a) 76 N⋅m (7.7 kg⋅m / 55.7 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(c) 126 N⋅m (12.8 kg⋅m / 93.3 lb⋅ft)
90A specification
b
c
LNW71CSF000401
(a) 40 N⋅m (4.1 kg⋅m / 29.7 lb⋅ft)

(b) 27 N⋅m (2.8 kg⋅m / 20.3 lb⋅ft)
(c) 41 N⋅m (4.2 kg⋅m / 30.4 lb⋅ft)
Emission Control (4HK1) 1F-1
ENGINE
Emission Control
(4HK1)
TABLE OF CONTENTS
EGR System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1F-2
Description of Function and Operation . . . . . . . 1F-2
EGR Valve and EGR Cooler . . . . . . . . . . . . . . . . 1F-3
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1F-4
List of Tightening Torques . . . . . . . . . . . . . . . . . 1F-7
1F-2 Emission Control (4HK1)
EGR System
Maintenance Precautions Description of Function and Operation
When assembling the EGR system, temporarily tighten The EGR system recirculates a part of the exhaust gas
once, then firmly tighten in order not to apply to the intake manifold, and by mixing in inert gas to the
unnecessary stress on the components. intake air, the combustion temperature is lowered and
the generation of NOx is suppressed.
The control method of this EGR employs an electronic
control method that ensures both drivability and low
emissions. This activates the DC (direct current) motor
using a control current from the engine control module
(ECM) to control the EGR valve.
For details on the EGR system trouble diagnosis, refer
to "Engine Control System" in Section 1A, Engine
Control System (4HK1).
Cooling water outlet Cooling water inlet
4
5
Engine speed
Engine load
LNW91FLF000401
Legend
1. ECM 4. Intake throttle valve
2. EGR valve 5. MAF sensor
3. EGR cooler 6. Intake throttle position sensor
EGR Valve and EGR Cooler

Components
2
1
6 5
LNW91FLF000101
Legend
1. EGR cooler duct 5. Exhaust EGR cooler duct
2. EGR valve 6. EGR cooler Assembly; 1st
3. EGR cooler exhaust bracket 7. Rear EGR cooler bracket
4. Front EGR cooler bracket 8. EGR cooler Assembly; 2nd
Removal NOTE:
After removing the EGR cooler duct, seal it so that
1. Drain the coolant.
foreign material does not get in.
2. Disconnect the EGR valve connector.
3. Remove the water rubber hose. 6. Remove the EGR cooler Assembly; 1st.
4. Remove the EGR cooler heater protector. 7. Remove the EGR cooler duct.
5. Remove the exhaust EGR cooler duct.
NOTE:
After removing the EGR cooler duct, seal it so that
foreign material does not get in.

8. Remove the EGR cooler Assembly; 2nd.
9. Remove the EGR valve.
NOTE:
After removing the EGR valve, seal it so that foreign
material does not get in.
Inspection
Inspection of gas leaks
• Check for gas leaks in each part of the EGR gas
line.
If any problem is found in the inspection results,
repair it or replace the part.
Inspection of the EGR valve

• Clean if there is carbon buildup.
LNW71FSH000401
• For details on the EGR valve electro-magnetic
system, refer to "Engine Control System" in
Section 1A, Engine Control System (4HK1).
3. Install the EGR cooler duct to the EGR valve and
cylinder head.
Installation • Insert the gasket and temporarily install the
NOTE: EGR cooler duct.
If the procedures or methods for assembling parts for 4. Install the EGR cooler Assembly; 2nd.
the EGR cooler are mistaken, it can lead to cracks to • Fit gaskets into both ends of the EGR cooler
pipe or gas leaks. Always follow the procedures. Assembly and temporarily install it.
After temporarily installing, securely tighten it. 5. Install the exhaust EGR cooler duct to the cylinder
head and exhaust manifold.
1. Tighten the front EGR cooler bracket and rear
EGR cooler bracket at the specified torque. (1) • Insert the gasket and temporarily install the
exhaust EGR cooler duct.
6. Install the EGR cooler Assembly; 1st.
Tightening torque • Fit gaskets into both ends of the EGR cooler
M8 24 N⋅m(2.4 kg⋅m/17 lb⋅ft) assembly and temporarily install it.
M12 104 N⋅m(10.6 kg⋅m/77 lb⋅ft)
NOTE:
2. Install the EGR valve to the inlet cover.
• After inserting each bolt, temporarily tighten bolts
• Insert the gasket and temporarily install the (2) to (7) at the torque of 4 N⋅m (0.4 kg⋅m / 35 lb⋅in)
EGR valve. using a tool (follow the tightening order shown in
the diagram).
• Temporarily tighten bolts (8) to (14) to a point
immediately before they are seated.
• Tighten at the specified torque in the order of (2) to
(14).
7. Tighten the EGR valve and inlet cover at the

specified torque. (2)


8. Tighten the EGR cooler duct, the EGR cooler
assembly and the exhaust EGR cooler duct at the
specified torque in the order of the numbers shown
in the diagram.
a. EGR valve and EGR cooler duct bolt (3)
b. EGR cooler duct and cylinder head bolts (4)
c. EGR cooler assembly; 1st and rear EGR cooler

bracket bolts (5)
d. EGR cooler duct and EGR cooler assembly;

2nd bolts (6)
e. EGR cooler assembly; 1st and EGR cooler

assembly; 2nd bolts (7)
f. Exhaust EGR cooler duct and exhaust manifold

bolts (8) to (11)
g. Exhaust EGR cooler duct and EGR cooler

assembly; 1st bolt (12)
h. EGR cooler exhaust bracket and front EGR

cooler bracket bolt (13)
i. Exhaust EGR cooler duct and EGR cooler

exhaust bracket bolt (14)

7 6
5
1
12
14
13
14
9 8,11
10 4
LNW91FLF000301
9. Install the EGR cooler heat protector and tighten it

10. Connect the water pipe and rubber hose.

• Install the clip to the specified position.
11. Connect the EGR valve connector.
12. Replenish the coolant.

d
c
b
o
n
g
j
m i
MFWB1FLF000101
(a) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(e) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(f) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(g) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(h) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(i) 35 N⋅m (3.6 kg⋅m / 26 lb⋅ft)
(j) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
(k) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(l) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
(m) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(n) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(o) 104 N⋅m (10.6 kg⋅m / 77 lb⋅ft)
MEMO
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Engine Exhaust (4HK1) 1G-1
ENGINE
Engine Exhaust
(4HK1)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1G-2
Description of Function and Operation . . . . . . . 1G-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1G-3
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1G-4
Phenomenon: Vibrations and Rattling Sounds
from the Exhaust System . . . . . . . . . . . . . . . . . 1G-5
Phenomenon: Clogging of the Exhaust System 1G-6
Phenomenon: Exhaust gas Leak, Noise . . . . . . 1G-7
Phenomenon: Exhaust Gas is Mostly Black
in Large Quantity. . . . . . . . . . . . . . . . . . . . . . . . 1G-8
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
List of Tightening Torques . . . . . . . . . . . . . . . . 1G-13
Diesel Particulate Defuser (DPD). . . . . . . . . . . . 1G-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1G-15
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-18
Exhaust Temperature Sensor. . . . . . . . . . . . . . . 1G-19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-19
Exhaust Differential Pressure Sensor . . . . . . . . 1G-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-20
1G-2 Engine Exhaust (4HK1)
Exhaust System
Maintenance Precautions Description of Function and Operation
Vibrations and looseness of the exhaust system are Exhaust brake assembly adjusts the exhaust pressure
caused by mis-positioning when assembling. to perform brake assistance, etc. Diesel particulate
Temporarily install all bolts until all components are diffuser (DPD) is equipped at the rear side of the
positioned. After positioning is completed, tighten them exhaust brake valve. The DPD is an integrated
from the engine side to the rear side. structure with the oxidation catalyst and filter. The
oxidation catalyst and filter clean exhaust gas. The
trapped PM (particulate matter) is combusted to
regenerate the filter when a certain pressure difference
between front and back of the filter is detected, and
when traveling a fixed distance. The tail pipe is
equipped with the silencer to increase the silencing
effect. The main components are: a front exhaust pipe,
exhaust brake, DPD, exhaust throttle, rear exhaust
pipe and tail pipe.
3 4
2
1
MFW81GMF000701
Legend
1. Front exhaust pipe A 5. Exhaust throttle
2. Exhaust brake assembly 6. Exhaust silencer
3. Front exhaust pipe B 7. Tail pipe
4. DPD assembly

• When inspecting or repairing the exhaust system,
check that there is an adequate gap between the
floor and body.
• Damage caused by heat from the body panel or
vibrations can cause exhaust gas to enter the
cabin. Be careful.
• Inspect for loose or damaged connections and
exhaust gas leaks.
• Inspect the clamp and rubber for degradation,
cracks or damage.
• If the pipes, DPD or silencer are damaged or
dented, repair or replace them.
• Inspect for dents or damage, or holes and
fractures caused by corrosion, and abnormal noise
when driving the vehicle.
• If a DTC relating to DPD is detected, inspect and
repair according to the troubleshooting of the DPD.
NOTE:
Before disassembling the DPD assembly, use the scan
tool to check the DPD pressure difference, status and
inspection/maintenance contents. For details, refer to
"Engine Control System" in Section 1A, Engine Control
System (4HK1).

• Vibrations and Rattling Sounds from the Exhaust
System
• Clogging of the Exhaust System
• Exhaust Gas Leak, Noise
• Exhaust Gas is Mostly Black in Large Quantity

Phenomenon: Vibrations and Rattling Sounds from the Exhaust System

Vibrations and rattling sounds from the Loose components, or improper Retighten after aligning the
exhaust system installation connections. Inspect the hanger,
installed brackets and clamps for
damage

Phenomenon: Clogging of the Exhaust System

Clogging of the exhaust system The exhaust brake and exhaust throttle Inspect and repair the control system.
are ON Refer to "Engine Control System" in
Section 1A, Engine Control System
Also, inspect the exhaust brake and
exhaust throttle shaft for strain. Replace
if there is a problem
Clogging of the exhaust pipe Repair or replace the exhaust pipe
DPD related DTC detection Inspect and repair according to the
engine control version troubleshooting
relating to DPD. Refer to "Engine
Control System" in Section 1A, Engine
Control System

Phenomenon: Exhaust gas Leak, Noise

Exhaust gas leak, noise Improper installation or connection Retighten after aligning the connections
Exhaust pipe, silencer or DPD damage, Replace the damaged parts
burning
Defective exhaust system components Replace the defective
(clamps, pipe, silencer)
Internal damage on DPD or silencer Replace the damaged parts

Phenomenon: Exhaust Gas is Mostly Black in Large Quantity

DPD failure Melted or broken filter Replacement
Clogging of the filter carbon Clean or replace
Exhaust Pipe
Removal 6. Remove the DPD differential pressure hoses (two
pieces).
1. Remove the tail pipe (1) from the silencer.
2. Remove the exhaust silencer assembly (2).
7. Remove the DPD assembly (6) from the front pipe.
2 3
1
1
2
6
MFW81GSH001501
MFW81GSH001601
Legend
3. Remove the exhaust throttle assembly. 1. Exhaust temperature sensor 2 (catalyst
entrance)
4. Remove the exhaust pipe adaptor (3). 2. Exhaust temperature sensor 1 (filter entrance)
3. Differential pressure hose (Front)
4. Differential pressure sensor assembly
5. Differential pressure hose (Rear)
6. DPD assembly
NOTE:
If it is unavoidable to remove the differential pressure
sensor assembly, be careful of the following points.
• Absolutely never loosen the four differential
pressure sensor installation screws (2). If they are
loosened, replace the differential pressure sensor
1 2 3 4 5 6 7 assembly.
• Do not reuse the differential pressure sensor
assembly if it was dropped.
MFW81GSH001701 • Do not use a tool such as an impact wrench which
Legend causes vibrations when installing and removing the
1. DPD assembly sensor assembly.
2. Gasket
3. Exhaust pipe adaptor
4. Gasket
5. Exhaust throttle assembly
6. Gasket
7. Exhaust silencer
5. Disconnect the DPD exhaust temperature sensor

connectors (two pieces).

• Install the front exhaust pipe A to the exhaust
manifold and tighten it at the specified torque.
1 2
NOTE:
Uniformly tighten the front exhaust pipe so that there is
no exhaust gas leak.
2. Install the transmission right side bracket from the

clamp of the front exhaust pipe A.
3. Install the exhaust brake assembly.

MFW81GSH002501 • Install the exhaust brake assembly (2) and front
exhaust pipe B (3) to the front exhaust pipe A
Legend
(1), and tighten them at the specified torque.
1. Differential pressure sensor assembly
2. Tightening screw (never loosen)
8. Remove the front exhaust pipe A (1) and B (3).
• Remove the clamp, and remove the front
exhaust pipe.
• Remove the exhaust brake assembly (2).
3
2
3
2
MFW81GSH001801
4. Install the DPD assembly to the front pipe.

MFW81GSH001801

Installation
NOTE: 5. Install the DPD differential pressure hose.
• Vibrations and looseness of the exhaust system • Insert the differential pressure hose surely to
are caused by mis-positioning when assembling. the bulge part of the pipe.
Therefore, temporarily tighten all bolts until all
• Insert the clip of hose surely.
components are positioned, and completely
tighten from the engine side to the tail pipe side. NOTE:
• Do not reuse the removed gasket and nut. • Do not mistake the front and rear directions.
1. Install the front exhaust pipe A. • Do not use cracked hoses.

• Absolutely do not over-tighten or remove the
differential pressure sensor assembly tightening
screw.
• There is the danger of the sensor mis-operation
when there is a gas leak from the joint sections.
After starting the engine, check that no gas is
leaking.
• Do not use a tool such as an impact wrench, etc., to
apply vibrations when installing the differential
pressure sensor.
1 2 3 4 5 6 7
2
1
MFW81GSH001701
3 Legend
1. DPD assembly
2. Gasket
4. Gasket
4 5. Exhaust throttle assembly
6. Gasket
7. Exhaust silencer assembly
6
5 9. Install the air pipe to the air cylinder of the exhaust
MFW81GSH002601
throttle assembly.
Legend
1. Differential pressure sensor assembly 4
2. Tightening screw (never loosen)
3. Differential pressure hose (rear) 3
4. Differential pressure hose (front) 2
5. Clip for differential pressure hose 1
6. Bulge section
5
6. Install the DPD exhaust temperature sensor
harness connector.
NOTE:
Do not mistake the front and rear directions.
6
7. Install the exhaust pipe adaptor to the DPD. MFW81GSH001201
Legend
1. Exhaust temperature sensor 2 (catalyst
entrance)
2. Exhaust temperature sensor 1 (filter entrance)
8. Place the exhaust throttle assembly in the exhaust 3. Differential pressure hose (Front)
pipe adaptor and install the exhaust silencer 4. Differential pressure sensor
assembly. 5. Differential pressure hose (Rear)
6. DPD assembly
10. Install the exhaust silencer assembly.
11. Install the tail pipe.

• Tighten the clamp.
NOTE:
• The clamp bolts in sequence, upper and lower.
• Install the clamp on an even keel.
MFW81GSH001501
Legend
1. Tail pipe
2. Exhaust silencer assembly
NOTE:
Start the engine after assembling each part, and check
for gas leakage from each joint and for vibration. When
the DPD assembly is disassembled, carefully check for
gas leakage as follows.
• Adequately warm up the engine.
• Rev the engine to its maximum speed. While
keeping this state, spray soapy water on differential
pressure hose connections and sleeve nut tightened
section to check for gas leakage.

e f
a c
b
MFW81GLF000701
(a) 67 N⋅m (6.8 kg⋅m / 49 lb⋅ft)

(b) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(e) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(f) 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
Diesel Particulate Defuser (DPD)

Removal a. Paint the arrow mark (1) on the filter body so
that exhaust gas flow direction may be
1. Remove the DPD assembly.
distinguished.
Refer to “Exhaust Pipe” in this section.
Disassembly
1
1. Loosen the sleeve nuts fastening the differential
pressure pipe.
2. Remove the clips (three places) that are fastening
the differential pressure pipe.
3. Remove the differential pressure pipe.
1 2 3
MFW81GSH004201
b. Loosen the nuts tightening the oxidation

catalyst section and separate the oxidation
catalyst section, and filter section.
c. Loosen the nuts that are tightening the filter to
separate the filter and the rear case.
NOTE:
5 4 Do not apply a strong impact to the DPD assembly or
drop it.
MFW71GSH003401
Legend
1. Differential pressure pipe (Front)
2. Differential pressure pipe (Rear) 4 5
3. Sleeve nut (Rear) 3
4. Clip
5. Sleeve nut (Front) 2
4. Remove the exhaust temperature sensors

(catalyst entrance, filter entrance). 1
Refer to "Exhaust Temperature Sensor" in this
section.
5. Disassemble the DPD assembly.
MFW71GSH003301
Legend
1. Oxidation catalyst section
2. Gasket
3. Filter section
4. Gasket
5. Rear case

Inspection • DPD light turns on, and turns off after
approximately 30 seconds.
1. Externally inspect the exhaust pipe components.
• After confirming that the DPD light goes out,
• Damage caused by heat from the body panel or
turn the key OFF and leave it for at least 15
vibrations can cause exhaust gas to enter the
seconds.
cabin. Be careful.
• Inspect for loose or damaged connections and NOTE:
exhaust gas leaks. However, as this differential pressure sensor zero-point
• Inspect the clamp and rubber for degradation, correction is susceptible to high temperature, do not
cracks or damage. conduct it within two hours of DPD regeneration.
• Inspect the pipe or silencer for dents, or cracks
caused by corrosion. If damaged, repair or replace Filter cleaning
them.
Ash cannot be regenerated by combustion unlike
2. Inspect the DPD related parts.
particulate matter (PM).
• Visually check the filter for erosion, damage or
clogging. Because the ash is calcined (tightly stuck) to the DPD
filter.
• Shine light on the filter from the opposite side. If
In order to remove ash, use a DPD ash removal device.
the light is visible from the other side of the
Refer to DPD ash removal device handling manual for
filter, replace the filter.
the handling of DPD ash removal device.
• Visually check the oxidation catalyst for
1. Set the DPD filter to the DPD ash removal device.
erosion, damage or clogging.
NOTE:
NOTE:
Set the DPD assembly so that arrow mark, which was
Before disassembling the DPD assembly, always use
painted at disassembly operation, face up.
the scan tool to check the DPD pressure difference,
status and inspection/maintenance contents. For
details, refer to “DTC List” in Section 1A, Engine
Control System.
MFW81GSH004101
2 2. Supply air up to the given pressure of 0.4 MPa(4.0

kg/cm2 / 58 psi) in the air tank.
Stop supplying when the air is pressurized up to
MFW41GSH001101 given pressure.
Legend
CAUTION:
1. Filter
Do not supply air exceed 0.5MPa(5.0 kg/cm2 / 73 psi)
2. Filter case
to the tank as indicated by the manometer mounted on
the pressure regulator.
At this point, check for air leaks from the pipe without
3. When the differential pressure sensor assembly
fail.
has been replaced, take the following actions (on
vehicle). 3. Press the device’s mechanical valve for three
• Turn the key from the OFF state to the ON state seconds. Implement backwashing and cleanse the
(Do not start the engine). DPD filter.

4. Repeat the work described in STEP2 and STEP3 • Do not reuse the removed gasket, nut and bolt.
three times.
CAUTION:
Ash may escape from the exhaust filter and
backwashing noises may be heard while in use.
1
Wear protective equipment, such as dust masks, safety
goggles and earplugs and operate the equipment while
keeping the face and hands at a safe distance.
Air-tightness check
Check for air-tightness when the DPD is disassembled
and reassembled (when installed to vehicle).
1. Warm up the engine and rev the engine to the
maximum speed with no load.
2. With the engine revved, check the pressure hose
connections, sleeve nuts (3) and (5) connections,
for gas leaks by spraying soapy water on them.
MFW81GSH004301
a. Insert a new gasket between the filter section

and the rear case, and temporarily tighten it
using new nuts and bolts.
b. Insert a new gasket between the filter section
1 2 3 and the oxidation catalyst section, and
temporarily tighten it using new nuts and bolts.
NOTE:
• Check that assembly position of the filter, and the
rear case and the filter and oxidation catalyst
section. Tighten both pipe brackets at two locations.
• Do not reuse the removed gasket and nut, bolt.
c. Tighten the nuts and bolts at the specified

5 4 torques.
• Tighten all nuts and bolts twice.
MFW71GSH003401
Legend
1. Differential pressure pipe (Front) Tightening torque 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
2. Differential pressure pipe (Rear)
3. Sleeve nut (Rear) NOTE:
4. Clip After tightening all nuts and bolts, within specified
5. Sleeve nut (Front) tightening torque be sure to tighten them again to the
same torque. (tighten twice)
Reassembly
1. Reassemble the DPD assembly.
NOTE:
• The DPD assembly must be installed with arrow
mark (1), which was painted at disassembly
operation, in the opposite direction of exhaust gas
flow.

CAUTION:
• If the procedures above are not observed, there is
4 the danger of the sleeve nut coming loose.
5
3
NOTE:
2 • Do not reuse the removed gasket, nut and bolt.
1 2 3
MFW41GSH001001
Legend
2. Gasket
3. Filter section
4. Gasket 5 4
5. Rear case
MFW71GSH003401
2. Install the exhaust temperature sensors (filter Legend

entrance, catalyst entrance). 1. Differential pressure pipe (Front)
Refer to "Exhaust Temperature Sensor" in this 2. Differential pressure pipe (Rear)
section. 3. Sleeve nut (Rear)
4. Clip
5. Sleeve nut (Front)
3. Tighten the sleeve nuts of the differential pressure

pipes (front) (rear) with your hand.
Installation
1. Install the DPD assembly.
NOTE: Refer to “Exhaust Pipe” in this section.
Wipe away the old seizure inhibitor and apply new
inhibitor on the sleeve nut threaded portion.
Used seizure inhibitor:

Bostik Never-Seez high temperature stainless grade
5-87411-039-0
4. Fasten differential pressure pipe with a clip.
5. Install the sleeve nut of the differential pressure

pipe by specified torque.
Tightening torque
Sleeve nut front 35 N⋅m (3.6 kg⋅m/26 lb⋅ft)
Sleeve nut rear 35 N⋅m (3.6 kg⋅m/26 lb⋅ft)

Inspection
Filter Inspection
Inspect the differential pressure.
Perform after installing the DPD to the vehicle.
1. Start the engine and confirm there is no exhaust
leakage from the DPD related parts (such as DPD
sensor, differential pressure sensor, and
connecting parts of hoses).
2. Inspect the differential pressure.
a. Observe the Exhaust Temperature 1 parameter
with a scan tool. Make
sure the temperature is less than
150°C (302°F). If more than 150°C
(302°F), let increase 1,000 r/min without load.
(Rotate the idle up sensor clockwise.)
b. Accelerate the engine to W.O.T. (accelerator
pedal full travel) and read the Exhaust
Differential Pressure parameter when the
Exhaust Temperature 1 parameter is reached
to 200°C (392°F).
3. If the inspection value is higher than limit value,
replace the filter.
Limit; 4HK1-TCS 4.0 kPa(0.041 kg/cm2 /0.58 psi)
NOTE:
After replacement of the DPD filter, perform DPD status
resetting.
DPD Regenerate Programming Procedure

DPD Regenerate data reset
• Carry out the following steps when changing the
DPD.
1. Install the scan tool.
identification > Engine > 4HK1-TC (C/Rail) >
Programming > DPD Regeneration data
reset.
4. Initiate the reset function in accordance with
the onscreen instructions.
5. After the reset is complete, if the “Programming
Completed Successfully” message is displayed,
follow the onscreen instructions to advance the
end procedure.
Exhaust Temperature Sensor

Removal
1. Remove the exhaust temperature sensor 4
connectors (two pieces).
2. Remove the clip that is holding the exhaust 5
temperature sensor harness in place.
2 3
3. Remove the exhaust temperature sensor (two
pieces). 1
NOTE:
• Wipe away the old seizure inhibitor and apply new
inhibitor on the sleeve nut threaded portion.
Used seizure inhibitor:

Bostik Never-Seez high temperature stainless grade
5-87411-039-0
6
However, it is not necessary to apply the anti-seize
compound when using a new sensor, as it is already
MFW81GSH001601
applied.
Legend
• When assembling, do not hit the tip of the sensor to
1. Exhaust temperature sensor 2 (catalyst
the other boss.
entrance)
• Do not use a sensor which has flaws or dents from 2. Exhaust temperature sensor 1 (filter entrance)
dropping or hitting. 3. Differential pressure hose (Front)
• Do not hit the protruded section after assembling 4. Differential pressure sensor
the sensor to the DPD assembly. 5. Differential pressure hose (Rear)
• Be careful not to mix up sensors ( catalyst entrance, 6. DPD assembly
filter entrance ) when assembling.
Installation
Screw size Connector color 1. Install the exhaust temperature sensor (two
Sensor M12 / 1.75 pieces).
Dark grey
(catalyst entrance) (0.47/0.069)
Sensor M12 / 1.25 Tightening torque 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
Light grey
(filter entrance) (0.47/0.049)
2. Install the exhaust temperature sensor connectors
(two pieces).
3. Fasten the exhaust temperature harness with the
clip.
4. Check for gas leakage and confirm that it is
securely sealed.
Exhaust Differential Pressure Sensor

Removal 3. Connect the differential pressure hoses (two
pieces).
1. Disconnect the differential pressure hoses (two
pieces). NOTE:
2. Disconnect the differential pressure sensor • Do not mistake the front and rear directions.
harness connector.
• Do not use cracked hoses.
3. Remove the differential pressure sensor.
• Remove the installation bolts. differential pressure sensor assembly tightening
• Remove the differential pressure sensor. screw.
• There is the danger of the sensor mis-operation
1 when there is a gas leak from the joint sections.
After starting the engine, check that no gas is
leaking.
2
3
• Do not use a tool such as an impact wrench, etc. to
pressure sensor.
MFW81GSH001401
F
Legend
1. Differential pressure sensor
2. Installation bolts
3. Differential pressure hoses
NOTE: 5 4
3 2
sensor (1), be careful of the following points.
• Absolutely never loosen the four differential
MFW81ESH000901
pressure sensor installation bolts. If they are
loosened, replace the differential pressure sensor. Legend
• Do not reuse the differential pressure sensor 1. Front mark
assembly if it was dropped. 2. Rear side differential pressure hose insertion
section
• Do not use a tool such as an impact wrench, etc. to 3. Front differential pressure hose insertion section
apply vibrations when installing the differential 4. Bracket
pressure sensor. 5. Installation bolts
Installation
1. Install the differential pressure sensor.
• tighten installation bolt by rule torque.
2. Connect the differential pressure sensor harness

connector.

Correctly assembled situation
LNW71GSH001001
0-point correction of the differential pressure

sensor
Perform 0-point correction on the differential pressure

sensor when the differential pressure sensor assembly
has been replaced. (on vehicle)
1. Turn the key from the OFF state to the ON state.
(Engine does not start.)
2. DPD light turns on, and then turns off after
3. After checking that the DPD light is extinguished,
turn the key off and leave for at least 15 seconds.
NOTE:
Performing 0-point correction tend to receive the
influence by heat easily. Do not perform corrections
until two hours after regenerating DPD.
MEMO
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Engine Lubrication (4HK1) 1H-1
ENGINE
Engine Lubrication
(4HK1)
TABLE OF CONTENTS
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . 1H-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1H-2
Description of Function and Operation . . . . . . . 1H-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1H-3
Oil Filter Cartridge . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-4
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-5
Oil Filter Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-6
List of Tightening Torques . . . . . . . . . . . . . . . . . 1H-8
Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-9
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-14
List of Tightening Torques . . . . . . . . . . . . . . . . 1H-17
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Components . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-21
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . 1H-25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-25
1H-2 Engine Lubrication (4HK1)
Lubrication System
Maintenance Precautions • Overlap the beginning and ending of the
application.
• Use a scraper to completely scrape off old liquid
gasket from the locations where it is used. After
cleaning using a rag, etc. to completely remove Description of Function and Operation
any oil, moisture and filth, apply the specified liquid
gasket. A full-flow filter element, water-cooling oil cooler, and
piston coolant oil jet are adopted for the lubrication
• Apply the proper amount to avoid an excess or
system.
lack in application. If an excessive amount is
applied, the oil gallery and oil jet head can clog,
which leads to seizures. If an insufficient amount is
applied, it causes the oil and water leaks.
Lubricating system diagram
Oil pressure switch

30 (0.3/4.5)
Battery
Engine control
100 (1.0/14) Oil pressure
switch
indicator light
Relief valve
Full flow filter Oil cooler Oil gallery (2nd)
Oil gallery (1st) Bypass valve
196 (2.0/28) 440 (4.5/64)
Crank Relief
Valve
shaft valve
train
bearing (Front cover)
Check
valve
780 (8.0/114)
Turbo Air
Oil pump Relief valve Conrad
charger compressor
bearing
Gear
Oil train
strainer
Oil jet
Oil pan
kPa (kg/cm2/psi)
MFWB1HLF000101

Inspecting the oil pressure - If the oil is insufficient, refill it to the “MAX for
1. Inspect whether the engine oil is dirty, or contains refuel” marking.
diesel oil or water. If the engine oil is dirty, or If the oil level exceeds the “MAX for inspection”
contains diesel oil or water, (after investigating the marking, make sure to replace the oil.
causes and taking appropriate measures for diesel
oil or water contained,) change the oil.
2. Inspect the engine oil level. If the oil level is low,
replenish the engine oil.
3. Install the oil pressure gauge. 3 4
4. Warm up the engine.

5. Measure and confirm that the oil pressure is 210 2
5
kPa(2.1 kg/cm2/29.9 psi) or higher at 1,400 r/min. 6
6. Stop the engine.
7. Remove the oil pressure gauge. 1
8. Install the pressure switch. 7
9. Start the engine and check that there is no oil leak.
Engine oil used

• Low ash oil for DPD
10W-30 Besco Clean LNW71HSH000201
Legend
NOTE:
1. MIN
Always use this engine oil for this engine.
2. Supply purpose MAX
3. Inspection purpose MAX
Engine oil level
4. Oil replacement is needed
• Park the vehicle on a level area. Inspect the 5. Good oil level
engine oil level with a level gauge prior to starting 6. Can be replenished up to supply purpose MAX
the engine or following more than 30 minutes after 7. Requires replenishment
stopping the engine.
• Vehicles installed with this engine are equipped
with DPD, so the method in inspecting the engine Engine oil leakage
oil level is different. • Inspect for oil leakage from the oil seals, cylinder
When a fixed amount of particulate matter (PM) head cover, and oil pan, etc. while the vehicle is
accumulates in the DPD filter, the DPD vehicle lifted up.
automatically performs regeneration (combustion).
To perform this regeneration, a slight amount of
fuel is injected into the combustion chamber after
combustion in the engine and is fed to the DPD
filter as exhaust-mixed gas. A portion of the fuel is
mixed into the engine oil causing the engine oil
increase from when it is filled, but this is not a
problem.
• Oil amount inspection method
- Oil level inspection method using a level gauge
- Remove the oil level gauge and wipe off any
adhering oil.
- Insert it all the way in again, and pull it out.
If the oil is between the “MAX for inspection”
and “MIN” markings, the level is acceptable.
Oil Filter Cartridge

Components
1
LNW21HSF000101
Legend
1. Oil filter cartridge
Removal • Tighten the cartridge at the specified torque.

1. Place a pan under the oil filter cartridge.
2. Use the oil filter wrench:1-8522-1097-0 to remove Tightening torque 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
the oil filter cartridge.
or
After touching the oil seal, further tighten 1 and 1/4
turns.
NOTE:
When attaching and removing the cartridge, be careful
not to sandwich the crankshaft position sensor
harness.
LNW21HSH000601
Installation
1. Install the oil filter cartridge.
• Apply grease (Besco L2 or L3) or engine oil to
the cartridge seal and use the oil filter
wrench:1-8522-1097-0 to install.

LNW71HSF000401
(a) 64 N⋅m (6.5 kg⋅m / 47 lb⋅ft)

Oil Filter Assembly

Components
MFW71HMF000201
Legend
1. Oil pressure switch 4. Nut
2. O-ring 5. Oil filter cartridge
3. Oil filter body 7. Bolt
1. Remove the oil pipe eye bolt. 1. Install the O-rings (1) and (2) to the oil filter body.
2. Place a pan under the oil filter assembly.
3. Remove the oil pressure switch. 1
4. Remove the oil filter body.
5. Remove the O-ring.
MFW51HSH000201
2. Install the oil filter body to the cylinder block and

tighten it at the specified torque.
LNW21HSH000301
3. Install the oil pressure switch to the oil filter body.

• Apply liquid gasket (LOCTITE 262) to 2 or 3
threads from the leading end of the threaded
portion of the oil pressure switch, and install it
to the position shown in the diagram.
LNW21HSH000401
4. Install the oil pipe.


MFW71BLF000801
(a) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)

(b) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(c) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
Oil Cooler
Components
4
3
2
8
7
MFWB1HLF000501
Legend
1. Bypass hose 5. Harness bracket
2. EGR cooler water pipe (IN) 6. Supply pump
3. EGR cooler water pipe (OUT) 7. Oil cooler
4. Common rail (Fuel rail) 8. Water inlet pipe
Removal
Fuel.
2. Remove the air compressor.
Refer to "Timing Gear Train" in Section 1B, Engine
Mechanical.
3. Remove the A/C drive belt.
4. Remove the idle pulley bracket.

• Remove the A/C drive belt and the bracket • Twist in the removed oil cooler mounting bolt
mounting bolt to remove the bracket with the into the replacer hole (1) shown in the diagram
tensioner and idle pulley. and remove the oil cooler.
LNW41BSH003401 LNW21HSH006401
5. Remove the EGR cooler water pipes (IN/OUT). 8. Remove the O-ring.
6. Remove the clip of the head side for the water
bypass hose and remove using the water inlet pipe
and the assembly.
Disassembly
1. Remove engine mounting bolts.
2. Remove the element (1).
3. Remove the O-rings (2).
2
1
1 3
4 2
MFW71HSH000301
Legend
1. Bypass hose
2. EGR cooler water pipe (IN) LNW21HSH001201
3. EGR cooler water pipe (OUT) Legend
4. Water inlet pipe 1. Element
2. O-rings
7. Remove the oil cooler assembly.
Reassembly
1. Install the O-rings (2) to the oil cooler case.
2. Install the element (1).

3. Tighten the element mounting bolt at the specified • Refer to the diagram for the tolerance range for
torque. mis-positioning the liquid gasket.
1 2
Tightening torque 20 N⋅m (2.0 kg⋅m/14 lb⋅ft) 3
4 5 6
2 b c
a
MFW81HSH000201
Legend
1. O-ring
2. O-ring
LNW21HSH001201 3. Liquid gasket
Legend 4. OK
1. Element 5. OK
2. O-rings 6. NG
7. a : 0.1 to 2.0 mm (0.004 to 0.080 in)
8. b :2 to 4 mm (0.08 to 0.16 in)
9. c : 1 mm (0.04 in)
Installation
1. Install the O-rings (1) and (2).
• Apply liquid gasket (ThreeBond 1207B) along 2. Install the oil cooler assembly.
the groove in the flange surface (3). • Align to the cylinder block stud (13), install the
• Install the O-ring to the oil path entrance / exit oil cooler, and tighten it at the specified torque
areas. in the order shown in the drawing.
NOTE:
The liquid gasket should not adhere to the O-ring. Tightening torque 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
• After applying the liquid gasket, install within 5

minutes.
11 8 4 1 5 9 12
13
14
7 3 2 6 10 15
LNW21HSH006301
3. Install the water inlet pipe.

• Position to the groove (1) of the water inlet pipe
flange surface, and apply liquid gasket
(ThreeBond 1207B) in a width of approx. 2 to 5
mm(0.08 to 0.20 in)
• Refer to the diagram for the tolerance range for
mis-positioning the liquid gasket.
1
1
1
LNW21HSH005201
Legend
2 3 4 1. Nut
2. Bolt
b c
4. Install the EGR cooler water pipe.

a
MFW81HSH000101
Legend
1. liquid gasket
2. OK
3. OK
4. NG
5. a : 0.5 to 2.0 mm (0.02 to 0.08 in)
6. b : 2 to 5 mm (0.08 to 0.20 in)
7. c : 1 mm (0.04 in) more than
• Install to the position shown in the drawing and

tighten together with the oil cooler.
• indicates the nut (1).
NOTE:
The installation of the water inlet pipe is directly after
the installation of the oil cooler (because liquid gasket MFW71HSH000201
is used with the tightening).
5. Install the idle pulley bracket and tighten it at the
specified torque.

LNW41BSH003401
6. Install and adjust the A/C drive belt.

Refer to "Drive Belt" in Section 1C, Coolant
System.
7. Install the air compressor.
Mechanical.
Fuel.
Oil Pan
Components
5
6
MFW81HLF000301
Legend
1. Oil level switch 5. Gasket
2. Oil pan gasket 6. Drain plug
3. Oil pan 7. Oil pan rubber
4. Clip
Removal 2. Disconnect the oil level switch connector.

1. Drain the engine oil. 3. Remove the oil pan.
• After draining the oil, tighten the drain plug at 4. Remove the oil level switch from the oil pan.
Installation
Tightening torque 83 N⋅m (8.5 kg⋅m/61 lb⋅ft) 1. Install the oil level switch to the oil pan.
NOTE:
Do not forget to tighten the drain plug. Tightening torque 9 N⋅m (0.9 kg⋅m/78 lb⋅in)

2. Install the oil pan. • Use the flywheel housing, the front cover and
• Apply a bead of liquid gasket (ThreeBond the crank case stud as a guide to assemble the
1207C) in the width of 3 mm (0.1 in) to the joints oil pan gasket (3) and install the oil pan (2).
(arrows at four locations) of the cylinder block, Next, tighten the oil pan rubber assembly (1)
front cover and flywheel housing. with the mounting bolt and nut to fasten.
• After applying the liquid gasket, install the oil
pan within 5 minutes.
LNW21BSH004601
3 2
LNW21BMH000101
Legend
1. Oil pan rubber
2. Oil pan
3. Oil pan gasket
• After tightening the (1), (2), (3), and (4) locations in

the drawing, tighten the others. (No particular
order is required.)

1 2
4
3
LNW21BSH013801
NOTE:
Recheck the tightening of the oil pan drain plug.
3. Connect the oil level switch connector.

4. Fill the engine oil.

MFW71HLF000401
(a) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)

(b) 83 N⋅m (8.5 kg⋅m / 83 lb⋅ft)
(c) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in)
(d) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in))
Oil Pump
Components
4
3
1
LNW21HMF000601
Legend
1. Oil pump assembly 5. Driven gear and shaft
2. Spring 6. Oil pump body
3. Ball 7. Slinger
4. Split pin
Removal • Remove the pressure plate from the flywheel.

1. Drain the engine oil.
6. Clutch disk
2. Remove the coolant.
• Remove the clutch disk from the flywheel along
with the clutch aligner.
Refer to "Cylinder Head" in Section 1B, Engine
Mechanical.
7. Remove the supply pump assembly.
For details on Smoother vehicles, refer to
Fuel.
"Transmission Assembly" in Section 5B, Automatic
Transmission Smoother (MZW). 8. Remove the flywheel.
For details on M/T vehicles, refer to "Transmission Refer to "Flywheel" in Section 1B, Engine
Assembly" in Section 5C, Manual Transmission Mechanical.
(MZW). 9. Remove the crankshaft rear oil seal.
5. Clutch pressure plate Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanical.
clutch disk. 10. Remove the oil pan.
• Remove the pressure plate mounting bolts in a 11. Remove the power steering pump.
diagonal line order. 12. Remove the power steering pump idle gear cover.

13. Remove the power steering pump idle gear. 15. Remove the idle gear A.
LNW81BSH003601 LNW21HSH005501
14. Remove the flywheel housing. 16. Remove the oil pump assembly.
• Do not forget to remove the bolt shown in the
drawing.
LNW21HSH001801
LNW21BSH053601
Disassembly
1. Remove the driven gear and shaft.
2. Remove the split pin.
3. Remove the spring.
4. Remove the ball.
Inspection
1. Measure the clearance between the gear and the
inner wall of the oil pump body.
• Use a thickness gauge to measure the
clearance between the gear and the oil pump
body.
• If the clearance between the gear and the inner
wall of the body exceeds the limit, replace the
gear assembly or driven gear assembly.
Clearance between gear and the inner • Use a dial indicator to measure the inner
wall of the body mm (in) diameter of the oil pump body and cylinder
block bush.
0.125 – 0.221
Standard values • If the clearance between the drive gear shaft
(0.00492 – 0.00870)
and the bush exceeds the limit, replace the
Limit 0.30(0.012) driven gear assembly.
Clearance between the driven gear shaft

and the bush mm (in)
0.04 – 0.07
Standard values
(0.0016 – 0.0028)
Limit 0.20(0.0079)
LNW21HSH001901
2. Measure the clearance between the drive gear

shaft and bush.
diameter of the driven gear shaft.
LNW21HSH002201
Outer diameter of the drive gear shaft mm(in)
15.989 – 16.000
Standard values
(0.62949 – 0.62992) Reassembly
1. Install the ball.
Limit 15.900(0.62598)
2. Install the spring.
3. Install the split pin and bend as shown at (1).
LNW21HSH002101
LNW21HSH006201

• Fit the idle gear shaft into the position shown in
4. Apply engine oil to the driven gear and shaft, and the drawing and apply engine oil to the shaft.
install them to the oil pump body. • Rotate the crankshaft in the forward direction to
align the first cylinder piston to the top dead
center.
LNW21HSH002401
LNW21HSH005601
Installation
1. Install the oil pump assembly.
• Apply liquid gasket (ThreeBond 1141E) as • Align the crankshaft gear and idle gear A
shown in the drawing, and install it to the alignment marks and install to the cylinder
cylinder block within 5 minutes. block.
After that, tighten it at the specified torque.
NOTE:
Apply liquid gasket so that it does not get in the hole at
the arrow in the drawing, to the gear, and inside the oil
pump body.
L
LNW21HSH002601
• It is oil application, and the application range

does things more than 17 mm (0.67 in) to bolt
from the bolt tip.
• It is oil application to the washer both sides.
• Tighten the mounting bolt at the specified
torque.
MFWB1HSH000101

2. Install the idle gear A.

• Clean the cylinder block back side. Particularly,
clean the liquid gasket that projects out when
the crank case is installed.
• As shown in the drawing, uniformly apply liquid
gasket (ThreeBond 1207C) to the inside of the
bolt hole (excluding the bolt hole at the arrow).
• After applying the liquid gasket, install it quickly.
Bead width 3.0 mm(0.14 in)

Bead height 2.0 to 4.0 mm(0.08 to 0.16 in)
LNW21BSH033201
• Position with the cylinder block knock pin to

install the flywheel housing.
Flywheel housing tightening torque

Bolts : (1) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
Bolt : (2) 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
Bolt : (3) 38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
Bolt : (4) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)

• Tighten (3) and (4) from the cylinder block side.
1
1
2
4
MFWA1BMF000801

• Apply engine oil to the gear assembly sections
of the idle gear shaft.
• Assemble the idle gear and shaft, install as
shown in the drawing, install to the flywheel
housing and tighten it at the specified torque.
LNW21BSH053601
5. Install the power steering pump idle gear cover.

• Install the O-ring to the cover, install it to the
flywheel housing and tighten the mounting bolt
LNW21BSH004301

12. Install the clutch pressure plate.
clutch disk.
• Install the clutch disk to the flywheel.
• Align the pressure plate installation hole to the
knock pin in the flywheel and install the
pressure plate to the flywheel.
• Tighten the pressure plate at the specified
torque in a diagonal line order.

Refer to "Transmission Assembly" in Section 5B,
MFW81BSH007501 Automatic Transmission Smoother (MZW). Also,
refer to "Transmission Assembly " in Section 5C,
Manual Transmission (MZW).
6. Install the power steering pump and tighten it at its
specified torque.
Refer to "Cylinder Head" in Section 1B, Engine
Mechanical.
Power steering pump mounting bolts (1) 15. Refill the coolant.
Tightening torque 50 N⋅m (5.1 kg⋅m/37 lb⋅ft) 16. Fill the engine oil.
1
MFW71BSH003301

Refer to "Oil Pan" in this Section.
8. Install the crankshaft rear seal.
Refer to "Crankshaft Rear Oil Seal" in Section 1B,
Engine Mechanical.
Refer to "Flywheel" in Section 1B, Engine
Mechanical.
10. Install the supply pump assembly.
Fuel.
11. Install the clutch disk.
Oil Pressure Switch

Inspection
Inspect the continuity between the switch terminal and
body ground without a load applied.
Replace with a normal part if there is no continuity in
the inspection.
LNW21HSH003301
Inspection of the circuit

1. Turn the engine control switch ON.
2. Disconnect the oil pressure switch connector
connection, and inspect whether the oil pressure
warning light lights up when the harness side
connect is connected to the ground.
If it does not light up, inspect the circuit between
the meter and the oil pressure switch. Repair any
open circuit.
LNW21HSH003401
MEMO
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Engine Speed Control System (4HK1) 1I-1
ENGINE
Engine Speed Control System
(4HK1)
TABLE OF CONTENTS
Accelerator Pedal Position Sensor. . . . . . . . . . . . . 1I-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-3
Idle Up Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-5
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-5
1I-2 Engine Speed Control System (4HK1)
Accelerator Pedal Position Sensor

Components
1
4
MFW71IMF000201
Legend
1. Bolt 4. Pedal
2. Control link and bracket assembly 5. Pedal stopper bolt
3. Accelerator pedal position sensor
Removal 2. Remove the control link and bracket assembly

installation nut.
NOTE:
When removing the harness connector, remove the
battery earth.
1. Turn OFF the ignition switch.
MFWB1ISH000101

3. Remove the accelerator pedal installation bolts. Installation
4. Remove the harness connector to the Accelerator 1. Install the Accelerator Pedal Position (APP) sensor
Pedal Position (APP) sensor. to the control link and bracket assembly.
5. Remove the Accelerator Pedal Position (APP)
sensor from the control link and bracket assembly.
LNW71FSH002501
LNW71FSH002401
LNW71FSH002401
2. Connect the Accelerator Pedal Position (APP)

LNW71FSH002501
sensor harness connector.
3. Install the accelerator pedal installation bolt.
4. Install the control link and bracket assembly.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MFWB1ISH000101
5. After installing the pedal, check that the gap (a) is

at the specified value when the pedal is fully
depressed.
Gap (a) [reference value]: 1.0 mm (0.039 in)
• If it needs adjustment, loosen the nut (2), turn
the bolt (1) to adjust, and then fix the nut (2).
1
2
a
MFWB1ISH000201
Idle Up Sensor
Removal
1. Disconnect the idle up sensor harness connector.
2. Remove the knob (3).
3. Remove the nut (2).
4. Remove the idle up sensor (1).
LNW81ISH000101
Installation
1. Install the idle up sensor (1).
2. Install the nut (2) and tighten at the specified
torque.
Tightening torque 0.9 N⋅m(0.09 kg⋅m/8 lb⋅in)
3. Install the knob (3).
LNW81ISH000101
4. Connect the idle up sensor harness connector.

MEMO
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Induction (4HK1) 1J-1
ENGINE
Induction
(4HK1)
TABLE OF CONTENTS
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-2
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-4
List of Tightening Torques . . . . . . . . . . . . . . . . . .1J-6
Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . .1J-7
Maintenance Precautions . . . . . . . . . . . . . . . . . .1J-7
Failure Symptom List . . . . . . . . . . . . . . . . . . . . .1J-8
Phenomenon: When Output has Dropped
Although the Engine Appears Normal. . . . . . . . .1J-9
Phenomenon: When Output has Dropped
Although the Turbocharger Generally
Appears Normal . . . . . . . . . . . . . . . . . . . . . . . .1J-10
Phenomenon: When There are
Abnormal Turbocharger Vibrations . . . . . . . . . .1J-11
Phenomenon: When Oil is Leaking from the
Exhaust or Intake and Exhaust Gas is White . .1J-12
Phenomenon: When Noise is Generated
from the Turbocharger . . . . . . . . . . . . . . . . . . .1J-13
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-14
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-16
List of Tightening Torques . . . . . . . . . . . . . . . . .1J-19
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-20
Components . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-22
Turbocharger Control Module . . . . . . . . . . . . . . .1J-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-23
MAF Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-24
Boost Pressure Sensor . . . . . . . . . . . . . . . . . . . .1J-25
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-25
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-25
1J-2 Induction (4HK1)
Air Cleaner Element

Components
1 2 3 4
7 6
MFW81JMF000101
Legend
1. Body assembly 5. Match mark
2. Element 6. Inner element
3. Wire clamp 7. Water drain valve
4. Air cleaner cover
Removal
1. Tilt the cab.
2. Remove the air cleaner cover.
• Remove the wire clamps (1) at four locations by
pressing them inside to remove the air cleaner
cover.
1
2
1
MFW81JSH000301
Legend
1. Air cleaner assembly
2. MAF sensor
2. Air cleaner inspection

• Inspect the element on a regular basis or when
the air cleaner warning light turns on.
3. Clean the element.
MFW81JMH000101
• When it is dirty with dry dust (dust sand etc),
3. Remove the element. clean it by blowing the compressed air.
• Do not remove the inner element when the • Blow the compressed air from the inside of the
outer element is cleaned. element while rotating the element.
• Never clean the inner element. Replace the
NOTE:
inner element at the same time of replacing the
outer element. • Do not hit or strike the element to clean.
• Do not exceed an air pressure of 686 kPa(7.0 kg/
NOTE: cm2 /99.5 psi)
• Make sure to use a genuine dry type element • Replace the element after using it for a year or after
because an MAF sensor is used. Do not use a wet washing it 6 times, whichever is earlier, and when it
type element because it may cause the sensor to is damaged.
become dirty.
• Use a genuine air cleaner element. If other
element is used, it may cause the sensor to send a
wrong signal.
Inspection
1. MAF (mass air flow) sensor inspection
• Refer to “Engine Control System” in Section 1A,
MAF sensor inspection.
CAUTION:
Do not touch the sensing section of the sensor with
hand because it is heated to 170 to 300°C(338 to
572°F) when the sensor is conduct electricity.
HCW310SH000101

• When blackened by oil burnt smoke such as 5. Inspect the water drain valve (1) at the lower side
soot of the air cleaner for clogging.
Dissolve a mild detergent in water and soak for Moreover, it checks whether the adhesion of water
approximately 30 minutes. Thoroughly rinse drain valve is good.
with water and allow to dry naturally (for 2 to 3
days).
Do not exceed a water pressure of 275 kPa(2.8
kg/cm2 /40 psi)
1
MFW81JSH000401
Installation
HCW31BSH057501
1. Install the air cleaner element.
4. Inspect the element for breakage or damage. 2. Install the air cleaner cover.
• Place a light in the element to inspect the • Face the ISUZU mark on the cover upward and
element for damage or pin hole, and inspect the engage the concave and convex sections (3) at
seal section for breakage. the left side of the cover.
• Hook the wire clamps to the body assembly (1)
NOTE:
at four locations, and pull it towards you to
• Make sure to replace the element if an abnormality install the air cleaner cover (2).
is found.
• Replace the element after using it for a year or after
washing it 6 times, whichever is earlier, or when it is
damaged.
HCW31BSH057601
1
2
3
MFW81JMH000201

a b
d
c e
i h
MFWA1JLF000201
(a) Hose - Intercooler: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)

(b) Pipe - Hose: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(c) Hose - Pipe: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(d) Air cleaner - Duct: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(e) Turbocharger - Hose: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(f) Duct - Turbocharger: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(g) Hose - Engine: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(h) Hose - Pipe: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(i) Intercooler - Hose: 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
NOTE:
Tighten (c) and (e) when the hose is cool.
NOTE:
Tighten (d) and (f) when the hose is cool.
Turbocharger Assembly
Maintenance Precautions • Take measures to prevent foreign material from
entering the turbine housing, compressor housing,
• The turbocharger has an extremely precise finish
the oil filler and outlet while performing the
and rotates at high speeds (approx. 100,000 r/
maintenance work.
min), and therefore, it cannot be disassembled.
Replace the whole turbocharger assembly, if even • After maintenance of the turbocharger, pour in 3 to
small abnormalities such as bent fins, bent 5 cc(0.00066 to 0.0011 lmp⋅gal) of clean engine oil
housing or scratches are found. Also, when into the turbo oil inlet hole before installing the oil
removing the turbocharger assembly or performing pipe.
maintenance for other parts, do not loosen or
remove the actuator or bracket of the turbocharger.
MFW71JMF000101
Legend
1. Compressor housing 3. Actuator
2. Turbine housing

• Output has Dropped Although the Engine Appears
normal.
• Output has Dropped Although the
Turbocharger generally appears normal.
• There are Abnormal Turbocharger Vibrations.
• Oil is Leaking from the Exhaust or Intake.
The Exhaust gas is White.
• Noise is Generated from the Turbocharger.

Phenomenon: When Output has Dropped Although the Engine Appears Normal

When output has dropped although the The turbine fins or compressor fins are Replace the turbocharger assembly
engine appears normal deformed or damaged
The fin and housing interfere Replace the turbocharger assembly
There is a large amount of carbon Clean or replace the turbocharger
deposit adhering to the turbine scroll assembly
and are in contact with the turbine fins
The turbine shaft sticks or doesn’t Replace the turbocharger assembly
rotate smoothly
There is a large amount of clearance in Measure it and replace it if it exceeds
the shaft direction or rotation direction the standard value
of the turbine shaft

Phenomenon: When Output has Dropped Although the Turbocharger Generally Appears
Normal

When output has dropped although the Gas leaks from exhaust sections Repair or replacement
turbocharger generally appears normal Excessive exhaust resistance caused Repair or replacement
(The fuel system and other mechanical by deformed exhaust muffler, or carbon
parts are normal.) clogging
Air leakage from the compressor outlet Repair
side
Dirty air cleaner element Cleaning or replacement
Clogging of intercooler cooler section Cleaning
Locking of the exhaust brake valve Repair or replacement
Defective boost sensor Replacement the boost sensor
Cause due to the vehicle side, such as Repair
dragging of the brakes
Decrease in battery performance, low Repair or replace
or excess voltage due to defective
generator

Phenomenon: When There are Abnormal Turbocharger Vibrations

When there are abnormal turbocharger The cause is bearing damage and Replace the turbocharger assembly
vibrations contact of the rotating section with the
surrounding sections
The cause is degraded oil, or entry of
foreign material in the oil hose, clogging
of the oil filter, or bearing failure caused
by repeated sudden starting and
stopping
When there is no problem in the Replace the turbocharger assembly
lubricating oil system, but there is
damage from the rotating section and
the surrounding sections in contact, it is
suspected that the rotating section has
become unbalanced or the shaft is
bent. This is the cause of either bearing
wear or damage of turbine wheel or
compressor wheel by foreign material

Phenomenon: When Oil is Leaking from the Exhaust or Intake and Exhaust Gas is White

When oil is leaking from the exhaust or Raised oil level due to dirty or clogged Clean or replace
intake. oil separator
Exhaust gas is white (normal engine) Clogging, collapsing or deformation of Repair or replacement
the oil return pipe
Diluted engine oil Replace the engine oil

Phenomenon: When Noise is Generated from the Turbocharger

When noise is generated from the Air leaks from the coupling of the rubber Repair
turbocharger hose on the compressor expulsion side
or gas leaks from the exhaust
Contact of the turbine fin with the Replace the turbocharger assembly
housing
Internal damage from foreign material Replace the turbocharger assembly
Wear or seizure of the turbine shaft Replace the turbocharger assembly
bearing
Components
2 3 4
MFWA1JLF000101
Legend
1. Oil feed pipe 5. Exhaust adaptor Assembly
2. Turbocharger 6. Oil return pipe
3. Water return pipe 7. Water feed pipe
4. Exhaust manifold

Removal 2. Remove the oil return pipe (1).
1. Remove the oil feed pipe assembly (3).
MFW71JSH000401
MFW71JSH000701
Legend 3. Remove the water pipe assemblies (1, 2).

1. Eyebolts
2. Clamps
3. Oil feed pipe assembly
1 2 1
MFWA1JSH000201
Legend
MFWA1JSH000301 2. Water pipe assembly (feed)
Legend
2. Eyebolt

4. Remove the turbocharger assembly (4). 5. Remove the heat protector and exhaust adaptor
assembly.
2 1
1 2 3 4
4
MFWB1BSH002301
MFW71JSH000101
Legend
1. Nuts Legend
2. Exhaust manifold 1. Turbocharger assembly
3. Bolt 2. Gasket
4. Turbocharger assembly 3. Exhaust adaptor assembly
4. Heat protector
Inspection
1
Visual and aural inspection
2 Remove the turbine outlet adaptor, and compressor
inlet rubber hose to visually inspect the turbocharger.
Do not disassemble or adjust the turbocharger main
unit. Do not disassemble the actuator. loosen the
bracket as these may cause improper operation.
• Inspect for abnormal sounds coming from the
turbocharger while it is running.
• Inspect the compressor housing and turbine
housing and fins whether there is interference,
damage and cracking.
3
• Inspect for oil leaking to the scroll of the housing.
MFWB1BSH002401 • Inspect for large amounts of carbon deposit
Legend adhering to the turbine scroll and whether they are
1. Exhaust manifold not in contact with the fins.
2. Nuts • Manually turn the turbine shaft to inspect for
3. Turbocharger assembly contact or catching.
• Move the shaft to inspect for too much clearance in
the shaft and rotating directions.
NOTE:
The engine blow-by gas is returned to the compressor
inlet, so the oil content that is slightly contained in the
blow-by gas may adhere to the inner walls of the
compressor inlet and outlet, but this is not a failure of
the turbocharger.

Play in the shaft direction of the wheel shaft
• Use a dial indicator to measure the play of the
shaft direction of the wheel shaft.
• Apply approximately 12 N (1.2 kg/2.6 lb) of force
alternately on the compressor wheel ends. 1
Play mm (in)
Standard values 0.03 – 0.10 (0.0012 – 0.0039)
Limit 0.13 (0.0051)
LNW21BSH022301
Legend
1. Oil outlet
2. Oil inlet
Installation
1. Install the heat protector and exhaust adaptor
assembly.
LNW21BSH022201 Tightening torque

Exhaust adaptor 33N⋅m (3.4 kg⋅m/25 lb⋅ft)
Clearance between turbine shaft and bearing Heat protector 8 N⋅m (0.8 kg⋅m/69 lb⋅in)
• Use a dial indicator to measure the clearance
between the wheel shaft and bearing.
Clearance mm (in) 1
Standard values 0.08 – 0.11 (0.0031– 0.0043)
2 3 4
Limit 0.17 (0.0067)
MFW71JSH000101
Legend
1. Turbocharger assembly
2. Gasket
3. Exhaust adaptor assembly
4. Heat protector
2. Install the turbocharger assembly (4).
1
Tightening torque
Nut (1) 52 N⋅m (5.3 kg⋅m/38 lb⋅ft) 2
Bolt(3) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
1
3
3 MFWB1BSH002401
Legend
1. Exhaust manifold
2. Nuts
4 3. Install the water pipe assemblies (1, 2).

MFWB1BSH002301
Legend
1. Nuts Tightening torque
2. Exhaust manifold Turbocharger side 27 N⋅m (2.8 kg⋅m/20 lb⋅ft)
3. Bolt Cylinder block side 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Tightening torque
Nut (2) 52 N⋅m (5.3 kg⋅m/38 lb⋅ft)
1
MFWA1JSH000201
Legend
2. Water pipe assembly (feed)

4. Install the oil return pipe (1).
1 2
Tightening torque
Turbocharger side 9 N⋅m (0.9 kg⋅m/78 lb⋅in)
Cylinder block side 21N⋅m (2.1 kg⋅m/15 lb⋅ft)
MFWA1JSH000301
Legend
1 1. Oil feed pipe assembly
2. Eyebolt
Tightening torque
MFW71JSH000401
Eyebolt (1) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
Clamp bolt (2) 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
5. Install the oil feed pipe assembly (1).
2
Tightening torque
Eyebolt (2) 17 N⋅m (1.7 kg⋅m/12 lb⋅ft)
MFW71JSH000701
Legend
1. Eyebolts
2. Clamps

n
e
d
a b
m g
l
j i
MFW81JLF000101
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(c) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(d) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(e) 33 N⋅m (3.4 kg⋅m / 25 lb⋅ft)
(f) 7.8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
(g) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(h) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(i) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(j) 9 N⋅m (0.9 kg⋅m / 78 lb⋅in)
(k) 21 N⋅m (2.1 kg⋅m / 15 lb⋅ft)
(l) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)
(m) 17 N⋅m (1.7 kg⋅m / 12 lb⋅ft)
(n) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
Intercooler
Components
2
4
6 7
1
11
9
10
MFWA1JLF000301
Legend
1. Rubber hose (inlet) 7. Intercooler outlet duct
2. Inlet pipe (turbocharger - intercooler) 8. Rubber hose (outlet)
3. Rubber hose (turbocharger outlet) 9. Intercooler
4. Radiator assembly 10. Nut
5. Radiator stay 11. Bolt
6. Boost sensor

Removal 6. Remove the intercooler installation nut and bolt
from the radiator assembly and remove the
1. Disconnect the boost pressure sensor connector
intercooler.
(2) of the intercooler outlet duct.
1 2 3 Inspection
1. If the intercooler fins are deformed, this can lead to
a drop in heat dissipation and reduce engine
performance. Repair the fins. When repairing, be
careful not to damage the base of the fins.
2. Inspect the inside of the intercooler for filth. If it is
significantly dirty, clean it.
CAUTION:
• Do not perform high-pressure washing onto the
radiator, intercooler and surrounding parts.
Cleaning
Washing the intercooler core
MFWA1JSH000101 CAUTION:
Legend Do not perform high-pressure washing onto the
1. Boost pressure sensor radiator, intercooler and surrounding parts when they
2. Boost pressure sensor connector are still installed on the vehicle.
3. Air intake duct
fabric tape.
2. Sufficiently wet the front and back surfaces of the
2. Remove the boost pressure sensor (1). intercooler.
Refer to the "Boost Pressure Sensor" in this • Adhering matter which easily comes off with a
section. splash of tap water should be washed off
NOTE:
1 Do not use a high-pressure washer or brush.

NOTE:
corrosion.

washer.
MFWA1JSH000401
• Start washing from the engine side of the
intercooler.
3. Remove the inlet and outlet rubber hoses of the NOTE:
intercooler.
• Apply the high-pressure water in a direction
4. Remove the intercooler outlet duct. perpendicular to the fins.
5. Remove the radiator assembly. • Do not bring the high-pressure water too close to
Refer to "Radiator" in Section 1C, Engine Cooling. the fins.
• Be careful not to deform the fins.

6. After washing is finished, inspect the fins to 6. Connect the boost pressure sensor connector (2).
confirm that the dirt is removed sufficiently.
• If washing is not sufficient, wash them again. 1 2 3
NOTE:
If some dirt is still left, fine black particles attached on
the fins can be seen.
7. Rinse off the detergent constituents on the fins and

sufficiently.
Installation
1. Install the intercooler to the radiator.
MFWA1JSH000101
Tightening torque 15 N⋅m (1.5 kg⋅m/11 lb⋅ft) Legend
1. Boost pressure sensor
2. Install the radiator assembly. 2. Boost pressure sensor connector
Refer to "Radiator" in Section 1C, Engine Cooling. 3. Air intake duct
3. Install the inlet and outlet rubber hoses of the
intercooler.
4. Install the intercooler outlet duct.
5. Install the boost pressure sensor (1).
Refer to the "Boost Pressure Sensor" in this
section.
MFWA1JSH000401
Turbocharger Control Module

Removal
1. Turn the engine control switch OFF.
2. Disconnect the harness connector (1).
3. Remove the turbocharger control module (2) from
the bracket.
MFW81BSH002201
Installation
1. Install the turbocharger control module (2).
2. Connect the harness connector (1).
MFW81BSH002201
MAF Sensor
Removal
1. Turn the engine control switch OFF.
3. Remove the MAF sensor.
MFW81JSH000101
Installation
1. Install the MAF sensor.
2. Connect the harness connector.

Boost Pressure Sensor

Removal
1 2 3
1. Disconnect the boost pressure sensor connector
(2).
2. Remove the boost pressure sensor (1).
1 2 3
MFWA1JSH000101
Legend
2. Boost pressure sensor connector
MFWA1JSH000101
3. Air intake duct
Legend 2. Connect the boost pressure sensor connector.

2. Boost pressure sensor connector
3. Air intake duct
Installation
1. Install the boost pressure sensor.
Tightening torque 2.5 N⋅m(0.25 kg⋅m/22 lb⋅in)

MEMO
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Pre-Heating System (4HK1) 1K-1
ENGINE
Pre-Heating System
(4HK1)
TABLE OF CONTENTS
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Function and Operation . . . . . . . 1K-2
Functional Inspection: . . . . . . . . . . . . . . . . . . . . 1K-3
Failure Symptom List . . . . . . . . . . . . . . . . . . . . 1K-6
Phenomenon: The Glow Indicator Light
Does not Light . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-7
Phenomenon: Preheating Does not Operate . . 1K-8
Phenomenon: The Preheating Time is
too Long or too Short . . . . . . . . . . . . . . . . . . . . 1K-9
Primary Specifications. . . . . . . . . . . . . . . . . . . . 1K-9
1K-2 Pre-Heating System (4HK1)
Pre-Heating System
Be careful because the glow plug can be damaged if it
is over-tightened.

Quick On Start (QOS) System
The QOS system makes it easier to start the engine in
low temperatures, and reduces the amount of white
smoke and noise generated immediately after starting
the engine. When the engine control switch is turned
ON, the ECM detects the temperature of the engine
coolant from a signal sent from the engine coolant
temperature (ECT) sensor. This can change the glow
time to always start the engine under optimum
conditions. Also, an after-glow function stabilizes the
idling immediately after starting the engine. ECM
determines the glow time according to the engine
coolant temperature, and starts the glow relay and glow
plug (preheat) indicator light.
For details on the glow control system, refer to the
"Engine Control System" in Section 1A, Engine Control
System.

Preheat system inspection and repair • Using a circuit tester, measure the resistance
1. Disconnect the system value of the glow relay (between 4 and 5).
• Remove the engine coolant temperature sensor • If the measurement reveals that the resistance
connector. value is not at the standard value, replace the
glow relay.
Glow relay resistance value is approximately

100Ω
3
2
2 3
4 5
5 4
LNW21KSH001101
• Connect a voltmeter between the glow plug and

LNW21KSH000301
engine ground.
• Turn the engine control switch ON (the engine
is stopped) position, and inspect the following.
• Location of glow relay installation;
- The glow indicator lights for 3.5 seconds. Outdoor relay box
- The voltage indicates the power voltage for
• If the inspection reveals an abnormality, inspect
the glow relay, engine coolant temperature
sensor and glow plug. If they are normal,
inspect the engine control system.
LNW71KSH000301
3. Engine coolant temperature sensor inspection
LNW21KSH000201
2. Glow relay inspection


• ECM engine coolant temperature sensor is a Resistance value at a certain temperature
thermistor type whose characteristic is that the (approximate value)
electrical resistance decreases as the
Engine coolant
temperature rises. Resistance valve
temperature
20 °C (68 °F) 2.45 kΩ
50 °C (122 °F) 0.81 kΩ
1 2
80 °C (176 °F) 0.32 kΩ
NOTE:
Be careful not to allow water to get into the terminal
section.
Wipe off the water droplets on the sensor after the
inspection.
1 2
MFW71CSH000601 Thermistor characteristic

30
Legend
20
1. Indicates the wiring
2. Indicates the wiring 10
3. ECM thermistor 7.0
)
5.0
Resistance value(k
3.0
2.0
• Place the temperature sensor portion of the
1.0
engine coolant temperature sensor into water,
0.7
and inspect whether the resistance value 0.5
changes as in the graph while changing the
0.3
water temperature.
0.2
0.1
-20/-4 0/32 20/68 40/104 60/140 80/176 100/212 120/248
LNW91CMH000201
• Replace it if any abnormality is found during the

inspection.
MFW71KSH000201

4. Glow plug inspection
• Use a circuit tester to measure the resistance
value of the glow plug.
• If the measurement reveals that the resistance
value is not at the standard value, replace the
glow plug.
Glow plug resistance value

Approximately 6Ω (Room temperature)
NOTE:
Use a 4-piece set of genuine glow plugs.
LNW21KSH000701

• The Glow Indicator Light Does not Light
• The Preheating Does not Operate
• The Preheating Time is too Long or too Short

Phenomenon: The Glow Indicator Light Does not Light

The glow indicator light does not light Slow-blow fuse has blown Replace the slow-blow fuse
Fuse has blown Replace the fuse
Burnt-out indicator bulb Replace the indicator bulb
Engine control system failure Refer to "Engine Control System" in

Phenomenon: Preheating Does not Operate

The preheating does not operate Slow-blow fuse has blown Replace the slow-blow fuse
Improper or defective glow relay Re-attach the glow relay or replace it
connector contact

Phenomenon: The Preheating Time is too Long or too Short

The preheating time is too long or too Thermo-sensor problem, open circuit or Replace the thermo-sensor; repair the
short short circuit in the circuit circuit
Faulty glow plug Replace the glow plug, or tighten it
Item Model
Preheat device model Glow plug QOS
Glow plug rated voltage and current V-A 23 - 3.5
MEMO
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Power Take-Off (PTO) (4HK1) 1L-1
ENGINE
Power Take-Off (PTO)
(4HK1)
TABLE OF CONTENTS
Flywheel PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-2
Functional and Operational Description . . . . . . 1L-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-6
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-7
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-10
List of Tightening Torques . . . . . . . . . . . . . . . . 1L-14
1L-2 Power Take-Off (PTO) (4HK1)
Flywheel PTO
Functional and Operational Description Motive energy is outputted from the PTO gear located
in the upper section of the flywheel housing, from the
The PTO crank gear is added to the end of the
PTO crank gear via the idle gear. There is no
crankshaft, and the flywheel PTO is tightened to the
mechanism for turning the motive power ON/OFF
crankshaft together with the flywheel.
partway; motive power is output by direct coupling to
the engine, regardless of the clutch and transmission
being ON/OFF.
Components
3 4
2 5
8
9
15
10
11
12
14
13
MFW71LLF000501
Legend
1. Front bearing 9. Idle gear shaft
2. PTO gear 10. Idle gear bearing
3. O-ring 11. Spacer
4. Bearing case 12. PTO crankshaft gear
5. Rear bearing 13. Flywheel housing
6. PTO shaft 14. Crankshaft
7. Oil seal 15. Idle gear A
8. Idle gear

Removal
Removal of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000601
Legend
1. Flywheel housing 12. Idle gear cover
2. Front bearing 13. Bolt
3. PTO gear assembly 14. Nut
4. Rear bearing 15. Lock washer
5. Oil thrower 16. Idle gear
6. O-ring 17. Rear bearing
7. Bearing case 18. Outer spacer
8. Oil seal 19. Inner spacer
9. Flange 20. Front bearing
10. O-ring 21. Shaft
11. Nut
1. Remove the oil pipe of the PTO gear section. • Loosen the assembly case tightening bolt, and
• Remove the clip. remove the O-ring, oil seal, rear bearing, PTO
gear, front bearing inner race in an assembled
2. Remove the PTO assembly.
state.

Removal of the PTO idle gear assembly
2 3
1 2
1
4
6
3
10
MFW71LMH000101
9
Legend MFW71LMH000501
1. PTO gear assembly Legend

2. Oil pipe 1. Idle gear A
3. Idle gear cover 2. Front bearing
3. Idle gear
3. Remove the O-ring. 4. Rear bearing
5. Lock washer
Removal of the PTO crankshaft gear assembly 6. Shaft
1. Remove the transmission. 7. Bolt
• Refer to "Transmission Unit" in Section 5B, 8. Nut
Automatic Transmission (MZW). Also, refer to 9. Inner spacer
"Transmission Assembly" in Section 5C, 10. Thrust collar
Manual Transmission (MZW).
• Refer to "Flywheel" in Section 1B, Engine
Mechanical.
• Refer to "Crankshaft Rear Oil Seal" in Section
1B, Engine Mechanical.
4. Remove the PTO crankshaft gear and spacer.

1. Remove the idle gear cover (1). 2. Remove the PTO gear assembly from the bearing
Use replacer holes (M10 x 1.5) (2) to remove it. case.
3. Remove the oil seal from the bearing case.
4. Remove the front bearing and rear bearing from
1 the PTO gear assembly.
2
1
2 3
4
5
6
7
8
9
10
11
MFW71LSH000101

3. Remove the baffle plate and adaptor.
MFW71LSH000201
NOTE: Legend
Do not remove it when there is no need for removal. 1. Front bearing
2. PTO gear
3. PTO shaft
2 4. Rear bearing
5. Oil thrower
1 6. O-ring
7. Bearing case
3
8. Oil seal
9. Flange
10. O-ring
11. Nut
Disassembly of the PTO idle gear assembly

1. Remove the bearing tightening nut to remove the
lock washer.
2. Use the press to pull the shaft out from the idle
gear assembly, then remove the tapered roller
bearing (front and rear).
MFW71LSH000901
3. Remove the outer races (front and rear) from the
Legend idle gear.
1. Baffle plate 4. Remove the inner spacer (shim) and the outer
2. Adaptor spacer (snap ring) from the idle gear.
3. Flywheel housing
4. Loosen the idle gear shaft bolt.

5. Remove with the shaft and idle gear assembly in
one piece.
Disassembly
Disassembly of the PTO gear assembly
1. Remove the O-ring from the bearing case.
2
3
4
5 6
7
8
MFW71LSH001001 MFW41LSH000201
Legend 2. Inspect the PTO gear.

1. Shaft • Inspect the gear tooth surfaces for damage and
2. Front bearing wear.
3. Inner spacer
3. Inspect the idle gear bearing.
4. Outer spacer
5. Rear bearing • Inspect the bearing for peeling, wear and
6. Idle gear abnormal sounds.
7. Lock washer • Inspect the entire circumference from between
8. Nut the roller and ball bearing cage to the inner race
for damage or peeling.
• Inspect the roller and ball bearing cage for any
Inspection abnormal looseness caused by wear.
1. Inspect the PTO bearing. • Rotate the bearing to manually inspect for
abnormal sounds, and check for any
• Inspect the bearing for peeling, wear and irregularities in movement.
abnormal sounds.
• Inspect the entire circumference from between
the roller and ball bearing cage to the inner race
• Inspect the roller bearing cage for looseness
caused by wear.
• Rotate the bearing to manually inspect for
irregularities (such as bumpiness) in
movement.
MFW41LSH000301
4. Inspect
the idle gear.
• Inspect the gear tooth surface for wear and
damage, and the inner circumference for
damage.

NOTE:
There should be no gaps between the bearing end
surface and shaft surface.
3. Attach the O-ring to the bearing case and firmly fit

the rear bearing.
NOTE:
• Apply engine oil to the ball area before firmly fitting
the rear bearing.
• There should be no gaps between the bearing end
surface and case surface.
4. Firmly fit the PTO gear assembled at

Procedure 2. into the bearing case.
5. Press the oil thrower all the way in until it touches
the rear bearing.
MFW41LSH000501 6. Apply engine oil to the lip area of the oil seal, and
use oil seal installer (9-8522-1310-0) to fit it firmly
into the bearing case.
Reassembly 7. Insert and fasten the O-ring with a nut after
Reassembly of the PTO gear assembly assembling the flange to the PTO shaft.
Reassembly of the PTO idle gear
1
2 3
4
5
6 1
7
8 2
9
10 3
11 4
5 6
MFW71LSH000201
7
Legend 8
1. Front bearing
2. PTO gear MFW71LSH001001
3. PTO shaft
Legend
4. Rear bearing
1. Shaft
5. Oil thrower
2. Front bearing
6. O-ring
3. Inner spacer
7. Bearing case
4. Outer spacer
8. Oil seal
5. Rear bearing
9. Flange
6. Idle gear
10. O-ring
7. Lock washer
11. Nut
8. Nut
1. Firmly fit the PTO gear into the PTO shaft.
• Bake-fit at below 250 °C (482°F).
2. Firmly fit the front bearing into the PTO shaft.
• Firmly fit by pushing the inner race.

1. Use the snap ring pliers to insert the outer spacer a. Measure the gap in the idle gear bearing axis
(snap ring) into the idle gear. direction. Assemble the inner race of the idle
gear bearing without the inner spacer, and
measure the thickness (1) in the bearing axis
direction on a level block.
MFW41LSH000601
2. Fit the outer race of the tapered roller bearing

firmly into the outer space until they touch.
LNW71LSH001001
b. Next, assemble the inner spacer (2) and

direction in the same way.
2
LNW71LSH000201
3. Select the inner spacer.
LNW71LSH001101
• Select spacers so that the measurements

above satisfy 0 mm (0 in) < (3) - (1) < 0.05
mm (0.002 in).
• Note that there are 21 spacer sizes in
increments of 0.07 mm (0.0028 in), ranging
from 6.05 mm (0.2382 in) to 7.45 mm
(0.2933 in).
4. Install the front side inner race to the shaft.
NOTE:
Apply engine oil to the bearing for the assembly.

5. Install the PTO idle gear.
MFW71LSH000801
MFW71LSH000601
8. Tighten the nut (2) via the lock washer (1).
6. Install the inner spacer (1).
Tightening torque 147 N⋅m (15 kg⋅m/108 lb⋅ft)
• After tightening the nut, measure the clearance
in the PTO idle gear axis direction.
- If the clearance is not within specified value,
replace the spacer and readjust it.
1
Clearance in the axis direction
0 - 0.05 mm (0- 0.002 in)
Friction starting torque

0.2 N⋅m (0.02 kg⋅m/1.7 lb⋅in)
NOTE:
• Apply engine oil to the bearing for assembly.
• The clearance value in the direction of the axis is
important. Make adjustments so that it always falls
within the specified range.
MFW71LSH000701 • After tightening, bend the lock washer to fasten the
7. Install the rear side inner spacer (1). nut.
NOTE:
Apply engine oil to the bearing for assembly.
MFW71LSH000301

Installation 2. Apply molybdenum diphenyl to the bolt seat
surface and thread section, then tighten it at the
Installation of the PTO idle gear assembly
specified torque.
2 3 Tightening torque:
98 N⋅m (10.0 kg⋅m/72 lb⋅ft)
First time
Angle-controlled tightening
1 Second time
4 method 60 - 90°
• Confirm that the bolt is tightened at 157 N⋅m
5 (16 kgf⋅m/116 lb⋅ft) or more in the tightening
direction.
3. Install the adaptor to the flywheel housing.
6 • Apply liquid gasket (Three Bond No. 1207C) to
the area (1) shown in the diagram below before
7
installation.
2
8
10
9
MFW71LMH000501
Legend 1
1. Idle gear A 3
2. Front bearing MFW81BSH000201
3. Idle gear Legend
4. Rear bearing 1. Liquid gasket
5. Lock washer 2. Flywheel housing
6. Shaft 3. Adaptor
7. Bolt
8. Nut
9. Inner spacer
10. Thrust collar
1. Install the idle gear assembly.

• The idle gear A and crank gear should be
aligned.
NOTE:
• The idle gear assembly should be securely installed
to the cylinder block installation section.
• Apply engine oil to the bearing just before
installation.
• Apply engine oil to the inner circumference of the
bush and the thrust contact surface of idle gear A.
• Take sufficient care to ensure that the thrust collar
does not come off.

• Apply liquid gasket (Three Bond No. 1207C) to NOTE:
the area (1) shown in the diagram below. After firmly fitting it in, do not hammer the cover section
(4).
1
2
MFW81BSH000301
Legend
1. Liquid gasket
2. Adaptor
4. Install the baffle plate.
3
4
MFW71LMH000301
Installation of the PTO crankshaft gear assembly

1. Install the spacer to the crankshaft gear.
2. Position the crankshaft gear to the crankshaft
knock pin, then tap with a rubber hammer to set it.
3. Install the oil seal retainer.
• When installing, apply Three Bond No. 1207C.
4. Install the slinger oil seal set to between the
crankshaft gear and oil seal retainer.
• Refer to "Crankshaft Rear Oil Seal" in Section
MFW81BSH000401
1B, Engine Mechanical.
5. Install the flywheel housing. 5. Install the flywheel.
• Refer to "Flywheel" in Section 1B, Engine
Mechanical.
Mechanical.
6. Install the idle gear cover.
6. Install the transmission.
• Apply a thin layer of grease to the O-ring (1) to
• Refer to "Transmission Unit" in Section 5B,
install it.
Automatic Transmission (MZW). Also, refer to
• Apply liquid gasket (Three Bond No. 1207C) to "Transmission Assembly" in Section 5C,
seven places on the flange surface (2) and the Manual Transmission (MZW).
bolt seat surface (3).
• Tighten the bolt at the specified torque.
Tightening torque: 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)

Installation of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000601
Legend
1. Flywheel housing 12. Idle gear cover
11. Nut
1. Apply a thin layer of oil to the O-ring and install to 3. Install the PTO assembly to the flywheel housing
the bearing case. and tighten the bearing case at the specified
2. Firmly fit the front bearing outer into the gear case. torque.
• Apply engine oil to the ball part of the bearing Tightening torque: 47 N⋅m (4.8 kg⋅m/35 lb⋅ft)
before firmly fitting it in.

4. Install PTO oil pipe brackets (1) and (2).
MFW71LMH000401
5. Install the oil pipe of the PTO gear unit.

• Install the clip.

e d
MFW71LLF000301
(a) 47 N⋅m (4.8 kg⋅m/35 lb⋅ft)

(b) 480 N⋅m (48.9 kg⋅m/354 lb⋅ft)
(c) 98 N⋅m (10.0 kg⋅m/72 lb⋅ft) → Angle-controlled tightening method 60 - 90°
(d) 147N⋅m (15.0 kg⋅m/108 lb⋅ft)
(e) 51 N⋅m (5.2 kg⋅m/38 lb⋅ft)
MG4HK-WE-1101AU_67038奥付 10.10.25 3:09 PM ページ 1

First Edition
WORKSHOP MANUAL
ENGINE
(4HK1 model)
0-XXXKI
2011MY
2011MY

WORKSHOP MANUAL
ENGINE
(4HK1 model)
No.MG4HK-WE-1101AU
2011MY
2011MY

WORKSHOP MANUAL
ENGINE
(6HK1 model)
No.MG6HK-WE-1101AU
Section Sub Section
1C Engine Cooling
1D Engine Fuel
1F Emission Control
1G Engine Exhaust
1J Induction
2B Front Suspension
2C Rear Suspension
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4D Parking Brake
5E Clutch
9C Entertainment
9D Wiring System
9F Body Structure
9G Cab
9H Seats
9L Cab Mounting
MG6HK-WE-1101AU.book 1 ページ２０１０年１１月２４日　水曜日　午後１時５０分
ENGINE
Engine Mechanical
(6HK1)
TABLE OF CONTENTS
6HK1-TC Engine . . . . . . . . . . . . . . . . . . . . . . . . . 1B-2 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-116
Precautions for Servicing . . . . . . . . . . . . . . . . . 1B-2 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-117
Technical Service Information . . . . . . . . . . . . . . 1B-2 Timing Gears, Flywheel and Flywheel Housing 1B-118
Explanation of Types. . . . . . . . . . . . . . . . . . . . . 1B-4 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-118
Explanation of Functions and Operations . . . . . 1B-5 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-118
Function Inspection List . . . . . . . . . . . . . . . . . 1B-10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-122
Function Inspection: . . . . . . . . . . . . . . . . . . . . 1B-11 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-122
Compression Pressure Measurement. . . . . . . 1B-13 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-124
Judgment of Overhaul Timing . . . . . . . . . . . . . 1B-15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-124
Failure Phenomenon List . . . . . . . . . . . . . . . . 1B-16 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-132
Phenomenon: No engine revolutions . . . . . . . 1B-17 Crank Pulley, Gearcase Cover and Crankshaft 1B-133
Phenomenon: Engine rotates but Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-133
does not start . . . . . . . . . . . . . . . . . . . . . . . . . 1B-18 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-133
Phenomenon: Lots of black exhaust gas . . . . 1B-19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-136
Phenomenon: Lots of white exhaust gas . . . . 1B-20 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-136
Phenomenon: Engine is knocking. . . . . . . . . . 1B-21 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-141
Phenomenon: Poor engine revolutions . . . . . . 1B-22 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-141
Phenomenon: Poor charge . . . . . . . . . . . . . . . 1B-23 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-152
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1B-23 Piston and Connecting Rod . . . . . . . . . . . . . . . 1B-153
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-25 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-153
Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . 1B-27 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-153
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-27 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-154
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-29 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-155
Engine Accessory Parts . . . . . . . . . . . . . . . . . . . 1B-32 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-159
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-32 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-162
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-35 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-165
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-36 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . 1B-166
Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-38 Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-166
Engine Exterior Parts . . . . . . . . . . . . . . . . . . . . . 1B-42 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-166
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-42 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-167
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-46 Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-168
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-54 Tightening Torque Table . . . . . . . . . . . . . . . . 1B-172
Tightening Torque Table . . . . . . . . . . . . . . . . . 1B-71
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-75
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1B-75
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-76
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-81
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-84
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-89
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-96
Tightening Torque Table . . . . . . . . . . . . . . . . 1B-108
Rocker Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-109
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-109
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-110
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-112
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-113
Component Parts . . . . . . . . . . . . . . . . . . . . . 1B-113
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 1B-113
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-114
6HK1-TC Engine
Precautions for Servicing Technical Service Information
Pay close attention to the following points when How to use a plastigage
servicing the engine to prevent damage to the engine,
and to preserve reliability of engine performance.
• When lifting up or supporting the engine, do not Type Measurable range mm(in)
apply the jack to the oil pan. PG-1 (green) 0.025 – 0.076(0.001– 0.003)
When lowering the engine to the ground, use an
engine palette or wooden frame to support the PR-1 (red) 0.051 – 0.152(0.002 – 0.006)
engine foot and flywheel housing. PB-1 (blue) 0.102 – 0.229(0.004 – 0.009)
• When removing the air intake system, cover the air
intake opening to prevent debris from entering the <Example> How to measure the gap between the
cylinder. If debris is allowed to enter, it may cause connecting rod bearing and crank pin.
severe damage to the cylinder etc when the engine
• Clean the connecting rod and bearing, and
is running.
assemble the connecting rod.
• When carrying out service work on the main body
• Cut the plastigage on the pin width of the crank,
of the engine, always removes the battery earth
and lay it parallel while avoiding the crank pin oil
cable. Failing to remove the battery earth cable
hole.
during such work may cause damage to the wire
harness or electrical parts. If the electricity supply • Line up the connecting rod mark and cap mark and
is required for inspections etc, make sure you do assemble the crank pin, apply molybdenum-
not cause a short circuit etc. disulfide to the thread section and seating surface
of the tightening bolt, and tighten the cap
• Apply a sufficient amount of engine oil to the
alternately to the specified torque.
rotational movement surfaces to lubricate and
protect them during initial engine running. NOTE:
• When removing valve related parts, pistons, piston Never move the connecting rod when using a
rings, connecting rods, connecting rod bearings plastigage.
and crank shaft journal bearings, be sure to
organize and keep the parts in order. • Gently remove the gap and connecting rod, and
• When re-assembling the parts, assemble the same measure the crushed width of the plastigage (gap)
parts in the same location they were in when they with the scale printed on the bag.
were removed.
• Replace gaskets, oil seals, O-rings etc. with new
ones each time they are disassembled.
• Completely remove any old liquid gasket from
locations that use liquid gasket, and clean the
locations so there is no oil, water, or dirt on those
locations. Apply the specified liquid gasket then re-
assembles the parts.
• Re-assemble the parts within 5 minutes of applying
the liquid gasket.
If more than 5 minutes pass before reassembly,
remove the liquid gasket and re-apply it.
• Tighten to the specified torque strength when
assembling or attaching parts, and make sure that
the parts are attached correctly.
Specific precautions for working on this engine HCW30ASH002001
All of the holes and gaps in the fuel lines within the fuel
system injectors are made to extremely precise
specifications. These parts are highly sensitive to dust
or debris, and dust or debris entering these parts may
cause damage to the fuel lines. Therefore, you should
aim to completely prevent any dust or debris from
entering these parts.
HCW30ASH002101 HCW30ASH002301
<Example> Measuring the gap between the crank

bearing and crank journal.
• Clean the cylinder block, crankcase bearing
mounting face, and bearing, and attach the
cylinder block to the crankcase.
• Gently rest the crankshaft on the cylinder block,
rotate approx. 30 until it falls into place.
• Cut the plastigage on the journal width of the
crank, and lay it parallel while avoiding the journal
oil hole.
• Gently place the crankcase on the cylinder block,
apply molybdenum disulphide to the thread section
and seating surface of the tightening bolt, and
tighten to the specified torque in order.
NOTE:
Never rotate the crankshaft when using a plastigage.
• Gently remove the crankcase, and measure the

crushed width of the plastigage (gap) with the
scale printed on the bag.
HCW30ASH002201

Explanation of Types
MFW71BMF000801
Legend
1. Engine number imprint location (6HK1-……)

Explanation of Functions and Operations
Engine structural diagram
Left side (full cab)
MFWA1BMF001901

Right side (full cab)
MFWA1BMF002401
Upper surface (full cab)
MFWA1BMF001801

Left side (wide cab)
MFWA1BMF002901
Right side (wide cab)
MFWA1BMF003001

Upper surface (wide cab)
MFWA1BMF000901
Electronic engine control EGR device

Control units control fuel injection volume, fuel injection The ECM performs control based on information such
timing, EGR, idling speed etc. and intake/exhaust gas as water temperature, engine r/min, and engine load,
from injection. and exhaust gasses are cleaned by recycling part of
the exhaust gas.
Cylinder block
The main components are EGR valve, EGR cooler,
The cylinder block, which is made of cast iron, has a
exhaust brake valve, and various sensors.
symmetrical, rigid construction centered on the
crankshaft center, with equal center distances from Connecting rod cap bolt
each bore. The bearing cap is of a ladder frame The connecting rod cap attachment bolt is attached
construction, and is attached using the angle method. using the angle method.
Cylinder liner Common rail electronic fuel injection system
The cylinder liner is lined-up with the internal diameter The common rail electronic fuel injection system
of the cylinder block, and the cylinder liner is grade consists of a supply pump that sets the target pressure
marked on the left hand side of the cylinder performing and supplies high pressure fuel, a common rail that
cylinder liner selection attachment. accumulates the high pressure fuel, and injectors that
reduce the amount of high pressure fuel and then inject
Piston
it. Each of the controls is based on various signals, and
The pistons are constructed from aluminum alloy, and
the Engine Control Module (ECM) controls the injection
the combustion chamber is a round-shaped reentrant
timing and quantity for every kind of driving condition.
type.
Injectors
Cylinder head
The injectors use 7 multi-hole nozzles, and the opening
The cylinder heads are constructed of cast iron, and
and closing of an electromagnetic valve in the injector
there are 4 valves per each cylinder. The head bolt is
head to adjust the injection timing and quantity.
attached using the angle method.
Fuel filter with sedimenter
Crankshaft
The filter has a sedimenter that removes moisture
TUFFTRIDE treatment process is applied, and the
content by the difference in the specific gravity of diesel
grades of each journal diameter are marked on the #1
fuel and water, and it is also equipped with an indicator
balance weight.
that informs when water has accumulated.

Preheating system
The QOS-II system has been adopted for the
preheating system. Furthermore, the controller has
been integrated with the Engine Control Module (ECM).
Lubricating system
The full flow bypass single-unit oil filter uses the water-
cooled oil cooler and oil jet for piston cooler.
An integrated Diesel Particulate Defuser (DPD)
oxidation catalyst is installed for reducing exhaust gas.

Function Inspection List
• Valve clearance inspection and adjustment
• Compression pressure measurement
• Judgment of overhaul timing

Function Inspection:
Valve clearance inspection and adjustment • Completely loosen each adjustment screw for
1. Remove the head cover. the bridge and rocker arm.
2. Valve clearance inspection.
• Rotate the crankshaft forwards and line up the
top compression dead point of the 1st cylinder.
• Insert a 0.4 mm (0.0157 in) thickness gauge
into the space between the rocker arm and
bridge to inspect the clearance, and adjust the
clearance if required.
Valve clearance
Intake valve 0.4 mm (0.0157 in)
Exhaust valve 0.4 mm (0.0157 in)
NOTE:
Adjust while cold.
BLW51BSH005501
1
• Insert a 0.4 mm (0.0157 in) thickness gauge
between the rocker arm tip (valve side) and cap
(attached to the top of the bridge), tighten the
adjustment screw on the rocker arm, then fix
the rocker arm adjustment screw nut at the
point where it is hard to insert and remove the
thickness gauge.
Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
2
MFWB1BSH003301
Legend
1. Gearcase cover marks
2. Crankshaft damper 0 degree mark
3. Valve clearance adjustment.
NOTE:
Make sure that the bridge is adjusted so that it is level
(touching the ends of the 2 valve shafts).
BLW51BSH005601

• With the thickness gauge inserted, check that
the tip of the adjustment screw and edge of the
valve shafts touch and the movement of the
thickness gauge becomes hard when the
bridge adjustment screw is gently tightened.
• Next, check that the opposite side of the valve
shaft is not floating and not slanting. If it is
floating or slanting, slightly loosen the bridge
adjustment screw and adjust the valve shaft
ends on both sides so that they touch correctly.
Valve bridge clearance: Less than 0.1 mm
(0.0040 in).
• Once both sides of the valve shaft edges are
adjusted to touch correctly, while fixing with a
flat head (minus) screwdriver so that the bridge
adjustment screw does not rotate, tighten the
bridge adjustment screw nut.
BLW51BSH005701
Tightening torque Tightening torque

22 N⋅m (2.2 kg⋅m/16 lb⋅ft) Rocker arm adjustment
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
NOTE: Bridge adjustment
Precise adjustments must be performed. If adjustment 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
Screw/nut:
of the bridge adjustment screw is not performed, faults
such as the bridge inclining and being pressed down,
burn, bridge guide chipping etc. will occur.
Valve clearance adjustment table

Cylinder No. 1 2 3 4 5 6
Arrangement
Condition IN EXH IN EXH IN EXH IN EXH IN EXH IN EXH
of valve
When the #1
cylinder is set
at the { { { { { {
compression
Valve to be top dead center
adjusted When the #6
cylinder is set
at the { { { { { {
compression
top dead center
Injection sequence (1 - 5 - 3 - 6 - 2 - 4)
4. Install the head cover.


Compression Pressure Measurement
1. Start the engine to warm it up to the normal
operating temperature, and stop it.
1 2 3
2. Disconnect the negative terminal of the battery.
3. Remove the intake pipe.
• Remove the nut for the bracket. 4
5
• Loosen the 2 clamps for the rubber hoses at the
intercooler outlet and the intake pipe (1).
MFWA1BSH001301
Legend
1. Intake throttle
2. Gasket
3. Inlet pipe
4. Bracket
5. Gasket
MFW61BSH000801
6. Remove the harness connector for the injector

4. Remove the 4 fixing bolts for the intake throttle. attached to the cylinder head cover; lower. (No fuel
• Remove the harness connector for the intake injection)
throttle.
NOTE:
• Remove the fixing bracket for the harness.
• When the harness connector is removed, the ECM
5. Remove the 3 fixing nuts for the inlet pipe. judges a malfunction and records a DTC.
• Remove the harness connector for the boost Always clear the ECM memory after completing the
sensor. measurements. (Refer to the Engine Control
• Remove the fixing bracket and clip for the System section for the ECM memory clear
injection pipe. procedure)
HCW46BSH002201

12. Turn the starter to test the compression pressure.
7. Remove the 4 fixing nuts for the harness connector
bracket. Compression
MPa (kgf/cm2/psi) / 200 r/min
• Remove the stud bolt (1) at the left hand side of pressure
the connector bracket.
Standard value 3.2 (33 / 469)
Limit 2.3 (23 / 327)
Difference between
290 kPa (3.0 / 43)
each cylinder
13. Measure the compression for each cylinder.
NOTE:
Use a fully charged battery in order to keep the engine
r/min more than 200r/min.
1 14. Disconnect the negative terminal of the battery.

15. Remove the special tools; the compression gauge
and the adaptor.
16. Install the stud bolt at the left hand side of the
connector bracket.
MFW71BSH015401 17. Install the harness connector bracket with the 4
nuts.
18. Install the harness connector for the injector at the
8. Remove all the grow plugs. cylinder head; lower.
9. Connect the negative terminal of the battery. 19. Install the inlet pipe with the 3 nuts.
10. Turn the starter and discharge foreign matter • Install the fixing bracket for the injection pipe
inside the cylinders. and the clip.
11. Install the special tools; the compression gauge (5- • Connect the harness connector for the boost
8840-2675-0) and the adaptor (5-8840-2815-0). sensor.
20. Install the intake throttle.
• Install the fixing bracket for the harness.
0
0
0
0 0 0
0
0
0
• Connect the harness connector for the intake
0
0
0
0 0
0
throttle.
21. Install the intake pipe.
• Install the bolt for the bracket.
• Tighten the 2 clamps for the rubber hoses at the
intercooler outlet and the intake pipe.
22. Install all the grow plugs.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft
• Install the 2 fixing clips for radiator overflow

water pipe.
MFW410SH000201
23. Connect the negative terminal of the battery.

Judgment of Overhaul Timing
Rate of increase of engine oil consumption
If the rate of consumption (the number of km that the
vehicle can drive on 1L) is taken as 100% for a new
vehicle, the vehicle needs overhauling when the rate
drops less than 50%.
Rate of increase of fuel consumption rate

If the rate of consumption (km/L) is taken as 100% for a
new vehicle, the vehicle needs overhauling when the
rate drops less than 60%.
Abnormal noises from within the engine

If the cause of the abnormal noises is from inside the
engine, perform an early overhaul and remedy the
problem.
There are many causes for abnormal noises to come
from the engine. However, it seems that most cases of
burning or debris in the engine occur when there is a lot
of wear on engine parts.

• No engine revolutions
• Engine revolutions do not start
• Lots of black exhaust gas
• Lots of white exhaust gas
• Engine is knocking
• Poor engine revolutions
• Poor charge

Phenomenon: No engine revolutions

No starter revolutions Bad battery relay Replace
Bad wiring Connect or repair
Insufficient battery capacity Recharge or replace
Fixing, or wear/damage to the starter Repair or replace
brush
Starter internal functional failure Disassemble and repair
Starter rotates but doesn’t engage the Flywheel starter gear wears Repair or replace
flywheel Poor adjustment of start magnetic Adjust or repair
switch
Starter pinion engages the link gear but Poor battery capacity Recharge or repair
does not rotate Insufficient connection pressure Disassemble and repair
between starter brush and commutator
Starter armature fixed Disassemble and repair
Engine internal seizure Disassemble and repair

Phenomenon: Engine rotates but does not start

Fuel is not arriving in the supply pump Air mixed in the fuel system Air removal
Air intake from the fuel pipe Air removal or replace
Out of fuel Add fuel
Blocked strainer in fuel suction section Clean or replace
Blocked fuel pipe Clean or replace
Functional failure in supply pump Disassemble and repair
Extreme cold period( fuel is not for cold Replace with suitable fuel
regions)
Blocked fuel filter Replace
Engine control system fault Diagnose the engine control system
Fuel is arriving in the supply pump Loose connection in injection pipe Tighten each section
Overflow valve not airtight Replace
Supply pump internal malfunction Replace
Bad wiring connection or broken wire Repair or replace
Revolution sensor failure Replace
Insufficient or unstable fuel injection Air mixed in the fuel system Air removal
quantity Blocked fuel pipe Clean or replace
Functional failure in supply pump Replace
Injector nozzle fixing Replace
Bad wiring connection or broken wire Repair or replace
Fuel filter blocked Replace

Phenomenon: Lots of black exhaust gas

Injection timing fault Engine control system fault Diagnose the engine control system
Injector poor injection condition Nozzle fixing Replace
Poor compression pressure Excessive valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Air cleaner element blocked Clean or replace
DPD failure Melted or broken filter Replace
Fault detected by engine control system Each sensor etc. malfunction Repair or replace
EGR or intake throttle valve failure EGR valve seizure Repair or replace
Exhaust brake valve seizure Repair or replace
Fixing of the intake throttle valve Repair or replace

Phenomenon: Lots of white exhaust gas

Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Poor compression pressure Excessive/too little valve clearance Adjustments
Valve stem fixing (valve open condition) Disassemble and repair
Poor valve spring Replace
Compression leak due to poor piston Disassemble and repair
ring etc.
Bad gasket Disassemble and repair
Piston burning Disassemble and repair
Bad fuel Water is mixed with the fuel Replace
Excessive oil consumption Piston ring worn or broken Disassemble and repair
Bad valve stem oil seal Disassemble and repair

Phenomenon: Engine is knocking

Fault detected by engine control system Each sensor etc. malfunction Replace
Control unit malfunction Replace
Fuel Inferior fuel used Replace
Intake air failure Air duct blocked Repair or replace
Engine malfunction Debris inside the cylinder Repair or replace
Piston, bearing etc. burning Repair or replace

Phenomenon: Poor engine revolutions

Revolutions do not increase Control unit malfunction Replace
Unstable revolutions Control unit malfunction Replace
Fuel filter element blocked Replace element
Injector failure Replace
Water is mixed with the fuel Replace
Air mixed in the fuel system Air removal
Exhaust brake valve fixing Repair or replace

Phenomenon: Poor charge

Does not charge Broken wire, short circuit, bad Repair or replace
connection in the wiring
Generator internal functional failure Disassemble and repair
Insufficient charge Short circuit, bad connection in the Connect or repair
wiring
Loose generator drive belt Adjust or repair
Bad battery Replace
Overcharge Wiring short circuit Connect or repair
Main Specifications
Model 6HK1-TCN 6HK1-TCC 6HK1-TCS

Water-cooled 4-cycle in-line 6-cylinder 24-valve
Engine type
OHC direct-injection diesel engine
Cylinder layout and
number - inside diameter mm (in) L6 - Dia 115 (4.53) - 125 (4.92)
- stroke
Total displacement L (in3) 7.79 (475.35)
Compression ratio 17.5
kPa (kgf /
Compression pressure cm2 / psi) / 3,240 (33 / 469) / 200
r/min
Dimensions (length / Full cab: 1,280 / 841 / 970 (50.4 / 33.1 / 38.2)
mm (in)
width / height) Wide cab: 1,311 / 841 / 1,003 (51.6 / 33.1 / 39.5)
Drying weight (excluding
N (kg / lb) 6,011 (613 / 1,352)
air cleaner)
Fuel injection timing BTDC 0°
Fuel injection sequence 1-5-3-6-2-4
Injection pump type Electronically controlled fuel injection system (common-rail type)
Inlet and exhaust valve
mm (in) 0.4 (0.016)
clearance (when cold)
Inlet valve opening and
Open 17° (BTDC)
closing timing
Inlet valve opening and
Close 42° (ABDC)
closing timing
Exhaust valve opening
Open 48° (BBDC)
and closing timing
Exhaust valve opening
Close 14° (ATDC)
and closing timing
Fuel filter type Filter paper type
Oil filter type Full-flow Filter paper type
Oil pump type Gear type
Model 6HK1-TCN 6HK1-TCC 6HK1-TCS

Oil cooler type
Water-cooled type
(Incorporated transaxle EGR cooler)
Total capacity: Shallow pan type 13.5 (2.97),
Deep pan type19.5 (4.29)
Engine oil amount L (Imp.gal) oil pan: Shallow pan type 11.0 (2.42),
Deep pan type 16.0 (3.52)
with combined oil filter
Cooling unit system Water-cooled forced circulation type
Full cab, Wide cab and Crew cab:
Except FTS: TCN / TCC M/T (29.5 / 6.49)
Total cooling water
L (Imp.gal) FTS: TCN / TCS M/T (30.0 / 6.60),
capacity
TCN / TCC A/T (32.5 / 7.15),
TCS A/T (33.5 / 7.37)
Water pump type Centrifugal belt type
Wax pellet type (with jiggle valve,
Thermostat type
without jiggle valve (one for each))
Air cleaner type Cyclone filter paper type
Type -
Battery type 65D23L - 2, 80D26L - 2, 115E41L - 2
number
Generator capacity V-A 24 - 50, 24 - 60, 24 - 90
Starter V - kW 24 - 5.0
Idle speed r/min 500 to 550
Turbocharger type GTA40V (Honeywell)
Inter-cooler type Aluminum tube and end plate type
Thermostat open valve
ºC (°F) 82 (180)
temperature
Thermostat totally open ºC / mm
95 / 8 (203 / 0.315)
temperature/lift amount (°F / in)
Exhaust gas recirculation (EGR) Provided

Special Tools
5-8840-2815-0
5-8840-2628-0
Compression gauge
Valve guide replacer
adaptor
5884028150
5-8840-2675-0 5-8840-2623-0
Compression gauge Injector sleeve remover
5884026750
5-8840-2826-0 5-8840-2627-0
Injector remover Oil seal installer
5884028260 5884026270
5-8840-0019-0 5-8840-2626-0
Sliding hammer small Bridge guide setting tool
5884026260
5-8840-2624-0
5-8840-2621-0
Injector sleeve setting
Valve spring replacer
tool
5884026210 5884026240
5-8840-2625-0
8-9439-6862-0
Valve stem seal setting
Pivot
tool
8943968620
8-9439-6858-0 5-8840-2397-0
Slinger replacer Cylinder liner remover
5884023970
9-8521-0157-0 1-8521-0050-0
Pilot bearing replacer Pulley puller
9852101570 1852100500
8-9439-6856-0 1-8522-0047-0
Oil seal setting tool kit Seal unit setting tool
1852200470
8-9439-6818-0 1-8522-1097-0
Crankshaft gear puller Oil filter wrench
8943968180 1852210970
8-9439-6819-0
9-8522-1310-0
Crankshaft gear setting
Oil seal installer
tool
9852213100
1-8522-1029-0
Piston ring setting tool
1852210290
Engine Assembly
Removal 10. Remove the two connectors of the cab tilt hydraulic
pump.
NOTE:
Precautions when installing or removing the engine. 11. Remove the connector of the voice alarm speaker.
• Always apply chock blocks to the vehicle wheels. 12. Remove the cab tilt hydraulic pump assembly.
• Select an engine hoist that is able to withstand the • Use the removed bolt to attach the removed
weight of the engine. hydraulic pump to the frame hole when
removing the cab back member, so the pump
• Do not get under the engine while it is hoisted.
does not get in the way.
• Never put your hands where they can get easily
13. Remove the reservoir tank hose clip.
caught.
14. Remove the power steering reservoir tank to free
1. Disconnect the negative terminal of the battery it.
cable. 15. Remove the oil level gauge.
2. Remove the engine side noise cover. 16. Remove the rubber hose clip of the oil level gauge
3. Remove the transmission assembly. guide tube, and the rubber hose.
• Refer to "Transmission ASM" in Section 5B, 17. Remove the cab back member.
Automatic Transmission Smoother. or 18. Remove the connector and terminal of the starter.
"Transmission ASM" in Section 5C, Manual Also remove the bracket of the harness.
Transmission. 19. Disconnect the wiring of the generator.
4. Drain the coolant. 20. Remove the turbocharger out rubber hose
(turbocharger – intercooler).
21. Remove the radiator breather hose.
22. Remove the radiator hose (upper side).
23. Disconnect the unipolar connector of the A/C
compressor.
24. Loosen the A/C compressor idle pulley lock nut,
and move the pulley with the adjust bolt to remove
the cooler belt.
25. Remove the mounting bolts of the A/C
compressor, and then remove it from the engine
side without disconnecting the pipes and secure it
1 to the chassis side with a belt, etc.
2
3 26. Remove the power steering oil pump.
• Remove the power steering oil pump, and
suspend it on the vehicle side with a belt, etc.
MFW61BSH006001
Legend
1. Intercooler
2. Radiator
3. Drain Plug
5. Remove the air compressor charge hose on the air

dryer side.
6. Remove the MAF sensor connector and harness
clip.
7. Loosen the clamp of the air cleaner duct (air
cleaner – turbocharger).
8. Remove the clip of the air compressor suction
hose.
9. Remove the air cleaner assembly installation nuts.

27. Remove the radiator hose (lower side). 35. Remove the hose of the fuel filter assembly. (feed
and return).
• Plug the hose so that fuel does not leak.
36. Remove the left and right noise covers on the cab
side, and the engine noise cover and mud-guard
on the right side.
37. Remove the engine mount.
• Before removing the engine mount, use the
hoist to suspend the engine.
• Remove the mounting nut and bolt of the
engine mount.
1
38. Remove the engine assembly.
• Slowly operate the hoist to raise the engine to
the top surface of the chassis frame.
2
3
MFW41CSH002101
Legend
1. Intercooler
2. Radiator
3. Radiator hose (lower side).
28. Remove the two connectors on the near side of the

ECM (noise cover side) and the two ECM
connectors.
29. Remove the engine harness and harness bracket
on the near side of the ECM.
30. Remove the heater hose.
31. Remove the clamp of the intercooler outlet rubber MFW71BSH006801
hose, and then remove the inlet pipe (1)

(intercooler – intake pipe).
• Turn the engine 90° and move it from the top
1 surface of the chassis frame to remove the
engine assembly.
MFW61BSH000801
32. Remove the radiator rubber ring. MFW71BSH006901
33. Remove the fan guide.

34. Remove the fan drive. (with fan)

Installation • Tighten the front side and rear side engine
mounts at the specified torque.
1. Install the engine assembly.
• Install the hoist wire to the engine hook and
hoist to install the engine. Tightening torque
• Operate the hoist to move the engine to the Front side
installation position. 83 N⋅m (8.5 kg⋅m/61 lb⋅ft)
(Engine foot side nut)
215 N⋅m (22 kg⋅m/159 lb⋅ft)
< with DRY condition >
Rear side * w/o MZW transmission
(Engine foot side bolt) 116 N⋅m (11.8 kg⋅m/85 lb⋅ft)
< with WET condition >
* MZW transmission
3. Install the fuel filter.

• Install the fuel filter assembly.
• Install the fuel hose.
• Connect the connector of the sedimenter.
MFW71BSH006901
• Turn the engine 90° and slowly lower the

engine to the installation position.
CAUTION:
Never get under the engine while it is hoisted.
MFW61DSH000101
4. Install the heater hose.

5. Install the bracket of the harness on the engine left
side (vehicle left side), and connect the connector.
6. Install the inlet pipe (1) (intercooler – intake pipe).
• Tighten the clip.
Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)
MFW71BSH006801
2. Install the engine mount.

• After temporarily tightening the installation nut
of the engine mount, remove the hoist.
1 11. Install the power steering reservoir tank and

tighten it at the specified torque.
12. Install the intake pipe (turbocharger – intercooler),
and then install the heat protector of the
turbocharger rubber hose.
13. Install the guide tube of the oil level gauge and the
oil level gauge.
• Install the rubber hose to the second spool or
the bracket of guide tube, and fix with the clip.
14. Install the power steering oil pump.
• Install the power steering oil pump and tighten
the bolts at the specified torque.
• Install the bracket of the power steering oil pipe.
MFW61BSH000801
• Adjust the adjust bolt so that the amount of flex
is approximately 6 to 7 mm (0.24 to 0.28 in)
when the center of the belt between the crank
pulley and idle pulley is pushed with a force of
7. Install the cooling fan. approximately 98 N (10 kg / 22 lb).
8. Install the bell mouth stay. After adjustment, tighten the center nut of the
9. Install the radiator hose (upper side). idle pulley.
16. Install the wiring of the generator.
17. Connect the starter wiring, and install the bracket
Tightening torque
of the C terminal.
5 N⋅m (0.5 kg⋅m/43 lb⋅in) 18. Connect the flexible joint section of the air
compressor charge hose.
10. Install the radiator hose (lower side). 19. Install the cab back member and tighten it at the
specified torque.
Tightening torque • Install the cab back member, and connect the
connectors of the relay connected to the cab
5 N⋅m (0.5 kg⋅m/43 lb⋅in) back member and the magnetic valve.
Tightening torque
94 N⋅m (9.6 kg⋅m/69 lb⋅ft)
20. Install the power steering reservoir tank.

21. Install the cab tilt hydraulic pump assembly.
22. Install the air cleaner assembly.
23. Install the air cleaner duct (air cleaner –
turbocharger).
1 • Tighten the clip.
Tightening torque
2 6 N⋅m (0.6 kg⋅m/52 lb⋅in)
3
24. Install the air compressor suction hose.
MFW41CSH002101
25. Install the harness connectors.
Legend
1. Intercooler • Connect the wiring connectors of the switches,
2. Radiator sensors, and units.
3. Radiator hose (lower side)

Automatic Transmission Smoother.
5C, Manual transmission.
27. Install the engine side noise cover.
28. Pour the coolant.
29. Connect the negative terminal of the battery cable.
NOTE:
Perform the following inspection when installing the
engine.
• Check the amount of engine oil and coolant.

• Adequately remove the air from the fuel system.
• Check the pulling margin of the parking brake
lever.
• Remove rags and all items that may get caught
which are near the engine, and wipe off any fuel or
engine oil stuck to the engine.
• Confirm that the DTC light is not lit.
• Confirm that the shift lever is in the neutral
position, and start the engine after announcing it to
those in the vicinity.
• Confirm that there is no oil or water leakage from
the engine parts.
• Confirm that there is no fuel, oil, or air leakage
from the connection of each pipe.
• Confirm that there is no abnormal noise coming
from each part.
• Confirm that no exhaust gas is leaking and that the
exhaust gas is colorless.
• After stopping the engine, inspect whether the oil
and coolant are at the specified level.
• Perform a test drive and confirm that there are no
abnormalities.
Engine Accessory Parts

Component Parts
Full cab (left side)
4 3
MFWA1BMF002001
Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive

Full cab (right side)
1
2
4 3
MFWA1BMF002501
Legend
1. Drive belt 3. Generator
2. A/C compressor 4. Starter motor

Wide cab (left side)
4 3
MFWA1BMF001001
Legend
1. Fan cover assembly 4. Power steering oil pipe
2. Cooling fan 5. Fan drive

Wide cab (right side)
1
2
4 3
MFWA1BMF001401
Legend
1. Drive belt 3. Generator
2. A/C compressor 4. Starter motor
Removal
1. Remove the fan cover assembly.
2. Remove the cooling fan.
3. Remove the fan drive.
4. Remove the drive belt(for fan, A/C compressor).
6. Disconnect the generator.
7. Remove the power steering oil pipe.
8. Remove the power steering oil pump.
NOTE:
Stopper the pump internal section so that debris cannot
enter.
MFW41BSH001501
9. Disconnect the starter.


Installation
1. Install the starter motor. 1
Tightening torque 2
82 N⋅m (8.4 kg⋅m/61 lb⋅ft)
2. Install the power steering oil pump.
Tightening torque
50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
MFW41BSH032301
6. Adjust the drive belt tension.

• Loosen the top and bottom mounting bolts of
the generator, and adjust the belt tension with
the adjusting bolt so that the tension is kept
within the standard values when the middle
section of the belt is pressed with the force of
about 98 N (10 kg /22 lb).
• When adjusting the A/C compressor belt,
loosen the nut of the idle pulley and use an
adjust bolt to adjust the belt.
MFW41BSH001501 Belt tension adjustment value

Amount of Frequency Tension
Generator flex of N
3. Install the power steering oil pipe. drive belt mm vibrations (kg / lb)
4. Install the generator. (in) Hz
5. Install the A/C compressor (2), and tighten the bolt 980 – 1176
(3). When using 4–5 (100 – 120
191 – 209
new belt (0.16 – 0.2) /
NOTE: 221 – 265)
Do not forget to insert spacer (1) between the bracket 706 – 804
and A/C compressor. When 6–7 (72 – 82
162 – 172
readjusted (0.24 – 0.28) /
159 – 181)
Tightening torque
40 N⋅m (4.1 kg⋅m/30 lb⋅ft)

7. Install the fan drive.
Amount of Frequency Tension
A/C
flex of N
compressor Tightening torque
mm vibrations (kg / lb)
drive belt 36 N⋅m (3.7 kg⋅m/27 lb⋅ft)
(in) Hz
392 – 588
When using 10 – 13 (40 – 60 8. Install the cooling fan.
115 – 141
new belt (0.39 – 0.51) /
88 – 132)
Tightening torque
294 – 392
When 13 – 15 (30 – 40 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
101 – 115
readjusted (0.51 – 0.59) /
66 – 88) Full cab and wide cab
NOTE:
• A V-rib belt is used for the generator drive belt. It is
necessary to adjust the tension more accurately 2
compared to conventional V belts. If the tension is 1
improper, the belt life will be reduced, or the belt can
squeak. Therefore, be sure to set the exact tension.
A method for checking whether the precise tension
has been set is to use a sonic tension meter to
confirm that the frequency of vibrations is within the
above values. Check whether the frequency of
vibrations is within the above values, and readjust
the belt if the value is improper.
• Securely tighten the bolt after the adjustment. 3
2 MFW61BSH001401
Legend
1 1. Fan bolts
2. Coupling bolts
9. Install the fan cover assembly.
3
4
MFW71BSH005801
Legend
1. Generator
2. Water pump
3. Crankshaft
4. Idle pulley
5. A/C compressor

MFWA1BMF002101
(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)

MFWA1BMF002601
(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)

MFWA1BMF001101
(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)

a
b
MFWA1BMF001501
(a) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)

(b) 82 N⋅m (8.4 kg⋅m / 61 lb⋅ft)
Engine Exterior Parts

Component Parts
1 2 3 4 5 6
10
11
18 17 12
16 15 14 13
MFWA1BMF002201
Legend
1. Intake pipe 10. Supply pump
2. EGR cooler water feed pipe 11. Crankshaft position sensor
3. EGR valve 12. Oil filter
4. EGR cooler water return pipe 13. Fuel suction pipe
5. Oil separator hose 14. Guide tube
6. Injection pipe 15. Oil separator
7. EGR pipe 16. Common rail (Fuel rail)
8. Pressure feed pipe 17. EGR valve duct
9. Leak-off pipe 18. Water duct

1 2 3 4
5
6
7
14
9
13
12 11 10
MFWA1BMF002701
Legend
1. Heat protector 8. Generator bracket
2. EGR cooler 2nd 9. Front engine foot
3. EGR cooler 1st 10. Turbocharger oil return pipe
4. Turbocharger 11. A/comp oil feed pipe
5. Exhaust manifold 12. Air compressor
6. Exhaust pipe adaptor 13. Rear engine foot
7. EGR cooler water feed pipe 14. Charge air pipe

1 2 3 4 5 6
10
12 11
18 17
16 15 14 13
MFWA1BMF001201
Legend
1. Intake pipe 10. Supply pump
2. EGR cooler water feed pipe 11. Crankshaft position sensor
3. EGR valve 12. Oil filter
4. EGR cooler water return pipe 13. Fuel suction pipe
5. Oil separator hose 14. Guide tube
6. Injection pipe 15. Oil separator
7. EGR pipe 16. Common rail (Fuel rail)
8. Pressure feed pipe 17. EGR valve duct
9. Leak-off pipe 18. Water duct

1 2 4
3 5
6 7
14
13
12 11 10
MFWA1BMF001601
Legend
1. Heat protector 8. Generator bracket
2. EGR cooler 2nd 9. Front engine foot
3. EGR cooler 1st 10. Turbocharger oil return pipe
4. Turbocharger 11. A/comp oil feed pipe
5. Exhaust manifold 12. Air compressor
6. Exhaust pipe adaptor 13. Rear engine foot
7. EGR cooler water feed pipe 14. Charge air pipe

Removal NOTE:
Before removing the harnesses, clearly indicate the clip
1. Remove the intake duct.
positions. (with paint, etc.)
Full cab and Wide cab (rigid cab mounting
model)
MFW91BSH002601
MFW71BSH006001
Legend
1. Air cleaner
3. Remove the oil level gauge.
2. Intake duct
4. Remove the stays of the guide tube, and remove
the guide tube (1) from the crankcase.
Full cab and Wide cab (coil spring cab

mounting model)
2 1
MFW71BSH001901
MFW71BSH006101
5. Remove the intake pipe.
Legend
• Loosen the hose clip, remove the nut at the
1. Air cleaner
stay section, and remove the intake pipe (1).
2. Intake duct
NOTE:
After removing the pipe, seal it to prevent foreign
2. Remove the engine harness. materials from getting into it.
• Remove the harnesses from the sensors and
accessories.
1
1
MFW61BSH000801 MFWA1BSH000401
6. Remove the fan guide stays (1).

Full cab and Wide cab
8. Remove the oil separator from the cylinder block
with the bracket attached to it.
• Remove the drain hose of the oil separator from
the oil pan.
2
1
MFW71BSH004301
7. Remove the oil separator hose (1).

3
MFW71BSH000301
Legend
1. Bracket
2. Oil separator
3. Oil drain hose
9. Remove the fastening clip of the water pipe. Next,

remove the hoses at the water pump side and the
EGR cooler side, and remove the water feed pipe
(1) for the EGR cooler.
10. Remove the fastening clip of the water pipe. Next,
remove the hose at the EGR cooler side, and
remove the water return pipe (3) for the EGR
MFW91BSH002701 cooler.

11. Remove the fastening clips of the water hose. 13. Remove the EGR cooler 2nd (1) and EGR cooler
Next, remove the water hose (2) for the EGR 1st (2).
cooler.
2
3
2
1
MFWA1BSH000801
MFWA1BSH000601
Legend
Legend 1. EGR cooler 2nd
1. EGR cooler water feed pipe 2. EGR cooler 1st
2. EGR cooler water hose 3. Exhaust manifold
3. EGR cooler water return pipe
14. Remove the suction air hose (air compressor).

12. Remove the EGR pipe (2) from the EGR cooler 15. Remove the charge air pipe (air compressor)
2nd (1) and the oil cooler. together with the bracket.
MFWA1BSH000701 MFWA1BSH001201
Legend
1. Charge air pipe
2. Air compressor
3. Bracket

16. Remove the water pipe (1) (cylinder block – air c. Remove the oil feed pipe (turbocharger).
compressor). d. Remove the water return pipe (turbocharger).
e. Remove the water feed pipe (turbocharger).
f. Remove the oil return pipe.
g. Remove the turbocharger assembly.
NOTE:
Plug the ports of the oil and the coolant to prevent
foreign material from getting into them. Plug the
compressor and the turbine side as well.
1 2 3 4
1 2
MFW71BSH008601
Legend
2. Air compressor
3. Water pipe (return to turbocharger) 5
17. Remove the air compressor from the flywheel

housing.
MFW61BSH006301
NOTE: Legend
After removing the air compressor, plug it to prevent 1. Intake pipe
foreign materials from getting into it. 2. Water return pipe
3. Connector
4. Oil feed pipe
5. Water feed pipe
MFW61BSH005501
18. Remove the exhaust pipe adapter.

19. Remove the turbocharger.
a. Disconnect the oil pressure switch connector.
b. Remove the intake pipe.

20. Remove the heat protector from the exhaust 22. Remove the intake throttle and inlet pipe.
manifold.
1 1 2 3
3 2
MFWA1BSH001401
BLW71BSH007901
Legend
Legend 1. Intake throttle
1. Exhaust manifold assembly 2. Gasket
2. Heat protector (front) 3. Inlet pipe
3. Heat protector (rear) 4. Gasket
21. Remove the boost sensor (1). 23. Remove the injection pipe.
1 NOTE:
Plug the common rail and the injector to prevent foreign
material from getting into them.
BLW71JSH001301

26. Remove the fuel leak-off pipe (1) from the various
parts.
1 2 3 4 5 6
7
MFWA1BSH001501
Legend
MFWA1BSH001601
1. Injection pipe # 1
4. Injection pipe # 4 27. Remove the common rail.
6. Injection pipe # 6 NOTE:
7. Common rail (Fuel rail) Careful handling of the sensor is needed to avoid
interference with other objects.
Plug it to prevent foreign materials from getting into it.
24. Remove the pressure feed pipe (1) from the

common rail and the supply pump.
25. Remove the fuel suction pipe (2) from the supply 1
pump.
MFW71BSH001201
Legend
1. Nuts
1 2
MFWA1BSH002501 3. Bolts

28. Remove the crankshaft position sensor (1) from d. Remove the bracket (2) and O-ring (7) from the
the flywheel housing (2). supply pump.
1 2 3 4 5
10
9
1 2
8 7 6
MFW71BSH002501 BLW71BSH000701
Legend
1. Supply pump
29. Remove the oil filter from the cylinder block. 2. Bracket
• Remove the oil filter after removing oil from the 3. Gear
oil drain hose. 4. Nut
5. Bolts
6. O-ring
7. O-ring
8. Nuts
9. Bolts
10. Nuts
31. Remove the EGR valve duct.
MFW71BSH001601
30. Remove the supply pump (1) together with the

bracket (2).
a. Remove the O-ring (6) from the supply pump.
b. Remove the nut (4) and gear (3) from the
supply pump. 3 2
c. Remove the bolts (9) from the supply pump.
MFW71BSH001301
Legend
1. EGR valve
2. EGR valve duct
3. Gaskets

35. Remove the noise cover from the cylinder block.
32. Remove the EGR valve.
1
MFWA1BSH002401
MFWB1BSH002801 Legend
Legend 1. Space rubber
1. EGR valve 2. Noise cover
2. Gasket
3. EGR valve duct assembly
36. Remove the inlet cover (1).
33. Remove the EGR valve duct assembly from the

inlet cover.
2
1
MFWA1BSH001901
1
MFWB1BSH002901 37. Remove the oil cooler from the cylinder block.
Legend • Remove the mounting bolts of the oil cooler. Put
1. EGR valve duct assembly the removed bolts into the replacer holes (the parts
2. Gasket indicated by arrows) and remove the cooler by
tightening all the bolts equally.
34. Remove the water duct from the oil cooler.


4. Install the noise cover.
5. Install the oil pressure switch.
1 6. Install the oil cooler.
• Apply liquid gasket (ThreeBond 1207C or
1216C) in the groove of the oil cooler to have
2 the bead width of 2 to 3 mm (0.08 to 0.12 in).
3 Insert the O-ring (1) and install it.
NOTE:
• Clean the O-ring groove, as it is difficult to fit in the
O-ring if liquid gasket remains in the groove.
• After applying the liquid gasket, install within 5
minutes.
• When installing the oil cooler to the cylinder

block, it is easier to perform the installation if
you temporarily attach M8 studs to the front and
MFW41BSH024201
back of the mounting screw holes to use as a
Legend guide.
1. Cylinder block
2. Oil cooler
3. Bolts
1
38. Remove the oil pressure switch from the cylinder
block.
39. Remove the generator bracket from the cylinder
block.
40. Remove the front engine foot from the cylinder
block.
41. Remove the rear engine foot from the flywheel
housing.
Installation
1. Install the rear engine foot, and tighten it at the MFW41BSH002001
specified torque.
• Tighten the oil cooler fixing bolts in the order

Tightening torque shown in the diagram.
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
Tightening torque
2. Install the front engine foot, and tighten it at the
specified torque. 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Tightening torque
78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
3. Install the generator bracket, and tighten it at the

specified torque.
Tightening torque
38 N⋅m (3.9 kg⋅m/28 lb⋅ft)

b. Install the gear and nut.
Tightening torque
64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
17 20
c. Install the O-ring.
21 13 9 5 1 4 8 12 16
22 • Rotate the engine in the forward direction. Align
25
the positions of the TDC (0°) mark (2) on the outer
26
24 circumference of the damper and the pointer (1).
18 14 10 6 2 3 7 11 15 19 NOTE:
27 23
Confirm that the first cylinder is at the compression top
dead center.
MFW41BSH024101 1
7. Install the water duct (suction) to the oil cooler.

8. Install the crankshaft position sensor (1) to the
flywheel housing (2).
Tightening torque
8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2
MFWB1BSH003301
• Before assembling the supply pump, align the

alignment marks (slits) on the gear.
2
1 2
MFW71BSH002501
9. Install the supply pump, gear and bracket together

to the cylinder block.
a. Install the O-ring and bracket.
Tightening torque MFW41BSH023701
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)


• Make sure to paint in white the gear edge surface
(1) that corresponds to 2-point marks (2) on the
Tightening torque
gear side surface.
Nuts (10) 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
Nut (8), Bolt (5) 77 N⋅m (7.9 kg⋅m/57 lb⋅ft)
Nut (4) 64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
Bolts (9) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
1 2 3 4 5
1
2 10
MFWB1BSH003001
• Horizontally insert the supply pump into the

cylinder block. 9
• Confirm that the white paint of the alignment mark
appears as indicated in the illustration when you 8 7 6
look at the gear from upslope, through the timing MFW61BSH001001
check hole on top of the flywheel housing.
Legend
1. Supply pump
2 2. Bracket
3. Gear
4. Nut
5. Bolt
6. O-ring
7. O-ring
1 8. Nut
9. Bolts
10. Nuts
• Re-confirm again that the ruling alignment mark of

the timing mark (crank damper) is aligned to 0°,
and the alignment mark of the supply pump gear is
aligned.
BLW71BSH005701 • If the marks are misaligned, reassemble the parts.
Legend • Install the plug to the flywheel housing after
1. Timing check hole checking the timing.
2. Supply pump gear 10. Install the oil filter.
• Assemble an O-ring to the groove of the
bracket, and install it to the cylinder block.
• Tighten the supply pump with a nut and bolt.
NOTE:
• ThreeBond 1208 or CH Dine 290 can be used to
prevent O-rings from falling off.

• Confirm that the O-ring is firmly in place without 13. Install the space rubber between the inlet manifold
protrusion or misalignment. and the oil cooler.
1
Tightening torque
38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
MFWA1BSH002401
Legend
1. Space rubber
2. Noise cover
MFW71BSH001601
14. Install the EGR valve duct assembly (1) to the inlet
cover.
11. Install the inlet cover (1).
• Install the gasket (2) to the inlet cover side.
Tightening torque
Tightening torque
25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
M 8 bolt 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
M 10 bolt 46 N⋅m (4.7 kg⋅m/34 lb⋅ft)
1
MFWA1BSH001901
MFWB1BSH002901


15. Temporarily install the EGR valve (1) to the EGR 17. Completely tighten the EGR valve.
valve duct assembly (3). • Securely tighten the EGR valve duct (2) and
• Install the gasket (2) to the EGR valve duct EGR valve (1).
assembly side.
Tightening torque
1
EGR valve
EGR valve duct 46 N⋅m (4.7 kg⋅m/34 lb⋅ft)
(EGR valve side)
2
EGR valve duct
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
3 (oil cooler side)
MFWB1BSH002801
16. Temporarily install the EGR valve duct to the EGR

valve and oil cooler.
• Install a gasket to the EGR valve side and oil
cooler side.
MFW61BSH001901
1
• Order for temporal tightening: nuts (1) before
bolts (2).
• Order for complete tightening: bolts (2) before
nuts (1).
Tightening torque
25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
3 2
MFW71BSH001301
Legend
1. EGR valve
2. EGR valve duct
3. Gaskets

21. Install the fuel suction pipe (2) to the supply pump
and fix it with a clip.
1
Tightening torque
18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
MFW61BSH001301
19. Install the fuel leak-off pipe (1).

• Assemble a new gasket to each connecting
section. 1 2
• Fix each part with a clip after tightening it.
MFWA1BSH002501
Tightening torque
Supply pump side 10 N⋅m (1.0 kg⋅m/87 lb⋅in) 22. Install the injection pipe and tighten the sleeve nut.
Tightening torque
MFWA1BSH001601
20. Install the pressure feed pipe (1).
Tightening torque
Supply pump side
44 N⋅m (4.5 kg⋅m/33 lb⋅ft)
Common rail side
1 2 3 4 5 6 1 2 3
7
MFWA1BSH001501 MFWA1BSH001401
Legend Legend
1. Injection pipe # 1 1. Intake throttle
2. Injection pipe # 2 2. Gasket
3. Injection pipe # 3 3. Inlet pipe
4. Injection pipe # 4 4. Gasket
24. Install the boost sensor (1).
1
23. Install the inlet pipe and intake throttle.
Tightening torque
Inlet pipe 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
Intake throttle 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
BLW71JSH001301
Tightening torque
2.5 N⋅m (0.25 kg⋅m/22 lb⋅in)

25. Install the heat protector to the exhaust manifold.
1
1
2
3 2
MFW71BSH008201
BLW71BSH007901
Legend
1. Exhaust manifold assembly 27. Install the oil return pipe.
2. Heat protector (front) • Install the oil pipe to the turbocharger and
3. Heat protector (rear) cylinder block.
NOTE:
Make sure to use a new gasket to prevent oil leakage.
26. Install the turbocharger.
• Refuel the appropriate amount of oil from the oil
inlet hole (1) of the turbocharger, and rotate the Tightening torque
turbine shaft to lubricate the shaft bearing Turbocharger side
section. 23 N⋅m (2.3 kg⋅m/17 lb⋅ft)
Cylinder block side
1
1
MFW61BSH005901
MFWA1BSH002701
• Fasten the gasket (2), and install the Legend

turbocharger (1) to the exhaust manifold. 1. Turbocharger
2. Oil return pipe
Tightening torque
52 N⋅m (5.3 kg⋅m/38 lb⋅ft)

28. Install the oil feed pipe.
• Install the turbocharger oil feed pipe (2)
perpendicularly to the cylinder block (1).
NOTE: 2
Make sure to use a new gasket to prevent oil leakage. 1
3
Tightening torque
Turbocharger side 34 N⋅m (3.5 kg⋅m/25 lb⋅ft)
Cylinder block side 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
MFWA1BSH002901
Legend
1. Water return pipe
2. Turbocharger
2 3. Water feed pipe
2 31. Install the inlet pipe (turbocharger out).

1
Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
MFWA1BSH002801
32. Connect the connector of the oil pressure switch.

29. Install the water feed pipe. 33. Install the exhaust pipe adapter (2).
• Fasten the gasket (1) between the turbocharger
NOTE: and the adapter (2) and install it.
Make sure to use a new gasket to prevent coolant
leakage.
Tightening torque
Turbocharger side 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Air compressor side 50 N⋅m (5.1 kg⋅m/37 lb⋅ft)
30. Install the water return pipe.
NOTE:
Make sure to use a new gasket to prevent coolant
leakage.
Tightening torque
Turbocharger side
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
Cylinder head side
1 2
3 4 3
4
MFW71BSH008401 MFWA1BSH002301
Legend
1. Gasket
2. Exhaust pipe adapter 34. Install the intake duct (1) to the turbocharger (3),
3. Heat protector and tighten it with a V-band (2) while aligning it with
4. Bracket the marking (4).
Tightening torque
• Assembly procedure 16 N⋅m (1.6 kg⋅m/12 lb⋅ft)
- Tighten by following the procedure below.
a. Temporarily tighten the adapter and bracket.
b. Temporarily tighten the bracket and cylinder
block.
1
c. Temporarily tighten the adapter and 2
turbocharger.
d. Perform the same procedure to completely
tighten the parts.
Tightening torque
Bolts and Nuts (2) 26 N⋅m (2.7 kg⋅m/20 lb⋅ft)
Bolt (1), (3) 45 N⋅m (4.6 kg⋅m/33 lb⋅ft)
Bolt (4) 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
3
MFW71BMH000101

• Apply liquid gasket (ThreeBond 1208 or CH
Dine 290) equally to three parts on the
4 circumference of the O-ring, and install the O-
ring in the groove of the air compressor.
Tightening torque
73 N⋅m (7.4 kg⋅m/54 lb⋅ft)
MFW71BSH006201
35. Install the air compressor to the flywheel housing.

• Tap the key into the shaft of the air compressor,
and tighten the installation nut of the drive gear
147 N⋅m (15 kg⋅m/108 lb⋅ft)
2
1 3
4 BLW71BSH015501
Legend
MFWB1BSH003101 1. Air compressor
Legend 2. Bolt (Long)
1. Gear 3. Bolts
2. Key 4. Nut

36. Install the oil feed pipe (air compressor) to the air
compressor and the cylinder block.
• Use a new gasket.
Tightening torque
Cylinder block side 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
1 3
1 2
MFW71BSH008601
Legend
2. Compressor
3. Water pipe (return to turbocharger)
2 38. Install the charge air pipe (1) to the air compressor
(2).
MFW71BSH002101
• Install the charge pipe with a clip.
Legend
1. Air compressor NOTE:
2. Oil feed pipe Apply oil so that it does not turn together with the
eyebolt. Never use soapy water, etc.
37. Install the air compressor water pipes (1) and (3). Tightening torque
Charge air pipe side
64 N⋅m (6.5 kg⋅m/47 lb⋅ft)
Tightening torque (Dry condition)
Water pipe adapter
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
side
MFWA1BSH002001

39. Install the EGR cooler. 40. Install the EGR cooler 2nd.
• Fasten the gasket at the exhaust manifold side
and install it.
NOTE:
Make sure to use a new gasket to prevent oil leakage. 2
1 1
MFWA1BSH000901
2
Legend
1. Bracket
2. EGR cooler 2nd
3. Bolt
MFW71BSH000701
Legend
1. EGR cooler 1st 41. Install the EGR pipe.
2. Exhaust manifold •
2
1
2
3
MFWA1BSH000701
MFW71BSH002001 Legend
1. EGR cooler 2nd
Legend 2. EGR pipe
1. Bolts
2. EGR cooler 1st
3. Bracket

42. EGR cooler and EGR pipe tightening procedure. • Numbers enclosed in squares indicate the
• Numbers alone indicate the order for temporal order for complete tightening.
tightening.
6 12 2 4
8 11
7 13
1 14
3 5
9 10
MFWA1BMF000601
f
e
MFWA1BMF000701
43. Install the EGR cooler water pipe, water hose and
(a) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
fix it with the clips.
(b) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(c) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft) 2
3
(e) 46 N⋅m (4.7 kg⋅m / 34 lb⋅ft)
(f) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(g) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
1
• The bolt (f) is not reusable.
MFWA1BSH000601
Legend
1. Water feed pipe
2. Water hose
3. Water return pipe

44. Put the bracket on the oil separator, and install it to
the cylinder block.
1
3 MFWA1BSH000401
MFW71BSH000301
Legend 46. Install the suction air pipe to the air compressor.
1. Bracket 47. Install the intake pipe (1).
2. Oil separator
3. Oil drain hose
Tightening torque
18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
45. Install the oil separator hoses (1).
MFW91BSH002701 MFW61BSH000801
48. Install the guide tube (1) into the crankcase, and fix
the stay section.
• Insert the O-ring into the guide tube, and press
it in until it touches the hole of the crankcase.
NOTE:
Take care not to cut the O-ring.

51. Install the intake duct.
Full cab and Wide cab (rigid cab mounting
model)
1
2
MFW71BSH001901
MFW71BSH006001
49. Insert the oil level gauge.
50. Install the engine harness to each connector, and Legend
clip it in the designated position. 1. Air cleaner
2. Intake duct
Full cab and Wide cab (coil spring cab

mounting model)
MFW91BSH002601
2
MFW71BSH006101
Legend
1. Air cleaner
2. Intake duct

a b
e d
MFWA1BMF002301
(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side

25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

a b
g
f e d
MFWB1BMF000701
(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(f) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(g) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

a b
e d c
MFWA1BMF001301
(a) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft) Injector side

25 N⋅m (2.6 kg⋅m / 19 lb⋅ft) Common rail side
(b) 44 N⋅m (4.5 kg⋅m / 33 lb⋅ft)
(c) 50 N⋅m (5.1 kg⋅m / 37 lb⋅ft)
77 N⋅m (7.9 kg⋅m / 57 lb⋅ft)
(d) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(e) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)

a b
d
g
f e
MFWA1BMF001701
(a) 52 N⋅m (5.3 kg⋅m / 38 lb⋅ft)

(b) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
(c) 26 N⋅m (2.7 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(e) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(f) 73 N⋅m (7.4 kg⋅m / 54 lb⋅ft)
(g) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)
Cylinder Head
Component Parts
5
1
2
6
25
7
3 24 8
4 23
9
10
22
11
12
13
21
20
18
19 14
17
16
15
MFW71BLF001401
Legend
1. Noise cover 14. Head gasket
2. Head cover 15. Water duct
3. Gasket 16. Plate
4. Bracket 17. O-ring (water pump)
5. Connector 18. O-ring
6. Harness assembly 19. Rubber plug
7. Injector leak-off pipe 20. Glow plug connector
8. Injector clamp 21. Glow plug
9. Injector assembly 22. Camshaft
10. Gasket 23. Rocker arm assembly
11. Bridge cap 24. Gasket
12. Bridge 25. Lower case
13. Cylinder head assembly

Removal
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.
1. Remove the engine exterior parts. Refer to “Engine

Exterior Parts”.
2. Remove the injection pipe.
1
3. Remove the noise cover. 2
3
1
BLW71BSH008901
Legend
1. Bracket
2. Head cover
2 3. Bolt
5. Remove the head cover.
BLW71BSH008301 NOTE:
Legend Make sure you do not lose the collar that is inside the
1. Noise cover head cover.
2. Head cover
6. Remove the gasket.
4. Remove the noise cover bracket.
NOTE:
If the bracket is not damaged, do not remove it.
BLW71BSH009001
7. Remove the lower case.


MFW41BSH026201
MFW71BSH005001
• Take out the injector harness terminal.

9. Remove the glow plug connector.
10. Remove the glow plug. 3
LNW71DSH003601
Legend
LNW21BSH055301 1. Injector
2. Injector harness
3. Terminal nut
11. Remove the harness assembly.
• Push the arrowed section of the connector with
your fingers to remove it.
NOTE:
Do not pull the wires or pry the connector with a
screwdriver.

• Remove the harness bracket with the harness • If it is difficult to remove the injector, set the
still attached. injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.
2
1 NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.
MFW41BSH027101
Legend
1. Harness terminal 1
2. Harness bracket
2
12. If there are no malfunctions with the connector, do
not remove it.
13. Remove the rubber plug.
14. Remove the injector leak-off pipe.
15. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).
LNW46CMH000301
Legend
1. Sliding hammer small
2. Injector remover
MFWA1BSH003101
NOTE:
16. Remove the injector assembly.
• Indicate the cylinder No. on the removed injector
• Loosen the clamp, and use the replacer to
before storing the injector.
remove the injector.
• Be careful not to strike the injection nozzle against a
hard surface.

24. Remove the camshaft.
NOTE:
After inspecting the removed bearing, temporarily
install the removed cap and bearing in their previous
locations so as not to confuse them with other parts.
MFW71BSH005301

18. Remove the plate.
19. Remove the water duct.
BLW51BSH001501
21. Remove the O-ring (water pump).
22. Remove the rocker arm assembly.
• Loosen both sides of the cam rocker arm shaft
• Loosen and remove the attachment bolts from
bracket and rocker arm assembly bracket
the outside in the numerical order shown in the
attachment bolts equally and remove them.
diagram.
NOTE:
NOTE:
If the attachment bolts (arrow) on both ends of the cam
Before lifting the cylinder head, check that all of the
rocker arm shaft brackets are removed, the rocker arm
bolts have been removed.
and bracket may spring out. Therefore, they should not
be removed.
MFW61BSH000301
23. Remove the bridge and bridge cap.

• Keep them in the order they were attached.
3 7 11 15 19 23 27 26 22 18 14 10 6 2
4 8 12 16 20 24 28 25 21 17 13 9 5 1
MFW41BSF000101
NOTE:
When the cylinder head is removed, idle gear C (1)
protrudes from the bottom of the cylinder head. Ensure
that the gear is not damage.
MFW41BSH002901
26. Remove the head gasket.

• Check for the presence of gas or water leaks.

Disassembly
1
2
29 4 6
28 5
3
27
26
25 7
24
22 23
8
9
21
20
10
18
19 16
17
11
12
15
14
13
MFWB1BLF001701
Legend
1. Bridge cap 16. Engine coolant temperature sensor
2. Bridge 17. Valve
3. Bridge guide 18. Valve seat insert
4. Nozzle sleeve 19. Thermostat
5. Idle gear C 20. Gasket
6. Idle gear C cover 21. Water outlet pipe
7. Engine hanger 22. Engine hanger
8. Oil seal 23. Cylinder head
9. Gasket 24. Spring seat
10. Inlet cover 25. Valve guide
11. Exhaust manifold (Front) 26. Valve stem oil seal
12. Heat protector 27. Valve spring
13. Heat protector 28. Spring upper seat
14. Exhaust manifold (Rear) 29. Split collar
15. Gasket

NOTE:
When placing the cylinder head assembly on the floor,
rest it on wooden planks to prevent the idle gear C that
protrudes from the bottom from getting damaged.
1. Remove the bridge cap.

2. Remove the bridge.
3. Remove the intake cover.
4. Remove the gasket (intake cover).
5. Remove the heat protector.
2
7. Remove the gasket (exhaust manifold). 1
8. Remove the bracket.
9. Remove the heat protector.
10. Remove the engine hanger.
11. Remove the engine coolant temperature sensor. BLW51BSH000101
12. Remove the water outlet pipe. Legend
13. Remove the thermostat. 1. Idle gear C
14. Remove the gasket (thermostat). 2. Shaft
15. Remove the camshaft position sensor.
16. Remove the idle gear C cover.
• Gently tap the outer perimeter of the sealing 18. Remove the split collar.
cup with the tip of a screwdriver (1) as shown in • Place the cylinder head on wooden planks.
the diagram, then invert the cup and use pliers
• Use a valve spring replacer (5-8840-2621-0)
etc. to extract it.
and pivot (8-9439-6862-0) remove the split
NOTE: collar, then remove the spring seat, spring,
Be sure not to damage the cover insertion section. seal, and valve. At this time, also remove the
spring seat that is inserted in the lower side of
the spring.
• Install tickets numbered according to cylinder to
the removed valves.
MFW41BSH009701
17. Remove idle gear C. MFW41BSH009801
• Extract the idle gear shaft and remove the

gears.
19. Remove the valve spring upper seat.
20. Remove the valve spring.
21. Remove the valve.

23. Remove the valve spring seat.
MFW41BSH010101
MFWB1BSH003201
26. Remove the nozzle sleeve. Place a injector sleeve
remover (5-8840-2623-0) against the bottom side
24. Remove the valve guide. of the head, and hit it to extract the sleeve.
• Insert the valve guide replacer (5-8840-2628-0) NOTE:
into the valve guide from the bottom of the
head, and hit it with a hammer to extract it. • Make sure you do not damage the bottom side of
the head.
• Do not re-use extracted nozzle sleeves.
MFW41BSH010001
MFW41BSH010201
25. Remove the valve seat insert.
• Use a welding burner to burn 2 sections (700 to
800°C / 1292 to 1472°F) on the inner surface of
27. Remove the bridge guide.
the insert, leave it to self cool for between 3 to 5
minutes, then extract it with a screwdriver. • Electrically weld the bridge guide head section
nut (1), install a sliding hammer and extract it.
CAUTION: • Do remove it if there is no wear.
Do not rapidly cool it. Do not damage the cylinder head
when extracting.

2. Inspect the bridge.
• Check there is no hesitance in the bridge and
bridge guide.
• Measure the gap between the bridge and
bridge guide.
1
Gap
Assembly standard Limitations for use
0.020 – 0.056 mm 0.1 mm
(0.0008 – 0.0022 in) (0.004 in)
MFW41BSH010301

Place a dolly against the inside of the head, and hit
it to extract the seal.
Inspection
1. Inspect the bridge cap.
• Inspect the cap and rocker arm adjustment bolt
strike surface for wear or damage.
• If the amount of wear is greater than 0.1 mm MFW41BSH010601
(0.004 in), or if linear wear has occurred,
replace it.
3. Measure the idle gear C (1) axial direction gap.
Bridge cap wear limit • Measure idle gear C axial direction gap and the
0.1 mm (0.004 in) shaft diameter.
Axial direction gap

Nominal Assembly Limitations
dimensions standard for use
0.09 – 0.144 mm 0.2 mm
—
(0.004 – 0.0057 in) (0.008 in)
Shaft diameter
30 mm — 29.85 mm
(1.18 in) (1.175)
MFW41BSH010501

• Measure the free length of the valve spring.
Free length
Nominal Limitations for
dimensions use
Inlet 59.9 mm 58.7mm
(2.36 in) (2.31 in)
Exhaust 70.3 mm 68.9 mm
(2.77 in) (2.71 in)
1
BLW51BSH002301
4. Measure the valve spring.

• Measure the squareness of the valve spring.
Squareness
Assembly Limitations for use
standard
Inlet — 2.6 mm (0.10 in)
Exhaust — 2.9 mm (0.11 in)
MFW41BSH010901
• Measure the load of the valve spring when

attached.
Attached load/attached length N (kg / lb)

Assembly Limitations for
standard use
333 (34.0 / 75.0) / 315 (32.1 / 70.8) /
Inlet
47 mm (1.85 in) 46 mm (1.81 in)
490 (50.0 / 110.0) 463 (47.2 / 104) /
Exhaust
/47 mm (1.85 in) 47 mm (1.85 in)
MFW41BSH010801

• Insert a valve into the valve guide, and
measure the looseness of the valve at a
position (a) 10 mm (0.3937 in) from the top of
the guide.
Gap between valve guide and valve stem

Assembly standard Limitations
for use
0.039 – 0.071 mm 0.2 mm
Inlet valve
(0.0015 – 0.0028 in) (0.008 in)
0.064 – 0.096 mm 0.25 mm
Exhaust valve
(0.0025 – 0.0038 in) (0.01 in)
MFW41BSH011001
5. Inspect the valve.

• Measure the valve stem abrasion. 1
• Measure the 3 locations in the diagram.
a
Valve stem outer diameter

Nominal dimensions Limitations for use 2
8 mm (0.315 in) 7.88 mm (0.310 in)
• If the amount of valve stem abrasion exceeds

the limit, replace both the valve and the valve
guide. MFW61BSH001501
Legend
1. Valve
2. Valve guide
• Measure the thickness of the valve.
Valve thickness
Nominal Limitations for
dimensions use
Inlet valve 1.71 mm
(0.0673 in) 1.3 mm
(0.0689 in)
MFW41BSH011101
Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.0906 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve
(0.0457 – 0.0606 in) (0.1102 in)
MFW41BSH011301
• Inspect and repair the valve seat striking 3

surface. 2
• Apply red lead paint to the valve insert, and
inspect the width of the seat striking surface.
Also, inspect for lack of strike, and that the
strike position is in the center of the valve seat
face.
MFW51BSH003501
Width of seat striking surface Legend

1. Striking width
Assembly standard 2. Amount of depression
Inlet valve 2.7 mm (0.106 in) 3. Seat angle
• If there is a defect in the valve striking width or Perform valve slide matching
the striking surface, use a seat cutter that • Apply compound to the valve striking surface,
matches the stem diameter to repair it. and perform sufficient slide matching between
the valve seat and valve striking surface.
Valve seat angle (deg)

Inlet valve 30
Exhaust valve 45
Valve stem diameter

8 mm (0.315 in)
• After valve seat grinding, measure the amount

of valve depression to be sure that it is within
the useable limit.
MFW41BSH011601
• After valve slide matching, clean the cylinder

head and valve.
6. Inspect the valve seat insert.
• Measure the amount of valve depression (1).
• Insert a new valve into the valve guide, and
measure the dimensions from the bottom of the
cylinder head to the valve surface.
Amount of valve depression

Nominal dimensions Limitations
for use
0.73 – 1.10 mm 2.3 mm
Inlet valve
(0.0287 – 0.0433 in) (0.09 in)
1.16 – 1.54 mm 2.8 mm
Exhaust valve MFW41BSH011801
(0.0457 – 0.0606 in) (0.110 in)
• Inspect the cylinder head for cracks and

damage.
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary.
NOTE:
When magnetizing using the magnetic flaw detector,
always demagnetize when the test is complete.
(Remnant magnetism is less than 5G)
MFW41BSH011701
7. Inspect the cylinder head.

• Measure the amount of distortion of the cylinder
head.
• Clean off the carbon without damaging the
processing surfaces of the cylinder head, valve
seat, insert etc.
• Place a straightedge against the mounting
surface of the cylinder head, and measure the MFW41BSH011901
amount of distortion in locations A to F on the
diagram using a thickness gauge.
• With the hydraulic test, apply 490 kPa (5 kgf/
Amount of distortion cm2/71 psi) of water pressure for 3 minutes,
and inspect each section of the head for water
Limitations for use 0.2 mm (0.008 in) leaks.
NOTE: NOTE:
Cannot be repaired because the timing gear backlash Perform the hydraulic test with the nozzle holder
will change. attached.

Reassembly • Apply engine oil to the outer periphery of the
guide, and use a bridge guide setting tool (5-
1. Install the oil seal to the cylinder head.
8840-2626-0) to hammer it in to the finishing
• I can possess an injection pipe insert with an oil depth of the cylinder head hole. (Reference:
seal installer (5-8840-2627-0). The bridge guide height is approx. 37.5 mm
• Hit the seal evenly so that it does not slant. (1.476 in) (b) from the head upper surface)
NOTE:
Take care not to damage the lip section.
b
a
MFW61BSH000901
(a) 122.5 mm (4.823 in)

MFW41BSH012001 (b) 37.5 mm (1.476 in)
3. Install the nozzle sleeve.

• Install the O-ring (1) and (2) to the nozzle
sleeve, and apply engine oil.
• Apply sealant (LOCTITE LT620) to the nozzle
1 2
3 sleeve tapered section (3).
MFW81BSH006201
Legend
1. Cylinder head
2. Oil seal
3. Oil seal installer
2. Install the bridge guide.


• Apply engine oil (4) to nozzle sleeve installation
side.
1
2
2
3 6
5 3
LNW21BMH001001
Legend
MFW61BMH000101
1. Punch bar
Legend 2. Ball
1. O-ring (white paint) 3. Guide sleeve
2. O-ring 4. Nozzle sleeve
3. Apply LOCTITE 5. Injector clamp
4. Apply engine oil 6. Injector clamp bolt
4. Install the valve seat insert.

• Install the injector sleeve setting tool (5-8840- • Carefully clean off the carbon, rust, etc. from
2624-0) and install nozzle sleeve to the cylinder the mounting surface of the insert, and press fit
head. the insert using a press.
• Push the nozzle sleeve in with a guide sleeve
so that it is firmly seated at the bottom side of
the cylinder head.
• After inserting the guide sleeve, fix it with the
injector clamps and injector clamp bolts.
• Insert the ball (bearing steel ball 9.525 mm/
0.375 in) into the guide sleeve, and use a
punch bar and hammer to knock the ball out.
NOTE:
• After carefully removing the shavings from the
cylinder head screw section, insert the sleeve.
• Lift the cylinder head so that the ball can come out
from the bottom.
MFW41BSH012401
1
a
Legend
1. Dolly 6. Install the lower spring seat.
2. Insert
3. Press
• Apply oil to the oil seal, and use a setting tool
(5-8840-2625-0) to tap in the valve guide.
5. Install the valve guide.
NOTE:
• Apply engine oil to the outer periphery of the Check the valve seal for shape deformation and
guide. Next, assemble the ring onto the valve cracks, and that the spring has not detached.
guide replacer (5-8840-2628-0) and insert the
guide, then tap in the ring until it hits the head
surface.
NOTE:
Replace the valve guide as a set with the valve.
MFW41BSH012601
8. Install the valve.

• Apply engine oil to the valve stem, and insert
the cylinder head.
MFW41BSH012501
NOTE:
Check the assembly of the valve.
Dimensions (a) of the valve guide surface from the “ E “ Mark : Exhaust
cylinder head upper surface “ I “ Mark : Inlet
17.1 – 17.9 mm (0.6732 – 0.7047 in)
9. Install the valve spring. 12. Install a gasket in the thermostat flange part.
• Place the cylinder head on wooden planks. 13. Install the thermostat.
• Install the valve spring with the side that has the • Install the rubber gasket to the flange section.
identification paint facing the cylinder head • Line up the position of the jiggle valve (1) as
surface. shown in the diagram.
Identification paint
Inlet valve spring Blue
Exhaust valve spring Red
10. Install the spring upper seat.

11. Install the split collar.
• Use a valve spring replacer (5-8840-2621-0)
and pivot (8-9439-6862-0) to push the valve
1
spring in, then install the split collar.
• After attaching, gently hit the valve stem head
section with a rubber mallet so the split collar
falls into place.
NOTE:
Check that the split collar is firmly in the valve stem MFW91BSH000801
slot.

• Install the thermostat as shown in the diagram,
and install the water outlet pipe.
Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
NOTE:
If you install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.
1
2
3 2
Legend Legend
1. Water outlet pipe 1. Plug
2. Incorrect attachment prevention stopper 2. Engine coolant temperature sensor
3. Thermostat with jiggle valve 3. Plug
15. Install the engine coolant temperature sensor. 16. Install the rear side engine hanger (2) to the
• Install the Plug in position (1), (3) shown in the cylinder head.
diagram.
• Apply ThreeBond 1207C or LOCTITE 271 to
Tightening torque
the thread section and attach.
Bolt (1) 48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
Bolt (3) 94 N⋅m (9.6 kg⋅m/69 lb⋅ft)
Tightening torque
Plug (1) 108 N⋅m (11 kg⋅m/80 lb⋅ft) •
Plug (3) 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)

1 2
• Install the engine coolant temperature sensor in
position (2) shown in the diagram.
• The thread section of the new plug switch is
treated with plating processing.
When reusing plug switches, apply ThreeBond
1207C or LOCTITE 271, and install to the 3
location shown in the diagram.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MFWA1BSH002101
17. Install the bracket.
Tightening torque
28 N⋅m (2.9 kg⋅m/21 lb⋅ft)

NOTE:
Install before assembling the exhaust manifold.
MFW41BSH013501
Legend
1. Casting surface side
MFW71BSH005501
2. Gasket
18. Install the exhaust manifold gaskets.

• Install so that the protruding section of the 19. Install the exhaust manifold.
gaskets is down. • Move each of the seal ring alignment holes
120° and assemble them to the rear exhaust
manifold.
1 2 3
MFW41BSH013401
NOTE: MFWB1BSH003401
Check that the gasket is securely attached to the Legend
cylinder head. If it is attached incorrectly, it will ride up 1. Exhaust manifold (rear side)
on the casting surface side of the cylinder head as 2. Seal ring
shown in the diagram. 3. Exhaust manifold (front side)

• Install the exhaust manifold. • Tighten them in the order shown in the diagram.
Exhaust nut (10 pieces)
Tightening torque
55 N⋅m (5.6 kg⋅m/41 lb⋅ft)
Exhaust distance nut (2 pieces)

Tightening torque
34 N⋅m (3.5 kg⋅m/25 lb⋅ft) 1
4
11 8 69
• Assemble the distance tube, flat washer and 7 3 2 5 10
coned disc spring washer as shown in the 12
diagram, and tighten the exhaust manifold.
• Only the distance nut can be re-used.
1 2
MFW61BSH000601
20. Install the heat protector.

3
• Install the gasket to the inlet cover (1), and
tighten in the order shown in the diagram.
4
Tightening torque
25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
MFWB1BSH003501
Legend
1. Distance tube
2. Nut
3. Coned disc spring washer
4. Distance nut
• Tighten the distance nut (arrow) in the 7th and

12th attachment positions shown in the
diagram.
1
MFWA1BSH001901

NOTE:
Remove any deposits, carbon, sealing compound, etc.
from the upper surface and lower surface of the
cylinder block.
Reamer bolt
13 9 6 7 10 14
3
12 2 5 1 4 8 11
MFWB1BSH003601
22. Apply engine oil to the bridge and install it.
NOTE: MFW41BSH003001
Move it up and down to check that it moves smoothly.
23. Apply engine oil to the bridge cap and install it. • Install the dowel to the cylinder block, line up
the cylinder head bolt holes and gently rest it
on.
MFW41BSH014001
MFW41BSH003101
Installation
1. Install the head gasket.
• Apply approx. 2 mm (0.0787 in) thickness,
approx. 3 mm (0.1181 in) width of liquid gasket
(ThreeBond 1207C) to the alignment sides of
the cylinder block and flywheel housing, and
install the head gasket.
• After applying the liquid gasket, install the
cylinder head within 5 minutes.

• Apply molybdenum-disulfide to the thread
section and seating surface of the M14 bolts,
and engine oil to the thread section of the M10
bolts, and tighten them to the specified torque
and angle in the order shown in the diagram.
Tightening torque
98 N⋅m (10.0 kg⋅m/72 lb⋅ft) →
M14 bolt 147N⋅m (15.0 kg⋅m/108 lb⋅ft) →
Angle method 30° to 60°
M10 bolt
38 N⋅m (3.9 kg⋅m/ 28 lb⋅ft)
(#27, 28)
26 22 18 14 10 6 2 3 7 11 15 19 23 27
25 21 17 13 9 5 1 4 8 12 16 20 24 28
BLW71BSF000101
NOTE: 1. Position the marked line (2) on the crank

To check the tightness of the M14 bolts, rotate the tool pulley and the alignment mark (1) on the
in the tightening direction. gear case cover and set to compression top
dead center of the first cylinder.
Checking tightening torque

142 N⋅m (14.5 kg⋅m/105 lb⋅ft) 1
3. Install idle gear C.

a. Assembly of the idle gear C
NOTE:
When disassembling the idle gear C, assemble it while
paying attention to the following points because it is
difficult to position the idle gear C shaft.
2
MFWB1BSH003301

2. With the idle gear B assembled, insert the 2. Assemble the camshaft with the gear
idle gear C from above the cylinder head. installed to mesh with the idle gear C
• Apply engine oil to the inner installed to the cylinder head.
circumference of the idle gear C bushing At this time, when the marked line on the
and the thrust bearing surface. crank pulley and alignment mark on the front
cover are positioned compression top dead
3. Apply engine oil to the outer circumference
center of the first cylinder), install so that the
of the shaft and pass from the cylinder head
alignment mark B on the camshaft gear
rear surface hole to the gear center hole.
matches the top surface of the cylinder
4. Apply engine oil to the both surfaces of the head.
thrust collar, and molybdenum disulfide to
the threaded portion of the bolt and seat
surface. Assemble the bolt which is installed
to the thrust collar.
However, the bolt should be tightened at a
torque of 40 N⋅m (4.1 kg⋅m/30 lb⋅ft), and
loosen by 30° – 90° after tightening.
(Confirm that the idle gear C moves.)
1
2 3
MFW41BSH003201
3. Set the cam bearing upper to the camshaft

5
cap, and apply engine oil to the bearing
inner circumference.
6 4. Assemble the #2, #3, and #4 caps (1).
Apply engine oil to the threaded portion and seat

surface
Tightening torque
Cap bolts 28 N⋅m (2.9 kg⋅m/21lb⋅ft)
Cap nuts 28 N⋅m (2.9 kg⋅m/21lb⋅ft)
NOTE:
BLW71BMH000501 Do not assemble the rocker arm.
Legend
1. Insertion Direction
2. Shaft
3. Thrust Collar
4. Bolt
5. Idle Gear C
6. Bushing
b. Installation of the camshaft gear.

1. Set the cam bearing lower to the cylinder
head. Apply engine oil to the bearing inner
circumference.

2. Hold down the camshaft gear by hand and
tighten the idle gear C bolt at the specified
torque.
1
Apply molybdenum disulfide to the threaded
portion and seat surface
Tightening torque
Idle gear C bolt 71 N⋅m (7.2 kg⋅m/ 52 lb⋅ft)
NOTE:
When tightening, be careful that the idle gear C shaft
position does not move a lot.
3. After tightening the idle gear C, check the

backlash to ensure that it is within the
standard value below.
BLW71BSH009901
Between the idle gear C and camshaft gear

c. Tightening the idle gear C. 0.015 – 0.146 mm (0.0006 – 0.0057 in)
1. Manually rotate the camshaft gear in the left
direction (when looking from the engine If the camshaft gear does not move with
rear) (2), gently mesh the idle gear C to the rattling when manually moving it, there is the
direction of the arrow (1) in the diagram, and possibility that the backlash has excessively
set the idle gear C shaft position. built up. Check the backlash and readjust.
NOTE: NOTE:
Be careful as backlash can excessively build up if too If the backlash cannot be adjusted, assembly with the
much force is applied when rotating the camshaft gear. service idle gear C shaft (8-97186-398-1).
4. Remove the cam cap and camshaft.

5. Use a flat blade screwdriver (large size),
etc., to check the backlash of the idle gear C
2 while holding down the idle gear B.
1
1 Between the idle gear C and idle gear B
0.015 – 0.217 mm (0.0006 – 0.0085 in)
2 4. Install the idle gear C cover.
BLW71BSH009801
Legend
(1) Lightly engage the idle gear C.
(2) Rotate the camshaft gear counterclockwise.
1. Camshaft Gear
2. Idle Gear C
3. Idle Gear B

• Apply liquid gasket (ThreeBond 1386 or
LOCTITE 962T) to the entire circumference of • Clean the camshaft bearing and mounting
the insertion hole, and tap in the cover so that section, install the bearing, and apply engine oil
the edge is 0.5 to 1.5 mm (0.0197 to 0.0591 in) to the rotational movement surface of the
inside the cylinder head beveling as shown in bearing.
the diagram.
• Engage idle gear C with the camshaft gear so
that the camshaft gear B mark lines up with the
top surface of the cylinder head as shown in the
diagram, then gently install the camshaft.
NOTE:
• Make sure you do not damage the camshaft
bearing.
a • Check that the camshaft gear B mark is on the top
surface of the cylinder head.
• If the camshaft gear B mark is not in line with the
cylinder head top surface, realign the B mark.
BLW51BSH002401
Legend
(a) 0.5 to 1.5 mm (0.0197 to 0.0591 in)
5. Install the camshaft.

• At this time, check that the alignment mark
white paint can be seen as shown in the
diagram (#1 cylinder is in the top compression
dead point) from the flywheel housing side
timing check hole when looking from above the
slanting surface of the supply pump gear.
MFW41BSH003201
2
• Clean the camshaft bearing and cap, assemble
the bearing and cap, and apply engine oil to the
rotational movement surface.
• Face the arrow on the top surface of the
1 camshaft bearing cap towards the engine front
side, and install in numerical order. Tighten both
sides of the cap at the same time as the rocker
arm.
NOTE:
Point the arrow on the top surface of the cap towards
the engine front side, and check that they are attached
in numerical order.
BLW71BSH005701
Legend
1. Timing check hole
2. Supply pump gear

• Apply engine oil to the thread and seating
section, and tighten uniformly from the center 7. Install the bridge (2) and bridge cap (1).
outwards.
• Apply engine oil to the bridge and bridge cap
and install them.
Tightening torque
28 N⋅m (2.9 kg⋅m/21 lb⋅ft)
MFW61BSH000401
8. Install the rocker arm assembly.

BLW51BSH001501 • Clean the camshaft bearing and cam rocker
arm shaft bracket, assemble the bearing and
bracket, and apply engine oil to the rotational
movement surface.
• Extract the gear alignment pin and take care
not to drop it inside the engine. • Fully tighten the rocker arm adjustment screw,
and apply engine oil to the roller section.
NOTE: • Install the rocker arm assembly.
Do not forget to remove the gear alignment pin.
6. Install the camshaft position sensor.

3
Tightening torque
8 N⋅m (0.8 kg⋅m/69 lb⋅in) 2
MFW51BSH003601
Legend
1. Front cam bracket
2. Rocker arm bracket
3. Rear cam bracket
MFW71BSH004101

• Tighten them in the numerical order shown in
the diagram.
Tightening torque
Cam rocker arm shaft
28 N⋅m (2.9 kg⋅m/21 lb⋅ft)
bracket
Rocker arm bracket 56 N⋅m (5.7 kg⋅m/41 lb⋅ft)
NOTE:
• Only for the camshaft bearing mounting section,
apply oil to the stud bolt screw section, and nut
thread part and seating surface, and tighten them.
• Refer to “Valve clearance adjustment” section for
details on valve clearance adjustment.
MFW41BSH003801
• Apply liquid gasket (1) (ThreeBond 1207B) to

the top surface of the rubber plug.
4 6 8 9 7 5 3 1
2 NOTE:
Install the lower case within 5 minutes of applying the
liquid gasket.
11 12 13 10
MFW41BSH003501
9. Install the rubber plug.

• Apply liquid gasket (ThreeBond 1207B) to the
rubber plug, and install it to the cylinder head.
NOTE:
If there are cracks in the rubber plug, do not re-use it.
MFW41BSH003901

• Insert gasket into the tip of the injector and
insert it into the cylinder head.
• Insert the injector clamp at the same time.
NOTE:
• The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.

12. Install the injection pipe.
and install it.
that it is airtight to the injector and common rail
side.
• Tighten the injection pipe clip (1) at the
specified torque.
Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)
MFW71BSH005301
1
11. Apply engine oil to the thread section and seating 1
section of the injector clamp bolt, and temporarily 1
tighten it.
1
a
1
2 3
MFW81BSH010001
5
13. Tighten the injector clamp (temporarily tightened
earlier) at the specified torque.
6
Tightening torque
BLW71BSH020401 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
Legend
1. O-ring 14. Tighten the injection pipe at the specified torque.
4. Injector clamp Tightening torque
5. O-ring Injector side 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
6. Gasket Common rail side 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
16. Insert gasket into the lower case slot and install it
to the cylinder head.
1 2 3 4 5 6
Tightening torque
13 N⋅m (1.3 kg⋅m/113 lb⋅in)
7
MFWA1BSH001501
Legend
1. Injection pipe #1
7. Common rail (Fuel rail) MFW41BSH027201
15. Install the leak-off pipe to the injector. 17. Install the injector harness assembly.
• Install the harness bracket with the harness still
attached.
Tightening torque
12 N⋅m (1.2 kg⋅m/104 lb⋅in)
Tightening torque
NOTE: 22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten • Install the terminal nut to the injector, and
anything. tighten to the specified torque strength.
Tightening torque
2 N⋅m (0.2 kg⋅m/17 lb⋅in)
NOTE:
• As the terminal is a single unit, tighten the nuts 2 to
3 turns each until fully tightened.
• Over tightening the nuts will cause damage to the
terminal stud. Therefore, they should never be over
tightened.
MFW41BSH023501

NOTE:
•
Check that there is no debris on the upper surface of

the cylinder head.
2
1
8 4 1 5 9
11
7 3 2 6 10
MFW71BSH007101
Legend
1. Harness terminal
2. Harness bracket
MFW41BSH035801
18. Install the gasket.

• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head • Install the noise cover bracket to the cylinder
cover. head cover.
NOTE:
Check that the collar has not fallen out. Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
1
2
BLW71BSH009001
BLW71BSH008901
19. Install the head cover. Legend

1. Bracket
• After temporarily tightening all of the bolts,
2. Head cover
tighten them in the order shown in the diagram.
3. Bolt
Tightening torque
13 N⋅m (1.3 kg⋅m/113 lb⋅in) 21. Install the noise cover.

• Install the noise cover (1) to the head cover (2),
and tighten the nut and bolt.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MFW41BSH003701
2
24. Install the O-ring.
• Install the O-ring to the water pump.
• Apply soapy water (1) to the perimeter of the O-
ring.
BLW71BSH008301
1
22. Install the glow plug.
Tightening torque
20 (2.0 kg⋅m/14 lb⋅ft)
NOTE:
Take care not to over tighten the glow plugs, as
doing so will damage them.
23. Install the glow plug connector.
Tightening torque
1 N⋅m (0.1 kg⋅m/9 lb⋅in) MFW61CSH001101

25. Install the water duct.
• Install the O-ring to the water duct, but be
careful not to damage the water pump O-ring.
Tightening torque
M16 bolt 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)
26. Install the plate.

• Install after tightening the water duct.
Tightening torque
MFW61CSH001201
Legend
1. Water duct
2. Plate
27. Install the engine exterior parts.

• Refer to “Engine Exterior Parts”.
28. Pour in cooling water.

a
c
d
b e
p g
n
m h
l k
i
j
MFW81BLF000101
(n) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)

(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft) (o) 56 N⋅m (5.7 kg⋅m / 41 lb⋅ft)
(b) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in) (p) 22 N⋅m (2.2 kg⋅m / 16 lb⋅ft)
(c) 13 N⋅m (1.3 kg⋅m / 113 lb⋅in)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 2 N⋅m (0.2 kg⋅m / 17 lb⋅in)
(f) 12 N⋅m (1.2 kg⋅m / 104 lb⋅in)
(g) 30 N⋅m (3.1 kg⋅m / 22 lb⋅ft)
(h) M14: 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
147 N⋅m (15 kg⋅m / 108 lb⋅ft) →
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(i) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M16: 103 N⋅m (10.5 kg⋅m / 76 lb⋅ft)
(j) M8: 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
M10: 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(k) 1 N⋅m (0.1 kg⋅m / 9 lb⋅in)
(l) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(m) 28 N⋅m (2.9 kg⋅m / 21 lb⋅ft)
Rocker Arm
Component Parts
3
2
MFW41BLF001301
Legend
1. Front cam bracket 4. Bracket
2. Rocker arm 5. Rocker arm shaft
3. Washer

Disassembly
1. Remove the front cam bracket and rear cam
bracket.
Remove the rocker arm shaft tightening bolt (1)
while pressing down on the front cam bracket (2),
and remove the rocker arm, washer, and bracket in
this order.
2
MFW41BSH014301
• When measuring the distance between the

roller pin and roller, pass string etc.
Between the rocker arm and roller as shown in
the diagram, pull hard on the string in the
MFW41BSH014101 direction of the arrow, and measure the step
between the rocker arm and roller when the
roller is in the pushed out condition (A
Inspection dimension).
Next, mark the measurement points and extract
1. Inspect the rear cam bracket oil hole for blockages. the string, and with the roller pushed to the
back, measure the step between the mark
positions on the rocker arm and roller (B
dimension).
Check that the measured value of A dimension
minus B dimension is within the standard value.
Gap between the roller pin and roller

0.068 – 0.100 mm
0.2 mm (0.008 in)
(0.0027– 0.004 in)
MFW41BSH014201
2. Inspect the rocker arm roller section for wear or

damage.
• Inspect the roller surface for damage.
5
6
1
2
4
5
3
Legend
1. Roller
2. B dimension • Measure the diameter of the rocker arm shaft
3. Slide calipers and the gap between the shaft and rocker arm.
4. A dimension
5. Direction for pulling the string
6. Direction for pushing the roller in Nominal Assembly Limitations
Gap
between 0.01 –
3. Inspect the rocker arm shaft oil hole for blockages. the rocker 0.056 mm 0.2 mm
—
arm shaft (0.0004 – (0.008 in)
and rocker 0.0022 in)
arm
Rocker arm
22 mm 21.85 mm
shaft —
(0.87 in) (0.86 in)
diameter
MFW41BSH014501
• Measure the run out of the rocker arm shaft.
Amount of Run out

Limitations for use 0.3 mm (0.012 in)
MFW41BSH014701

Reassembly
1. Install the rear cam bracket to the rocker arm shaft.
Temporarily tighten installment bolt (1) so that it
does not slip out.
NOTE:
Fully fixing bolt when installing the cylinder head.
2
1
MFW41BSH015001
3. Install the front cam bracket.

• Install the front cam bracket to the rocker arm
shaft.
• Temporarily tighten installment bolt so that the
front cam bracket does not slip out.
MFW41BSH014801
NOTE:
Fully tighten the bolts when installing the cylinder head.
2. Install the rocker arm, washer, and bracket
sequentially as shown in the diagram.
MFW41BSH015101
MFW41BSH014901
• Apply engine oil to the rocker arm bushing (2)

and roller section (1) and install the rocker arm.
Camshaft
Component Parts
2
1
MFW61BLF000601
Legend
1. Bolt 4. Knock pin
2. Washer 5. Camshaft
3. Camshaft gear
Disassembly
1. Remove the camshaft gear.
• Fix the hexagonal section of the camshaft in a
vice through an aluminum adaptor, and
remove.

• Remove the camshaft gear attachment bolts,
insert wood chippings into the puller, and
remove the camshaft gear.
1
MFW41BSH015401
3. Visually inspect the camshaft and inspect for run

out.
LNW21BSH056201
• Inspect the journal section and cam section for
Legend wear, and replace any that have faults.
1. Wood chippings
• Use a V block to hold #1 and #7 journal
2. Remove the knock pin. sections, put a dial gauge against the #4
journal, gently rotate the camshaft through 1
rotation and measure the amount of run out.
Inspection
1. Inspect the gear teeth section, breakaway, pitching Camshaft amount of Run out
etc.
MFW41BSH015301
MFW41BSH015501
2. Measure the dimensions from the camshaft thrust

surface to the camshaft gear.
Dimensions from camshaft thrust surface to the

camshaft gear
27.945 – 27.985 mm
Assembly standard
(1.1002 – 1.1018 in)

4. Measure the amount of cam lift.
• Inspect the cam surface for damage, and
measure the amount of cam lift.
• Measure with 1 – 2 in the diagram.
Repair any slight damage or wear with an oil
stone.
Amount of cam lift (2 – 1)

standard use
7.851 mm 7.351 mm
Inlet
(0.309 in) (0.2894 in)
9.491 mm 9.040 mm
Exhaust
(0.3737 in) (0.3559 in)
MFW41BSH015701
6. Measure the gap between the journal and bearing.

• Measure the inner diameter of the camshaft
1 bearing using a cylinder gauge.
• Read the difference between the bearing inner
2 diameter and journal diameter.
If the oil clearance has exceeded the limit,
replace the bearing.
Clearance between the journal and bearings

0.025 – 0.087 mm 0.15 mm
(0.0010 – 0.0034 in) (0.0059 in)
MFW41BSH015601
5. Measure the cam journal.

• Measure the positions shown in the diagram
with a micrometer.
Diameter
Nominal dimensions Limitations for use
40 mm (1.575 in) 39.85 mm (1.569 in)
MFW41BSH015801

Reassembly
1. Install the knock pin.
2. Install the camshaft gear.
• With the camshaft gear center boss section
protruding side on the camshaft side, line up
the knock pin, and install the camshaft gear.
Tightening torque
142 N⋅m (14.5 kg⋅m/105 lb⋅ft)
NOTE:
• Take care not to damage the cam section and
journal section when tightening the gear.
LNW21BSH020301

MFW61BMF000201
(a) 142 N⋅m (14.5 kg⋅m / 105 lb⋅ft)

Timing Gears, Flywheel and Flywheel Housing

Component Parts
2
1
5
4
13
11 12 3
9
7
10 8
MFW81BLF003301
Legend
1. Idle gear A 8. Air compressor idle gear
2. Idle gear A shaft 9. Oil seal
3. Oil pump 10. Flywheel
4. Idle gear B 11. Cover
5. Idle gear B shaft 12. Flywheel housing
6. Slinger 13. Crankshaft position sensor
7. Air compressor idle gear shaft
Removal • Refer to “Oil Pan” in Lubrication System.

1. Lower the engine assembly from the vehicle. 4. Remove the Crankshaft Position Sensor (CKP).
• Refer to “Engine Assembly”.
• Refer to “Cylinder Head”.

• Remove it before removing the flywheel. 3. Remove the flywheel.
Manual transmission model
1
2
3
4
5
1 2
MFW81BSH010701
MFW71BSH002501
Legend
Legend 1. Flywheel housing
1. Crankshaft position sensor 2. Flywheel
2. Flywheel housing 3. Pilot bearing
4. Snap ring
Automatic transmission model
5. Washer
2
1 b. It is a specification of the automatic
transmission.
1. The flexible plate installation bolt is
removed.
2. Washer and flexible plate and flexible plate
adaptor are removed.
3. The installation bolt is removed.
4. Washer is removed.
MFW81BSH010501
Legend
1. Crankshaft position sensor
2. Flywheel housing

a. It is a specification of the manual transmission.
1. The installation bolt is removed.
2. Washer is removed.

1
2
3
4
5
6
MFW41BSH028801
MFW81BSH010801
Legend
1. Flywheel housing 10. Remove the oil seal.
2. Flywheel • Remove the flywheel housing oil seal while
3. Washer being careful not to damage the flywheel
4. Flexible plate adaptor housing surface to press fit the oil seal.
5. Flexible plate
6. Flexible plate washer NOTE:
• Always replace it when disassembling.
• Replace the slinger as a set along with the oil seal.
6. Remove the cover.
7. Remove air compressor idle gear .
8. Remove air compressor idle gear shaft.
NOTE:
• The bolts in the diagram tighten the flywheel
housing from the cylinder body side. Do not forget to
remove them.
• Three M8 bolts are used to install the idle gear A
shaft and flywheel housing. Do not forget to remove
them.
• After removing air compressor idle gear, there is
one M14 bolt installed.
Do not forget to remove it.
MFW41BSH004501
11. Remove the slinger, and measure the backlash of

each idle gear.
• Use a Slinger replacer (8-9439-6858-0) to
remove the slinger.
NOTE:
Replace the slinger as a set along with the oil seal.
Axial direction gap

Limitations for
Assembly standard
use
0.15 – 0.225 mm 0.3 mm
Idle gear A
(0.006 – 0.009 in) (0.012 in)
0.08 – 0.155 mm 0.2 mm
Idle gear B
(0.003 – 0.006 in) (0.008 in)
MFW41BSH004601
a. Measure the backlash.

• Measure the backlash of each idle gear.
Backlash
0.1 – 0.17 mm 0.3 mm
MFW41BSH004801
(0.004 – 0.007 in) (0.012 in)
12. Remove idle gear A.

13. Remove idle gear A shaft.
14. Remove the oil pump.
15. Remove idle gear B.
16. Remove idle gear B shaft.
MFW41BSH004701
b. Measure the axial direction gap.

• Measure the axial direction gap for each idle
gear.

Disassembly Inspection
1. Remove the snap ring from the flywheel. 1. Pilot bearing.
2. Use a Pilot bearing replacer (9-8521-0157-0) to • Inspect the pilot bearing for wear and abnormal
remove the pilot bearing. noises.
NOTE:
Do not clean it as it is a grease seal type.
MFW41BSH017901
3. Remove the flywheel starter gear from the

MFW41BSH018201
flywheel.
• Place wood chips on the flywheel, place an
application bar on the edge surface of the
2. Flywheel.
flywheel starter gear, and tap it evenly to
remove it. • Inspect the flywheel for cracks and impact
marks, and measure the amount of wear.
NOTE: Either repair or replace it if there are any
Inspect the flywheel starter gear for damage first, and if abnormalities.
there are no problems, do not remove it.
Nominal Limitations
dimensions for use
Dimensions
from the
clutch disc
friction surface 48 mm 49 mm
15 inch
to the (1.890 in) (1.929 in)
crankshaft
mounting
surface (a)
MFW41BSH018001

4. Inspect each gear teeth section, breakaway,
pitching etc.
a
MFW81BSH008101
MFW41BSH019501
3. Inspect the flywheel starter gear wear.
NOTE: 5. Measure the diameter of each idle gear shaft (1)

Inspect the tooth surface, and replace the flywheel and the gap between the shaft and idle gear.
starter gear if it is damaged or excessively worn.
mm (in)
Nominal Limitations
dimensions for use
Idle gear shaft A, B 29.959 – 29.980 29.8
circumference (1.1795 –1.1803) (1.1732)
Idle gear shaft C 29.959 – 29.980 29.8
circumferences (1.1795 –1.1803) (1.1732)
Air compressor
29.959 – 29.980 29.8
idle gear shaft
(1.1795 –1.1803) (1.1732)
circumferences
Gap between idle
0.020 – 0.062 0.2
gear A, B shafts and
(0.0008 –0.0024) (0.008)
gears
Gap between idle
0.020 – 0.062 0.2
gear C shaft and
(0.0008 –0.0024) (0.008)
MFW41BSH018401
gears
Gap between air
0.020 – 0.062 0.2
compressor idle
(0.0008 –0.0024) (0.008)
shaft gear

Installation
Completely remove the gasket from the flywheel
housing and cylinder block mounting surfaces.
1. Install idle gear B shaft.
1
• Install with the shaft oil hole towards the
cylinder head side.
Tightening torque
31 N⋅m (3.2 kg⋅m/23 lb⋅ft)
MFW41BSH019601
Reassembly
1. Install the flywheel ring gear to the flywheel.
• Place the flywheel starter gear on a metal grill,
heat the inner surface of the gear evenly with a
gas burner, point the larger side of the gear
beveling (1) towards the flywheel side and
install it.
NOTE:
• The temperature for the ring gear shrinkage fit is MFW41BSH004901
less than 200°C (392°F).

• During the shrink fit, put the load of 68.6 kN (6995
kg / 15424 lb) on the ring gear to keep flatness. 2. Install idle gear B.
• After shrink fit, check that the ring gear is firmly • Apply oil to the inner circumference of the idle
seated in the flywheel. gear and the thrust section, and tighten the bolt
through the thrust collar.
Tightening torque
95 N⋅m (9.7 kg⋅m/70 lb⋅ft)
NOTE:
After installing, check that it rotates when turned gently
by hand.
MFW41BSH019401
2. Install the pilot bearing to the flywheel.

3. Install the snap ring to the flywheel.

• Do not allow liquid gasket to get onto the gears or
arrow section hole.
• Make sure the driven gear does not fall out.
MFW41BSH005001
3. Install the oil pump.

MFW41BSH005201
• Apply engine oil to the oil pump gear insertion
section.
• Remove any liquid gasket that has overflowed
from the oil pump mounting surface, and apply • Line up the dowel and install the oil pump.
engine oil to the crankcase and cylinder block
bushing.
Tightening torque
NOTE: 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
Do not allow oil to get onto the oil pump mounting
surface. NOTE:
• There are no alignment marks on the gears.
• Install the oil pump before installing idle gear A.
MFW41BSH005101
MFW41BSH005301
• Apply liquid gasket (ThreeBond TB 1201 or
1207C) to the oil pump mounting surface as
shown in the diagram. 4. Install idle gear A shaft.
• Apply engine oil to the gear inner circumference
NOTE:
section and thrust section.
• Install within 5 minutes of applying the liquid gasket.
• Insert idle gear A shaft into the arrow section.
1
2
11
10
3
MFW51BSH001401
• Insert the gear into the shaft, and fit in the 5

collar.
6
NOTE: 7
8
• Rotate the crankshaft and set the #1 cylinder to the
top dead point.
MFW41BMH001101
Legend
1. Camshaft gear
2. Positioning
3. Idle B gear
4. Positioning
5. Air compressor gear
6. Air compressor idle gear
7. Crank gear
8. Oil pump gear
9. Supply pump gear
10. Idle A gear
11. Idle C gear
5. Install idle gear A.

• Line up the shaft knock pin and cylinder body
knock hole, and install so that the crank gear
(1) “L” mark and idle gear A (2) “O” mark also
line up.
• Apply molybdenum-disulfide paste to the
threaded section and seating section of the
bolts and the washer, and tighten them.
Tightening torque
134 N⋅m (13.7 kg⋅m/99.1 lb⋅ft)
NOTE:
• After installing, re-check that the marks are in line.

• After installing the flywheel housing, install the shaft • Tighten the knock pin location first. Tighten the
using 3 bolts. remaining sections in any order.
Tightening torque
1, 2, 4, 7, 9 96 N⋅m (9.8 kg⋅m/71 lb⋅ft)
5, 6 119 N⋅m (12.1 kg⋅m/87.5 lb⋅ft)
1 3 73 N⋅m (7.4 kg⋅m/54 lb⋅ft)
8 75 N⋅m (7.6 kg⋅m/55 lb⋅ft)
10 86 N⋅m (8.8 kg⋅m/64 lb⋅ft)
2 11 53 N⋅m (5.4 kg⋅m/39 lb⋅ft)
NOTE:
• Tighten sections (10) and (11) in the diagram from
the cylinder block side.
BLW51BSH002501 1
2
3

8
• Apply liquid gasket (ThreeBond 1207C or 1201) 4
to the flywheel housing as shown in the
diagram. 5
6
NOTE: 9
• Apply liquid gasket to the arrow sections of the 7
diagram.
• Install within 5 minutes of applying the sealing 10
compound.
11
MFW71BMH000401
1
7. Install air compressor idle gear shaft (2).
8. Install air compressor idle gear (1).
• Apply engine oil to the idle gear inner
MFWA1BSH003001
circumference and thrust section, insert the
gear into the shaft to assemble it.
Legend
• Tighten the bolts through the thrust collar.
1. Do not apply gasket to this location
Tightening torque
• Install the flywheel housing. 119 N⋅m (12.1 kg⋅m/87.5 lb⋅ft)
Slinger Oil seal

Product name
Front Rear Front Rear
Front adaptor { — { —
1 Rear adaptor — { — {
Sleeve slinger { { — —
Sleeve seal — — { {
Bolt adaptor { { { {
Bolt center { { { {
2
Bolt PTO — { — {
• Insert the slinger into the adaptor tip, and set

the adaptor on the crankshaft.
MFW41BSH005601
• Cover the adaptor with the sleeve, and tighten
the center bolt until the sleeve touches the
adaptor.
9. Insert and install the O-ring to the cover.
NOTE:
• As the slinger 4 lead thread section rotationally
Tightening torque
moves the seal lip section, take care not to damage
18 N⋅m (1.8 kg⋅m/13 lb⋅ft) it.
• The Installment locations of the slinger are set by
the 4 lead threads, and are separated by color.
Engine front side ; silver

(4 evenly provided thread grooves from the inside to
the outside in a counter-clockwise direction).
Engine rear side ; gray

the outside in a counter-clockwise direction).
MFW41BSH030701
10. Install the slinger to the crankshaft.

• Installment of the slinger and oil seal should be
performed with the separate setting tool kits (8-
9439-6856-0).
• Make sure the slinger direction is correct.
1
5
6 1
2 3
4 3
Legend Legend
1. Center bolt 1. Slinger press fit dimensions
2. Sleeve 2. Crankshaft
3. Adaptor (rear) 3. Slinger
4. Crankshaft
5. Rear slinger
6. Adaptor fixing bolts 11. Install the oil seal.
• Always apply engine oil to the lip section before
press fitting the oil seal, and use a setting tool
kit (8-9439-6856-0) to install it.
NOTE:
Do not allow oil to touch the oil seal perimeter and felt
section.
•
5 6 1
MFW71BSH006401
4 3 2
• Measure the eight equal periphery divisions to
check that the slinger is press fitted in within the
specified dimensions.
MFW41BSH006101
Slinger press fit dimensions (rear side) Legend

16.7 – 17.3 mm 1. Sleeve
Assembly standard
(0.66 – 0.68 in) 2. Center bolt
3. Adaptor ring
NOTE: 4. Oil seal
Measure from the crankshaft edge surface to the oil 5. Adaptor (rear)
seal lip section working face. 6. Adaptor bolts

• Line up the knock pin with the flywheel and
install it.
• Apply molybdenum-disulphide to the thread
section and seating section of the installment
bolts, assemble the washers, and tighten in the
order shown in the diagram.
• Insert the pilot bearing, and set the snap ring.
Tightening torque
Angle method
2nd time
60° → 60° to 90°
MFW71BSH006401 NOTE:
Always check all of the bolts to make sure you didn’t
forget to tighten one.
• Measure the eight equal periphery divisions to
check that the oil seal is press fit within the The tightening order is the same.
specified dimensions.
Oil seal press fit dimensions (rear side)

7.35 – 7.65 mm
Assembly standard
(0.29 – 0.301 in)
NOTE:
• If damage is left on the shaft section after extracting
the slinger, apply liquid gasket (ThreeBond 1207C)
to the inner surface of the slinger and install it.
• If oil is oozing out after installment, wipe it off.
1
BLW51BSH004901
2
1
4
3
MFW41BSH006201
Legend
1. Flywheel housing
2. Slinger
3. Oil seal press fit dimensions
4. Crankshaft

a. Flexible plate, Adaptor installation. Manual transmission model
1. Flexible plate adaptor is installed according
to the knock pin of the flywheel.
2. Install the flexible plate.
3. Flexible plate washer is set, and it installs it
with the bolt.
Tightening torque
87 N⋅m (8.9 kg⋅m/64 lb⋅ft)
1 1 2
2
3
MFW71BSH002501
4
5 Legend
6
1. Crankshaft position sensor
2. Flywheel housing
Automatic transmission model
2
1
MFW81BSH010801
Legend
1. Flywheel housing
2. Flywheel
3. Washer
4. Flexible plate adaptor
5. Flexible plate
6. Flexible plate washer
13. Install the crankshaft position sensor (CKP).

MFW81BSH010501
Legend
Tightening torque 1. Crankshaft position sensor
8 N⋅m (0.8 kg⋅m/69 lb⋅in) 2. Flywheel housing

• Refer to “Oil Pan” in Lubrication System.
• Refer to “Cylinder Head”.
16. Load the engine assembly into the vehicle.
• Refer to “Engine Assembly”.

b
h
c
d
g
f e
MFW71BLF002801
(a) 134 N⋅m (13.7 kg⋅m / 99.1 lb⋅ft)

(b) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)
(c) 95 N⋅m (9.7 kg⋅m / 70 lb⋅ft)
(d) 31 N⋅m (3.2 kg⋅m / 23 lb⋅ft)
(e) 119 N⋅m (12.1 kg⋅m / 87.5 lb⋅ft)
(f) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
Angle method 60° → 60° to 90°
(g) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(h) 8 N⋅m (0.8 kg⋅m / 69 lb⋅in)
Crank Pulley, Gearcase Cover and Crankshaft

Component Parts
1
2
3
19 20
18
17
16 8
15
6
7
14
9
10
13
12
11
MFW41BLF002901
Legend
1. Adjustment plate 11. Crankcase
2. Gearcase 12. Slinger
3. O-ring 13. O-ring
4. Piston, connecting rod 14. Water duct
5. Connecting rod bearing 15. Crank pulley
6. Thrust bearing 16. Damper
7. Thrust bearing 17. Oil seal
8. Crankshaft bearing 18. Gearcase cover
9. Crankshaft 19. Idle gear shaft
10. Crankshaft bearing 20. Idle gear
Removal 2. Remove the cylinder head.

Refer to “Cylinder Head”.
1. Lower the engine assembly from the vehicle.
Refer to “Engine Assembly”. 3. Remove the water pump.
Refer to “Water Pump” in Cooling System.

Refer to “Oil Pan” in Engine Lubrication.
5. Remove the crank pulley and damper.
8. Remove the adjustment plate.
9. Remove the gearcase cover.
10. Remove idle gear and idle gear shaft.
11. Remove the gearcase.
• Screw bolts into the gearcase replacer holes
(more than 2 locations), tighten them uniformly
and remove it.
MFW41BSH006501

• Remove the carbon from the top surface of the
liner using a scraper, etc.
MFW41BSH029601

• Remove the gearcase cover oil seal while being
careful not to damage the press fit surface.
NOTE:
Replace the slinger as a set along with the oil seal.
MFW41BSH006601
14. Remove the slinger.

• Use as Slinger replacer (8-9439-6858-0) to
remove the slinger. • Rotate the crankshaft, move the piston of the
cylinder to be removed to the bottom dead point
NOTE: position, and remove the cap.
Replace the slinger as a set along with the oil seal. • Rotate the crankshaft, and move the piston of
the cylinder to be removed to the top dead point
position. Use the shank of a hammer, etc. to
push out the bearing from the bottom of the
connecting rod so as not to damage it.
NOTE:
• Be careful not to damage the oil jet and cylinder
liner when pushing out the connecting rod.
• Keep the removed cap, bearing and connecting rod
separately according to the cylinder they came from.

NOTE:
After removing the oil pump, remove the crankcase.
MFW41BSH006701
16. Remove the connecting rod bearing. MFW81BSH011501

17. Measure the play in the crankshaft axial direction.
19. Remove the thrust bearings.
• Measure at the #7 bearing.
20. Remove the crankshaft bearings.
NOTE:
Play in the axial direction:
• When removing the crankcase, do not let the
Assembly standard Limitations for use bearing drop out.
0.04 – 0.205 mm 0.34 mm • Always clarify the cylinder number for the bearings.
(0.0016 – 0.0081 in) (0.0134 in)
• If the value exceeds the useable limit, replace

the thrust bearing.
MFW41BSH007001
MFW41BSH006801 21. Remove the crankshaft.

• Lift the crankshaft horizontally and remove it.
18. Remove the crankcase. NOTE:

• Remove the crankcase fixing bolts in the order It is easier to lift if the end thrust bearing is removed
from the outside to the inside. before lifting.
• Screw bolts into the crankcase replacer holes 22. Remove the thrust bearings.
(1) (4 locations), tighten them uniformly and
23. Remove the crankshaft bearings.
remove it.

NOTE:
Always clarify the cylinder number for the bearings.
Disassembly
Remove the gear.
Use a gear puller (Crankshaft gear puller: 8-9439-
6818-0) to remove it.
MFW41BSH031501
2. Inspect the crankshaft.

a. Inspect the crankshaft for cracks and the
bearing striking surface for damage.
• Inspect using a magnetic flaw detector or
dye penetrant testing method if necessary.
MFW41BSH018101
Inspection
1. Inspect the damper.
• Inspect the damper for cracks and breakaway.
NOTE:
• It must always be replaced if an abnormality is
found, as a faulty damper may cause damage to the
crankshaft.
• If there is an abnormality with the damper, inspect
the crankshaft and flywheel bolts.
MFW41BSH018501
MFW41BSH031601

b. Measure the wear of the crankshaft journal and • Hold the #1 and #7 journal sections with a
pin. crankshaft aligner or V block. Place a dial
• Measure the 4 locations each as shown in gauge against the crankshaft #4 journal,
the diagram for the journal and pin locations. gently rotate the crankshaft position, and
measure the dial gauge run out.
A 1 2
B B
MFW41BSH018601
MFW41BSH018701
Crankshaft outer diameter mm (in)

Crankshaft deflection
dimensions standard for use Assembly standard Limitations for use
#4 journal 0.06 mm (0.0024 in) 0.45 mm (0.0177 in)
Dia 81.851 –
81.871 d. Measure the gap between the bearing and
(3.2225 – crankshaft journal.
Journal 3.2233)
82 0.05
outer Other than
(3.2283) (0.0020) Tightening torque
diameter #4
Dia 81.881 – 98 N⋅m (10 kg⋅m/72 lb⋅ft) →
81.901 M14 bolt 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) →
(3.2237 – Angle method 30° to 60°
3.2244)
Dia 72.902 – • Measure the bearing inner circumference
Pin outer 73 72.922 0.05 (when installed in the crankcase) and outer
diameter (2.874) (2.8702 – (0.0020) diameter of the crankshaft journal, and
2.8709) calculate the gap.
• Clean the bearing and bearing mounting
c. Measure the crankshaft run out. surface, assemble the bearing, and tighten
the crankcase to the specified torque. Use a
cylinder gauge to measure the bearing inner
diameter at the 4 locations shown in the
diagram.
• Measure the outer diameter of the
crankshaft at the 4 locations shown in the
diagram using a micrometer.

Existence of a TAFTRIDE layer
• Clean the crankshaft. Remove oil using an organic
solvent etc. on the inspection sections (except for
the area within 10 mm (0.3937 in) around the oil
hole).
MFW41BSH018801
MFW41BSH018501
Inspect for the existence of a TAFTRIDE layer

12 • Drip the inspection solution onto the inspection
A
section using a syringe or glass rod, etc. At this
B B
time, keep the inspection section flat so that
inspection solution does not run off.
*Inspection fluid 5 to 10% solution of Ammonium
A
copper (II) chloride dihydrate in distilled water.
MFW41BSH018901 2
1
Assembly Limitations 3
standard for use
#4 journal
0.093 – 0.124 mm
Crank bearing (0.0037– 0.0049 in)
0.14 mm
and crankshaft Other than #4 (0.0055 in)
Journal gap journal
0.063 – 0.094 mm
(0.0025 – 0.0037 in)
LNW21BSH038001
Refer to general information if measuring with a Legend

plastigage. 1. Do not inspect within the 10 mm (0.3937 in)
around the oil hole
2. Inspection solution
3. Crankshaft

Judgment
• Crankshaft re-usable
There is no change in the inspection area after 30
to 40 seconds.
• Crankshaft not re-usable
The inspection solution (1) (light blue color)
became transparent, then changed to copper color
after 30 to 40 seconds.
MFW41BSH018501
1. Inspect the bearing.

Inspect the bearing for wear, damage, breakaway,
striking, etc.
HCW31BSH020701
Process after inspection

• As the inspection solution is highly corrosive, wipe
it off after the inspection is complete, and wash the
area with water, steam, etc.
NOTE:
The crankshaft has been treated with TAFTRIDE and
therefore cannot be repaired.
CAUTION:
Do not allow the inspection solution to come in contact
with your eyes, hands, clothing, etc. If for any reason
the fluid gets into someone’s eye, immediately wash it
with a lot of fresh water and seek immediate medical
attention. MFW41BSH019001
2. Crankshaft bearing selection procedure.

• When installing a new bearing, or when re-
placing a bearing that is already in use, refer to
the bearing selection table to select the correct
ones.
• Check the cylinder block journal hole inner
diameter grade and the crankshaft journal
diameter grade, select a new bearing and
install it.

• The journal numbers are in #1 to #7 order from NOTE:
the left side when viewed in the readable When installing, be aware of the differences in bearing
direction. configuration.
1 2
3
4
6
MFW41BSH035101
LNW21BSH024901
Legend
1. Upper bearing
2. Oil hole
4. Oil groove
5. Lower bearing
MFW81BSH006401

Grade combination Oil clearance
Cylinder block Crank journal Bearing
#1,2,3,5,6,7 #4
Grade Grade identification color
0.065 – 0.092 mm 0.095 – 0.122 mm
1 1 Black
(0.0026 – 0.0036 in) (0.0037 – 0.0048 in)
0.063 – 0.089 mm 0.093 – 0.119 mm
1 2 Brown
(0.0025 – 0.0035 in) (0.0037 – 0.0047 in)
0.067 – 0.094 mm 0.097 – 0.124 mm
2 1 Blue
(0.0026 – 0.0037 in) (0.0038 – 0.0049 in)
0.065 – 0.091 mm 0.095 – 0.121 mm
2 2 Black
(0.0026 – 0.0036 in) (0.0037 – 0.0048 in)

3. Inspect the crankshaft gear teeth section for Install the damper.
contact breakaway, wear, etc. • Install the damper to the crank pulley.
Tightening torque
48 N⋅m (4.9 kg⋅m/35 lb⋅ft)
IMPORTANT:
• Tighten the bolts diagonally across.
• Do not allow oil or lubricants to touch the damper.
MFW41BSH019101
Reassembly
Install the crank gear.
• Warm the gear to 175°C (347°F).
• Point the timing gear mark towards the flywheel
side, and insert the warmed gears together before
they cool. Also, while the gears are cold, line up
the crankshaft rear side pin position and gear MFW41BSH031501
groove, and use a crankshaft gear setting tool (8-
9439-6819-0) to insert until it hits the collar section.
Installation
Carefully clean and wash all parts before assembly.
1. Install the crankshaft bearing.
• If you are attaching a new bearing, refer to the
bearing selection table when selecting the new
bearing (refer to inspection section).
• Install the bearing to the cylinder block and
crankcase.
• Apply ample of engine oil to the bearing.
NOTE:
• The cylinder block side bearing has grooves on its
entire circumference and an oil hole (1).
The crankcase side bearing has grooves partially
and no oil hole.
• Install the bearings with their outer side dry.
MFW41BSH019201

• Bring the crankshaft near to the #7 journal side
so that it contacts with the thrust bearing.
MFW41BSH007101
MFW41BSH007301
2. Install the thrust bearings.

• Install the thrust bearings to the cylinder
block. • Install the thrust bearing to the cylinder block.
• Apply engine oil to the sliding surface of the • Apply engine oil to the sliding surface of the
bearing, face the oil groove (1) towards the bearing, face the oil groove towards the sliding
sliding surface of the crankshaft, line up with surface of the crankshaft, line up with the
the cylinder block #7 journal inside groove and cylinder block #7 journal outer groove and push
install the bearing. At this time, applying a thin it in by hand.
layer of grease to the cylinder block bearing
mounting surface allows the operation to be
performed more smoothly without anything
falling out.
MFW41BSH007401
4. Install the crankshaft bearing (lower).

MFW41BSH007201
5. Install the thrust bearing.
• Install the thrust bearing to the crankcase outer
side.
• Apply engine oil to the crankshaft journal, lift the
crankshaft horizontally and gently lower it on.

• Apply engine oil to the sliding surface of the
bearing, face the oil groove towards the sliding
surface of the crankshaft, line up with the
crankcase #7 journal external indentation and
install the bearing. At this time, applying a thin
layer of grease to the crankcase bearing
mounting surface allows the operation to be
performed more smoothly without anything
falling out.
NOTE:
Only use the thrust bearing lower on the crankcase
outer.
MFW41BSH007601

bearing.
• Point the thrust bearing oil hole to the cylinder
block rear, and gently install the so that the
thrust bearing does not fall out.
MFW41BSH007501
6. Install the crankcase.

• Line up the cylinder block groove, and apply a
bead of liquid gasket (ThreeBond 1207C)
approx. 3 to 4 mm (0.1181 to 0.1575 in) wide.
NOTE:
• Apply the gasket seamlessly without breaks in the
bead.
MFW41BSH007701
• Tighten the crankcase.

• Apply molybdenum-disulfide to the thread and
seating section of the M14 bolts, and tighten in
the numerical sequence shown in the diagram.
• Do not apply molybdenum-disulfide or engine
oil to the M10 bolts.

• Install the M10 bolts after tightening the M14
bolts. (no fixed order)
Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft) →
M14 bolt 132 N⋅m (13.5 kg⋅m/98 lb⋅ft) →
• Clean off any overflowing liquid gasket.
NOTE:
Check that the crankshaft rotates smoothly.
MFW41BSH007901
8. Install the piston and connecting rod.

• Apply oil to the entire circumference of the
piston ring, and offset the open end 120° as
14 10 6 2 3 7 11
shown in the diagram avoiding side pressure
13 9 5 1 4 8 12
direction.
• Apply molybdenum-disulfide or engine oil to the
piston as shown in the diagram.
2
MFW41BSH007801
1
7. Install the connecting rod bearing.

• If you are Installing new bearings, refer to the
bearing selection table when selecting the new
2
bearings (refer to inspection section).
• Clean the connecting rod and cap, line up the 3
groove and install the bearings. 2
bearing.
NOTE:
MFW61BSH000201
Install the bearings with their outer side dry.
Legend
1. Front mark
2. Ring gap 120° apart
3. Molybdenum-disulfide or Engine oil application

• Move the crankpin that assembles the piston
and connecting rod to the upper dead point of
the cylinder.
MFW41BSH008301
MFW41BSH008101
• Apply ample engine oil to the connecting rod
• Apply engine oil to the cylinder liner (1). bearings.
• Line up the connecting rod markings and cap
markings and install the cap.
• Apply molybdenum-disulfide to the thread and
seating section of the bolts, and tighten
alternately to the specified torque.
1
Tightening torque
39 N⋅m (4.0 kg⋅m/29 lb⋅ft) →
Angle method 60° → 30°
MFW41BSH008201
• Check the connecting rod cylinder number,

point the piston head front mark section to the
front side of the cylinder block, and insert it into
the cylinder.
• Use a piston setting tool, and use the shank of
a hammer, etc. to push the piston in until it hits
the crankpin.
NOTE:
MFW41BSH008401
• When pushing in the piston, push it in so that the
setting tool is in contact with the cylinder block.
Pushing in without adequate contact will damage
the piston ring.
• Take care not to damage the crankpin and oil jet.
• After inserting the piston connecting rod, install a
stopper so that the liner does not come out.

• Rotate the crankshaft by hand and check that it
does not catch against anything and rotates
smoothly. Also check that the oil jet is not
distorted, and that it does not interfere with 1
other parts.
MFW71BSH015101
• Tighten the gearcase.
Remove any overflowing liquid gasket from the power
steering idle gear shaft mounting holes.
9. Install the gearcase.
• Line up the gearcase groove, and apply a bead
of liquid gasket (ThreeBond 1207B) approx. 2 Tightening torque
to 3 mm (0.0787 to 0.1181 in) wide.
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• Assemble the O-ring (1).
NOTE:
• Do not forget to apply liquid gasket to the arrow
sections of the diagram.
• It is also OK to use ThreeBond 1208 or CH Dyne
290 to prevent the O-ring from falling out.
• This engine does not have an oil thermo valve
installed. Installing one would cause a blockage in
the oil line and cause burning.
MFW41BSH029901
• Fasten the adjustment plate together at the

arrowed position shown in the diagram.
Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

NOTE:
• No liquid gasket should be attached to the bolt holes
during the application.
MFW41BSH030401
19 N⋅m (1.9 kg⋅m/14 lb⋅ft)

1
• Apply oil to the idle gear rotational movement
section and install it to the shaft.
• Point the shaft notch section towards the
crankshaft side, and install it to the gearcase.
2
4
MFW41BSH029201
4
NOTE:
Take care not to damage the idle gear metal. MFW71BMH000501
Legend
11. Install the idle gear shaft.
1. Gearcase cover
12. Install the gearcase cover. 2. Applying liquid gasket (Correct)
Apply liquid gasket (ThreeBond 1207C) to the 3. Applying liquid gasket (Wrong)
gearcase cover. 4. Parts that need extra caution (as oil may leak)
• Line up the gearcase groove, and apply a bead 5. Bolt holes
of liquid gasket approx. 2 to 3 mm (0.0787 to
0.1181 in) wide.
• Tighten the gearcase cover. • Tighten the water pump assembly.
Tightening torque Tightening torque

19 N⋅m (1.9 kg⋅m/14 lb⋅ft) 19 N⋅m (1.9 kg⋅m/14 lb⋅ft)
• Tighten the knock pin position first, and tighten

it either clockwise or counter-clockwise.
MFW61CSH001301
Remove any overflowing liquid gasket from the power
steering idle gear shaft mounting holes.
For details, refer to the cooling system. 14. Install the slinger to the crankshaft front side.
NOTE: • Insert the slinger into the adaptor tip, and set
the adaptor on the crankshaft.
• After tightening the gearcase, install the water
Use a setting tool kit (8-9439-6856-0) and press
pump. (to prevent the liquid gasket from drying)
fit the slinger to the specified dimensions.
•
MFW61CSH000101
Legend
1. Do not apply gasket even if there is a groove.

• Cover the adaptor with the sleeve, and tighten
the center bolt until the sleeve touches the
adaptor.
1 2 4
5
MFW41BSH030201
MFW41BSH035001 • Measure the dimensions from the crankshaft

Legend edge surface to the oil seal lip section working
1. Slinger face.
2. Adaptor
3. Adaptor bolts
4. Sleeve Slinger press fit dimensions (front side)
5. Center bolt 17.7 – 18.3 mm
Assembly standard
(0.70 – 0.72 in)
NOTE:
• As the slinger 4 lead thread section rotationally NOTE:
moves the seal lip section, take care not to damage After press fitting the slinger, check that there is no
it. deflection.
• The installment locations of the slinger are set by
the 4 lead thread, and are separated by color.
Engine front side ; silver

the outside in a counterclockwise direction). 1
Engine rear side ; gray

(4 evenly provided thread grooves from the inside 2
to the outside in a counterclockwise direction).
MFW41BSH009301
Legend
1. Slinger pressure fit dimensions
2. Slinger
3. Crankshaft

15. Install the oil seal. • Measure from the crankshaft edge to the oil
• Apply a thin layer of oil to the oil seal lip section, seal surface.
and set it to the crankshaft.
• Insert the adaptor ring into the sleeve and press
Oil seal press fit dimensions (front side)
fit it.
8.35 – 8.65 mm
Assembly standard
NOTE: (0.33 – 0.34 in)
Always apply oil to the oil seal lip section.
NOTE:
Special tool Check that the oil seal is press fit with no deflection.
Setting tool kit: 8-9439-6856-0
2
1
1 2 3 4 5
4 3
MFW41BSH009501
MFW41BSH031201
Legend
1. Oil seal pressure fit dimensions
Legend 2. Front cover
1. Front adaptor 3. Oil seal
2. Oil seal 4. Crankshaft
3. Adaptor bolt
4. Sleeve
5. Center bolt
16. Crank pulley
Line up the knock pin with the crank pulley and
install it.
Tightening torque
200 N⋅m (20.4 kg⋅m/147.6 lb⋅ft)
NOTE:
• Tighten the bolts in diagonal lines.
• Do not allow oil or grease to touch the crank pulley
damper.
MFW41BSH030201
MFW41BSH031601

Refer to “Oil Pan” in Lubrication System.
Refer to “Engine Assembly”.

MFW71BLF001601
(a) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)

(b) 19 N⋅m (1.9 kg⋅m / 14 lb⋅ft)
(c) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) →
Angle method 60°→ 30°
(d) M14 : 98 N⋅m (10 kg⋅m / 72 lb⋅ft) →
132 N⋅m (13.5 kg⋅m / 98 lb⋅ft) →
M10 : 37 N⋅m (3.8 kg⋅m / 27 lb⋅ft)
(e) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(f) 200 N⋅m (20.4 kg⋅m / 147.6 lb⋅ft)
Piston and Connecting Rod

Component Parts
1 2
2
3
6
4
BLW61BLF000101
Legend
1. Piston ring 5. Connecting rod cap
2. Snap ring 6. Connecting rod
3. Piston 7. Piston pin
4. Bearing
Removal 4. Remove the cylinder head.

1. Remove the oil pan. Refer to “Cylinder Head”.
Refer to “Oil Pan” in Lubrication System. 5. Remove the piston and connecting rod.
Refer to “Rocker Arm ”.
Refer to “Camshaft ”.

• Completely remove the carbon from the top Disassembly
surface of the liner using a scraper etc.
1. Remove the bearing.
NOTE:
If the bearings are to be re-used, keep them according
to the cylinder number.
2. Use a replacer piston ring setting tool (1-8522-

1029-0) to remove the piston ring (1).
NOTE:
After moving, keep the bearing outer race etc.
According to cylinder number.
LNW21BSH005001
• Rotate the crankshaft, move the piston of the

cylinder to be removed to the bottom dead point
position, and remove the cap. 1
• Rotate the crankshaft, and move the piston of
the cylinder to be removed to the top dead point
position. Use the shank of a hammer etc. to
push out the bearing from the bottom of the
connecting rod so as not to damage it.
MFW41BSH016001
NOTE:
• Be careful not to damage the oil jet and cylinder
liner when pushing out the connecting rod.
• Keep the removed cap, bearing and connecting rod
4. Remove the piston pin (1).
separately according to the cylinder they came from.
NOTE:
After removing, keep the parts according to cylinder
number.
MFW41BSH006701
MFW41BSH016101

Inspection • Clean the carbon from the piston head
section and ring groove. Next, insert a ring
1. Measure the piston ring.
into the ring groove, and measure the gap
a. Inspect the piston ring for damage, and with a thickness gauge.
measure the open end gap.
• Insert the piston ring into the cylinder liner,
and press in the ring with the piston head to Gap between ring groove and ring
the minimum wear section of the liner (liner Limitations for
upper or lower section). Next, insert a Assembly standard
use
thickness gauge into the ring open end
alignment hole gap, and measure the gap. Top ring — —
0.015 – 0.055 mm
Second ring
NOTE: (0.0006 – 0.0022 in) 0.15 mm
When measuring, completely remove all carbon from 0.030 – 0.070 mm (0.0059 in)
the open end, and set the ring at a right angle in the Oil ring
(0.0012 – 0.0028 in)
cylinder liner.
Piston ring gap

Limitations for
Assembly standard
use
0.27 – 0.46 mm
Top ring
(0.0106 – 0.018 1in)
0.37 – 0.61 mm 1.2 mm
Second ring
(0.0146 – 0.0240 in) (0.0472 in)
0.27 – 0.56 mm
Oil ring
(0.0106 – 0.0220 in)
BLW61BSH000701
c. Measure the tensile strength of the piston ring.

• Use a piston ring tension meter to measure
the tensile strength.
NOTE:
• Measure the oil ring with the coil expander attached.
• Take the open end gap and measure it.
MFW41BSH016201 Tensile strength N (kg/lb)

standard use
b. Measure the gap between the piston ring 26 – 34 (2.65 – 3.47/ 11.8
groove and piston ring. Top ring
5.84 – 7.64) (1.2 / 2.65)
21.7 – 28.7 (2.21 – 5.9
Second ring
2.93/4.88 – 6.45) (0.6 / 1.33)
30 – 40 (3.06 – 4.08/ 28
Oil ring
6.74 – 8.99) (2.86 / 6.29)
2. Measure the piston pin. • When inserting the piston pin into the piston
• Measure the outer diameter of the piston pin, under normal temperatures, check that there is
and measure the gap between the piston pin enough resistance to require gentle pushing of
and piston pin hole, and the piston pin and the pin.
connecting rod bushing. • If the pin is very loose or slack under normal
• Measure the 6 piston pin locations in the temperatures, replace the piston or the piston
diagram. pin.
mm (in)
- 0.005 –
Piston pin
40 0.000 39.95
outer
(1.5748) (-0.0002 (1.5728)
circumference
–0.000)
0.009 –
Gap between
0.022
piston pin and — —
(0.0004 –
piston pin hole
0.0009)
Gap between 0.012 –
piston pin and 0.027 0.05
—
connecting rod (0.0005 – (0.002)
bushing 0.0011) LNW21BSH009701
3. Inspect and measure the piston.

a. Inspect for impact marks and cracks in the
piston.
• Completely remove any carbon or sludge
from the piston and clean it thoroughly
before inspection. Carefully inspect difficult
to see places, such as the piston ring
groove, etc.
• Inspect using a dye penetrant testing
method if necessary.

• Clean the bearing and bearing mounting
surface, and install the bearing.
Next, apply molybdenum-disulfide to the
thread section, tighten the connecting rod
cap, and measure the 4 locations of the
connecting rod bearing shown in the
diagram with a cylinder gauge.
Cap bolt tightening torque

39 N⋅m (4.0 kg⋅m/29 lb⋅ft) →
• Measure the outer diameter of the crankpin

in the 4 locations shown in the diagram
using a micrometer.
BLW61BSH000601
Gap between connecting
rod bearing and crank pin
b. Measure the piston outer diameter. Assembly standard Limitations for use
• Measure the piston pin at the location 85 0.037 – 0.076 mm 0.1 mm
mm (3.35 in) from the piston head section, (0.0015 – 0.0030 in) (0.004 in)
and measure the piston outer diameter in
the right angle direction. Refer to “How to use a plastigage” in general
information if measuring with a plastigage.
Piston outer diameter service replacement
114.944 – 114.979 mm (4.5254 – 4.5267 in)
Inner circumference gap between piston

and cylinder liner service replacement
0.052 – 0.106 mm (0.0020 – 0.0042 in)
1 2 B
A
NOTE: A
If, as a result of the measurements, the piston liner gap 1 2 B
exceeds the standard value, replace the piston or

cylinder liner.
• The dimensions above are of the liner and piston for
service replacement.
4. Measure the connecting rod. MFW41BSH016701

a. Measure the gap between the connecting rod
bearing and crank pin.
• Measure the connecting rod bearing inner
diameter and crank pin outer diameter.

• Assemble the connecting rod to the crank
pin, and measure the gap in the axial
direction.
Gap between connecting rod large edge section and

1 2 crankshaft axial direction
A
B B Assembly standard Limitations for use

A 0.17 – 0.3mm 0.35 mm
(0.0067 – 0.0118 in) (0.0138 in)
MFW41BSH016801
b. Measure the distortion of the connecting rod.

• Use a connecting rod aligner to measure the
torsion and the parallelism of the big and
small end bores.
NOTE:
The measurements are taken based on the bearing, so
make sure the bearing is not worn.
MFW41BSH017001
Torsion and parallelism of big and small end bores (for

100mm/3.937))
5. Inspect the connecting rod bearing for wear,
damage and breakaway.
0.05 mm (0.002 in) 0.2 mm (0.008 in)
MFW41BSH017101
6. Select the connecting rod bearing.

MFW41BSH016901
• When installing a new connecting rod or
replacing a bearing that is in use, do so in
accordance with the bearing selection table.
c. Measure the axial direction gap on the
• Pay attention to the big end bore diameter
connecting rod big end.
grade, select a bearing, and install it.

Reassembly
Piston selection
• When replacing the piston, there is only one grade
for service, and therefore no need to select a
piston.
• Piston and liner can be supplied as a set. In that
case, there is need to match the liner outer
diameter and cylinder block bore inner diameter
grades.
1
2 3
MFW41BSH035701
Legend
1. Front/back distinction boss
2. Big end bore diameter grade mark
3. Cylinder number
Grade combination
Connecting
Bearing Grade Oil BLW61BSH000601
rod
(identification color) Clearance
Grade
0.037 – 0.076 mm (for reference) Liner grade selection procedure
A Green
(0.0015 – 0.003 in)
• Matching the cylinder block bore inner diameter
0.037 – 0.076 mm and liner outer diameter grades.
B Yellow
(0.0015 – 0.003 in)
• From the number etched on the top surface of the
cylinder block, select liner 1X for 1 and 2, 3X for 3
and assemble them.
Combination of cylinder block and liner outer diameter

Block etching
Liner grade
number
1X; 117.991 – 118.000 mm
1, 2
(4.6453 – 4.6457 in)
3X; 118.001 – 118.010 mm
3
(4.6457 – 4.6461 in)
Cylinder block bore grade

1 Block etching
Bore inner diameter
number
LNW21BSH010801 118.001 – 118.020 mm
1, 2
Legend (4.6457 – 4.6464 in)
1. Bearing grade (identification color) 118.021 – 118.030 mm
3
(4.6465 – 4.6468 in)

• Measure the outer diameter of the piston at the
grade location. Clean carbon etc. From the liner,
measure at an equivalent location to the cylinder
block bore, and inspect whether the gap between
the piston and liner is within the standard value.
1
Grade selection measurement position

(from the longer-axis direction piston head)
85 mm (3.35 in)
Gap between piston and liner (longer-axis direction)

0.0052 – 0.106 mm
Assembly standard
(0.002 – 0.0042 in)
BLW71BSH009201
Legend
1. Grade etching location
• Measure the maximum and the minimum bores at

the three different positions from the top surface of
the cylinder block and obtain the average value of
the six measurements.
Measuring locations (from the top surface) 1
A B C
20 mm 110 mm 190 mm
(0.787 in) (4.331 in) (7.480 in)
MFW41BSH017401
• (For reference) Dimensions of piston for service.
Piston outer diameter 114.944 – 114.979 mm

(grade position) (4.5254 – 4.5267 in)
1. Install the piston to the connecting rod.

• Install the snap ring to one side of the piston
pin.
• Apply oil to the piston pin.
• Assemble with the piston head front side mark
(1) and connecting rod indented mark (rear side
mark) in reverse, fully insert the piston pin and
fix with the snap ring.
MFW41BSH017301
Measuring procedure when re-using pistons NOTE:

Check that the snap ring is securely installed to the ring
• When re-using pistons, measure the gap between groove. At this time, make sure the ring opening
the piston and liner. section is vertical. Also, check that the piston moves
smoothly.
MFW61BSH001601 BLW51BSH005301
• Point the 2T mark on the second ring upwards,

and use a piston ring setting tool (1-8522-1029-
1 0) to install it.
• Point the T1 mark on the top ring upwards, and
use a piston ring setting tool (1-8522-1029-0) to
install it.
• Apply oil to the entire periphery of the rings,
rotate the rings, and check that they rotate
2 smoothly without catching.
• The part ring gap of 1st piston ring, 2nd piston
ring, and oil ring is things that the direct shifts
by 120°.
NOTE:
• When re-using the piston ring, make sure it is not
MFW41BSH017601 inserted upside down.
Legend • There is no up or down side with the oil ring.
1. Front mark
2. Indented mark
2. Install the piston ring.

• Assemble the expander ring onto the piston,
and engage them so there is no gap, then
install the oil ring.
NOTE:
Set the expander ring gap and piston ring gap at 180
opposite directions.

2. Install the piston and connecting rod assembly.
• Apply oil to the entire circumference of the
piston ring, and avoid side pressure on the gap
as shown in the diagram.
• Apply molybdenum-disulfide or engine oil to the
1 piston locations shown in the diagram.
3 2
1
2
MFW61BSH000101
3
Legend 2
1. Top ring
2. Second ring
3. Oil ring
MFW61BSH000201
Installation Legend
1. Install the connecting rod bearing. 1. Front mark
2. Ring gap 120° apart
• When replacing the connecting rod or bearing, 3. Molybdenum disulfide or Engine oil application
replace the bearing based on the bearing
replacement table (refer to inspection).
• Clean the connecting rod and cap, line up the
prongs and install the bearing. • Move the crankpin that assembles the piston
• Apply oil to the rotational movement surface of and the connecting rod to the lower dead point
the bearing. of the cylinder.
NOTE:
Install the bearing with its back dry.
MFW41BSH008101
MFW41BSH007901

• Apply oil to the cylinder liner.
MFW41BSH008301
MFW41BSH008201
Legend
1. Oil application • Apply ample oil to the connecting rod cap
bearing.
• Line up the connecting rod cap marks and
install them.
• Check the connecting rod cylinder number,
point the piston head front mark to the front side • Apply molybdenum-disulfide to the thread and
of the cylinder block, and insert it into the seating section of the bolts, and tighten
cylinder. alternately to the specified torque.
• Use a piston setting tool, and use the shank of
a hammer, etc. to push the piston in until it hits Tightening torque
the crankpin.
39 N⋅m (4.0 kg⋅m/ 29b⋅ft) → Angle method 60° → 30°
NOTE:
• When pushing in the piston, push it in so that the
setting tool is in contact with the cylinder block.
Pushing in without adequate contact damages the
piston ring.
• Take care not to damage the crankpin and oil jet.
• Install a stopper so that the liner does not drop out.
• Set the crankpin to top dead center with each
cylinder, when inserting piston / connecting rod.
When inserting piston / connecting rod if the
crankpin is set to the bottom dead center, the oil jet
might hit connecting rod and if might break.
MFW41BSH008401
• Rotate the crankshaft by hand and check that it

does not catch against anything and rotates
smoothly. Also check that the oil jet is not
distorted, and that it does not interfere with
other parts.

NOTE:
Set the crankpin to the bottom dead center when
tighten connecting rod cap. (Because if doesn’t hit the
tightening tool to the oil jet.)
MFW41BSH008501

4. Install the camshaft.
Refer to “Camshaft ”.
5. Install the rocker arm shaft.
Refer to “Rocker Arm ”.
Refer to “Oil pan” in Lubrication System.

MFW61BMF000101
(a) 39 N⋅m (4.0 kg⋅m / 29 lb⋅ft) →

Cylinder Block
Component Parts
MFW41BLF001701
Legend
1. Cylinder liner 4. Cylinder block
2. Oil jet 5. Oil pressure switch
3. Crankcase
Disassembly 4. Remove the crankshaft.

1. Lower the engine assembly from the vehicle. Refer to “Crank Pulley, Gearcase Cover and
Refer to “Engine Assembly”. Crankshaft”.
2. Remove the cylinder head. 5. Remove the oil pressure switch.
Refer to “Cylinder Head”. 6. Remove the oil jet.
3. Remove the supply pump, air compressor, and oil 7. Remove the cylinder liner.
cooler. Measure the inner circumference of the cylinder
liner, and remove it after judging whether it is OK
Refer to “Engine Exterior Parts”. or not. Refer to the liner wear section.

• If the cylinder liner cannot be extracted by
hand, follow the following procedure.
• Securely hang the Cylinder liner remove (5-
8840-2397-0) anchor on the lower edge of the
liner, insert a turret into the center bolt so that it
does not catch on the collar section of the liner
for above, and tighten it with a bearing
mounting nut. Next, fix a handle to the nut, and
rotate the handle to extract the liner.
NOTE:
Take care not to damage the cylinder block bore
surface when extracting the liner.
MFW41BSH019901
5. Inspect the oil jet.

• Inspect the oil jet for blocked oil hole, bent pipe,
and check valve operation.
Check valve opening pressure

160 kPa (1.6 kgf/m2/23 psi)
MFW41BSH019801
Inspection
1. Carefully remove an deposits and other debris
from the upper surface of the cylinder block.
NOTE:
Take care not to damage the cylinder block.
2. Carefully remove and liquid gasket from the

crankcase mounting surface.
3. Clean the cylinder block and crankcase.
4. Inspect the crankcase.
• Inspect the crankcase for cracks and damage.
MFW41BSH020001
• Inspect using a magnetic flaw detector or dye
penetrant testing method if necessary.
6. Measure the wear of the cylinder liner.

• Measure the largest wear at around 20 mm
(0.7874 in) from the liner upper surface, and
replace the liner if it exceeds the specified
value.
Maximum wear on cylinder liner


• Inspect the cylinder block for cracks and
damage.
• Inspect using a dye penetrant testing method if
necessary.
• Check the screw thread for damage or faults.
• With the hydraulic test, apply 490 kPa (5 kgf/
cm2 / 71 psi) of water pressure for 3 minutes,
and inspect each section of the cylinder block
for water leaks.
MFW41BSH019701
7. Inspect and measure the cylinder block.

• Measure the amount of distortion of the cylinder
block.
• Place a straightedge diagonally on the cylinder
block surface, and measure 4 locations with a
thickness gauge (1).
MFW41BSH020201
Amount of distortion of cylinder block

Limitations for use 0.2 mm (0.008 in) Reassembly
1. Select a liner grade for the cylinder block and
NOTE: assemble them.
Cannot be repaired with grinding because the timing
gear backlash will change. CAUTION:
Do not use a thermo valve in the oil hole on the front
side of the cylinder block. Installing would may cause
burning.
a. Cylinder liner grade selection.

• Matching the cylinder block bore inner
diameter and liner outer diameter grades.
• From the number printed on the top surface
of the cylinder block, select liner 1X for 1
and 2, 3X for 3 and assemble them.
CAUTION:
• As the liners are very thin, do not use one that has
been dropped.
1 • If the liner grade is not selected correctly, there will
be insufficient cooling (gap size) which may cause
seizure.
MFW41BSH020101
• Inspect the cooling water pipes and oil pipes

between each of the cylinders for blockages or
corrosion.

• The dimensions for the liner grade are controlled
when the liner is produced, and are stamped onto
the upper side surface of the liner.
Cylinder block measurement location

1
(From cylinder block upper surface)
A B C
20mm 110 mm 190 mm
(0.79 in) (4.33 in) (7.48 in)
MFW41BSH020301
Legend
1. Grade print location
Matching cylinder block and liner outer diameter

grade
Block print 1 2 3
Liner outer
1X 3X
diameter
MFW41BSH020501
Cylinder block inner circumference, liner mm (in)

outer circumference grade
Grade (1) . (1X) (2) . (1X) (3) . (3X)
118.001 118.011 118.021
1
– – –
Block inner 118.010 118.020 118.030
circumference (4.6457 (4.6461 (4.6465
– – –
4.6460) 4.6464) 4.6468)
118.001
–
Liner outer 117.991– 118.000 118.010
diameter (4.653 – 4.6457) (4.6457
–
4.6460)
BLW71BSH009201
NOTE:
Legend
• The cylinder block grade is determined by 1. Grade etching
measuring the following 3 locations and a total of 6
locations on the cylinder block upper surface and
calculating the average value.
2. Install the cylinder liner.
• Wash the cylinder block and liner.
• After washing the cylinder block and liner, air
blow them.

NOTE: • Use a dial gauge and measure the amount of
Handle the liner carefully as it is very thin. Do not store liner protrusion.
the liner flat.
Assembly standard
0.06 – 0.1 mm
Amount of liner protrusion
(0.0024 – 0.004 in)
Difference of liner protrusion 0.03 mm
1 with next liner (0.0012 in)
MFW81BSH007901
Legend
1. Correct
2. Wrong
• Apply a thin layer of engine oil to the bottom MFW41BSH020801
surface of the outer perimeter of the cylinder

liner, and install it straight against the cylinder
3. Install the oil jet.
block.
NOTE:
Tightening torque
• When inserting the liner, do not strike it or use
excessive force. 21 N⋅m (2.1 kg⋅m/15 lb⋅ft)
• After inserting the liner, prevent the liner from falling
out when inverting the cylinder block. NOTE:
Do not bend the oil jet tip.
MFW41BSH020701
MFW41BSH020901
4. Install the oil pressure switch.

• Install the adaptor to the cylinder block.
• Apply ThreeBond 1241 to the adaptor for the oil
pressure switch, and install them to the cylinder
block.
Tightening torque
Adaptor 117 N⋅m (11.9 kg⋅m/86 lb⋅ft)
Oil pressure switch 18 N⋅m (1.8 kg⋅m/13 lb⋅ft)
MFW41BSH021001
Legend
1. Adaptor
2. Oil pressure switch

Refer to “Crank Pulley, Gearcase Cover and
Crankshaft”.
6. Install the supply pump, air compressor, and
oil cooler.
Refer to “Engine Exterior Parts”.
Refer to “Oil Pan” in Lubrication System.
Refer to “Engine Assembly”.

a
b
MFW61BLF000401
(a) 18 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

(b) 117 N⋅m (11.9 kg⋅m / 86 lb⋅ft)
(c) 21 N⋅m (2.1 kg⋅m / 15 lb⋅ft)
ENGINE
Engine Cooling
(6HK1)
TABLE OF CONTENTS
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1C-2
Explanation of Functions and Operations . . . . . 1C-3
Coolant Inspection . . . . . . . . . . . . . . . . . . . . . . 1C-5
Radiator Inspection . . . . . . . . . . . . . . . . . . . . . . 1C-7
Engine Cooling Water Replacement Procedure 1C-8
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1C-9
Phenomenon: Engine overheats. . . . . . . . . . . 1C-10
Phenomenon: Engine overcools . . . . . . . . . . . 1C-11
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1C-11
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1C-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-14
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-15
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-18
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-19
Tightening Torque Table . . . . . . . . . . . . . . . . . 1C-20
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-22
Fan Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-24
Tightening Torque Table . . . . . . . . . . . . . . . . . 1C-26
Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-28
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-29
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1C-32
Cooling System
Precautions for Servicing
WARNING:
cooling water is hot. Steam or hot water may spurt out,
which may cause serious scalding injuries. When
opening the radiator cap, do so when the cooling water
is cool, cover the cap with a thick cloth, and rotate it
slowly to release pressure before removing it.

Cooling water circulation system diagram
2 3 10
1
11
5
6
9
7
8
19
13 12
18
14
17
16 15
MFW71CLF000401
Legend
1. Radiator cap 11. Turbocharger
2. Reserve tank 12. Air compressor
3. Reserve tank filling hole 13. Water jacket
4. EGR cooler 14. Oil cooler
5. Water outlet pipe 15. Water pump
6. Thermostat 16. Lower hose
7. Engine coolant temperature sensor 17. Drain plug
8. Bypass passage 18. Cooling fan
9. Water jacket 19. Radiator
10. Heater core

Water pump structural diagram
3 4
2
10 8
9
MFW81CLF000601
Legend
1. Shaft 6. Impeller
2. Snap ring 7. Seal unit
3. Bearing 8. Spacer
4. Grease nipple 9. Pulley
5. Washer 10. Dust cover

Coolant Inspection
1. Coolant Concentration 2. Measurement of coolant concentration LLC
• Because the freezing temperature of the engine (specified product of Isuzu or equivalent)
coolant is changed with the concentration of the • Use an antifreeze hydrometer or thermometer,
engine coolant, change the concentration and measure the specific gravity and coolant
according to minimum temperature. temperature.
• Always use an engine coolant specified by Take care if the temperature is hot, as cooling
Isuzu or equivalent, or water. Never use other water may spurt out when the cap is removed.
coolants. • After measuring the temperature and specific
• Calculation to obtain the engine coolant gravity, calculate the concentration from the
concentration: table below.
Concentration of Engine Coolant (%) = Volume • Use a container that is deeper that the length of
of Engine Coolant (L) / [Volume of Engine the hydrometer to be used.
Coolant (L) + Volume of Water (L)] x 100 • The temperature of the cooling water to be
• If the mixing ratio of the engine coolant is higher measured should be within the 0 to 50°C (32 to
than 60%, overheats easily occur. If it is less 122°F) range.
than 30%, corrosion cannot be prevented
sufficiently.
Mixing percentage
Outside L (Imp.gal) Coolant of
Usage region Specifications
temperature Engine coolant Distilled water or concentration
(BESCO) Deionized water
Up to -12°C Except FTS: 8.85 20.65
Warm region 30%
(10.4°F) TCN/TCC M/T (1.947) (4.543)
FTS: TCN M/T
9.0 (1.98) 21.0 (4.62)
TCS M/T
FTS: TCC/TCN 9.75 22.75
A/T (2.145) (5.005)
FTS: TCS 10.05 23.45
A/T (2.211) (5.159)
Up to -30°C Except FTS: 14.75 14.75
Cold region 50%
(-22°F) TCN/TCC M/T (3.245) (3.245)
FTS: TCN M/T 15.0 15.0
TCS M/T (3.30) (3.30)
FTS: TCC/TCN 16.25 16.25
A/T (3.575) (3.575)
FTS: TCS 16.75 16.75
A/T (3.685) (3.685)
MFW41CSH000201
• Coolant tester
Use a coolant tester to measure the
concentration.

Radiator Inspection
Radiator cap
• Use a radiator cap tester to inspect the injection
valve opening pressure. If the inspection valve
opening pressure exceeds the standard value,
replace the radiator cap.
Positive pressure : 93 – 122 kPa

Cap operating (0.9 – 1.2 kg/cm2/13 – 17 psi)
pressure Negative pressure : Min. 4.9 kPa
(0.05 kg/cm2/0.7 psi)
MFW41CSH000901
MFW41CSH000801
• Inspect the condition of the negative pressure

valve at the center of the cap valve seat side. If the
valve seat does not operate smoothly because of
rust, dirt, etc, clean or replace the radiator cap.
Radiator core
• A distorted radiator fin may lead to a reduction in
heat dissipation effectiveness, which may in turn
cause overheating. Therefore, the fin must be
repaired. Take care not to damage the joint section
of the fin when repairing it.
• Remove dirt and other debris.
Inspection for cooling water leaks

• Using a radiator cap tester, apply 200 kPa (2.0 kg/
cm2 / 28 psi) of pressure and inspect the following
parts for leaks. Also inspect the radiator hose and
heater hose for damage and deterioration, and
inspect the hose clamps for looseness.
• Radiator assembly, water pump assembly, radiator
hose, heater hose.

Engine Cooling Water Replacement Procedure
NOTE:
Replace the coolant every 2 years.
Wash the radiator cap, radiator and coolant passage at
the same time.
1. Check that the engine is cool.
WARNING:
cooling water is hot. Steam or hot water may spurt out,
which may cause serious scalding injuries. When
opening the radiator cap, do so when the cooling water
is cool, cover the cap with a thick cloth, and rotate it
slowly to release pressure before removing it.

3. Loosen the radiator cooling water drain plug, and
drain the cooling water.
4. Close the drain plug.
5. Completely fill the radiator with tap water.
6. Inspect and clean the radiator cap. Replace the
cap if there are any abnormalities.
7. Securely close the radiator cap.
8. Fill the reserve tank with tap water up to the [MAX]
line.
9. Close the reserve tank cap.
10. Start the engine, allow it to idle for 20 minutes, then
stop the engine and drain the tap water after the
engine has cooled enough.
11. Completely fill the radiator with coolant.
12. Close the radiator cap securely.
13. Fill the reserve tank to its [MAX] line with coolant.
14. Close the reserve tank cap.
16. After running the engine at idle for 2 to 3 minutes
and in a usual idling revolution per minute, stop the
engine.
17. Once it has been confirmed that the coolant has
cooled down, remove the radiator cap and top up if
the level is low.
18. Close the radiator cap securely, and then warm up
the engine by running it at approximately 2,000 r/
min.
19. When the coolant temperature gauge’s needle
exceeds the gauge’s midway point, let the engine
idle for approximately 5 minutes, and then stop the
engine and let it rest.
20. Once it has been confirmed that the coolant has
cooled down, remove the radiator cap and top up if
necessary. If the coolant’s level is extremely low,
check for leaks.
21. Close the radiator cap securely.
22. Once again, fill the reserve tank to its [MAX] line
with coolant.

• Engine overheats
• Engine overcools

Phenomenon: Engine overheats

Engine overheats Insufficient amount of cooling water Add more
Thermostat malfunction Replace
Water pump malfunction Replace
Radiator blocked Clean or replace
Radiator cap malfunction Replace
Insufficient engine oil, or an incorrect Add or replace the engine oil
engine oil is being used
Cylinder head gasket malfunction Replace
Loose fan belt Adjust
Exhaust system blockage Clean or replace
Excess fuel injection volume Diagnose the engine control system

Phenomenon: Engine overcools

Engine overcools Thermostat malfunction Replace
Main Specifications
Item Specifications
Cooling method Water cooled preload forced-circulation type
Radiator Colgate type
Type
V-ribbed belt drive-swirl, type
Water pump Output volume

(Pump r/min: 3,300 r/min,
water volume: normal 310.5 L (68.3 Imp⋅gal) / min
temperature)
With jiggle valve 82°C (180°F)
Temperature for
thermostat open start Primary: 82°C (180°F)
Without jiggle valve
Secondary: 85°C (185°F)
Full cab, Wide cab and Crew cab:
Except FTS: TCN / TCC M/T (29.5 L / 6.49 Imp⋅gal)
Cooling water volume FTS: TCN / TCS M/T (30.0 L / 6.60 Imp⋅gal),
TCN/TCC A/T (32.5 L / 7.15 Imp⋅gal),
TCS A/T (33.5 L / 7.37 Imp⋅gal)
Reserve tank capacity 2.0 L (0.44 Imp⋅gal)
Radiator
Component Parts
1 2
6 5
MFW71CLF000201
Legend
1. Reserve tank hose 4. Intercooler
2. Upper hose 5. Fan shroud
3. Radiator 6. Turbocharger out intercooler hose
Removal
1. Drain off the cooling water from the radiator.

• Remove the drain plug, and drain off the cooling 4. Remove the lower hose.
water from within the radiator.
3 2 1 1 2 3
MFW71CSH001001
MFW71CSH001101
Legend
Legend 1. Intercooler
1. Intercooler 2. Radiator
2. Radiator 3. Lower hose
3. Drain plug
5. Remove the reserve tank hose.

2. Remove the intercooler hose (1). 6. Remove the fan.
• Remove the fan shroud bracket (1) in three
location, and remove the fan guide with the fan
coupling attached.
1
MFW71CSH000901
1
3. Remove the upper hose. MFW71CSH000801
7. Remove the radiator assembly.

• Remove the rubber from the radiator.

• Remove the radiator stay (1).
• Inspect the condition of the negative pressure
valve at the center of the cap valve seat side. If the
1 valve seat does not operate smoothly because of
rust, dirt, etc, clean or replace the radiator cap.
Radiator core
• A distorted radiator fin may lead to a reduction in
heat dissipation effectiveness, which may in turn
cause overheating. Therefore, the fin must be
repaired. Take care not to damage the joint section
of the fin when repairing it.
• Remove dirt and other debris.
Inspection for cooling water leaks

• Using a radiator cap tester, apply 200 kPa (2.0 kg/
cm2 / 28 psi) of pressure and inspect the following
MFW71CSH000701
parts for leaks. Also inspect the radiator hose and
heater hose for damage and deterioration, and
inspect the hose clamps for looseness.
• Remove the radiator assembly.
• Radiator assembly, water pump assembly, radiator
• Take care not to damage the radiator fin. hose, heater hose.
Inspection
Radiator cap
• Use a radiator cap tester to inspect the injection
valve opening pressure. If the inspection valve
opening pressure exceeds the standard value,
replace the radiator cap.
kPa (kg/cm2 / psi)

Positive pressure : 93 – 122
Cap operating (0.90 – 1.20 / 13 – 17)
pressure Negative pressure : Min. 4.9
(0.05 / 0.7)
MFW41CSH000901
MFW41CSH000801

Cleaning
Washing inside the radiator and the water passage.
Wash the inside of the radiator and coolant path with
water.
Wash away all scales and rust.
1
Washing the radiator core
CAUTION:
radiator, intercooler and surrounding parts when they
are still installed on the vehicle.

fabric tape.
radiator.
• Adhering matter which easily comes off with a MFWA1CSH001101
sufficiently in advance. Legend
1. Radiator
NOTE:
Do not use a high-pressure washer or brush. 6. After washing is finished, inspect the fins to
3. Prepare a mild detergent. • If washing is not sufficient, wash them again.
surface acting agent. NOTE:
NOTE: the fins can be seen.
any product other than a mild detergent may cause 7. Rinse off the detergent constituents on the fins and
corrosion. resin parts using the tap water.
sufficiently.
washer.
• Start washing from the engine side of the Installation
radiator. 1. Install the radiator assembly.
NOTE:
• Apply the high-pressure water in a direction Tightening torque
perpendicular to the fins. Upper side nut 41 N⋅m (4.2 kg⋅m/30 lb⋅ft)
• Do not bring the high-pressure water too close to Lower side nut 85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
the fins.

• When Installing the radiator, take care not to 4. Install the lower hose.
damage the fin.
Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)
MFW71CSH001201
• Install the radiator stay (1). 1 2 3
MFW71CSH001001
Tightening torque Legend

1. Intercooler assembly
13.4 N⋅m (1.37 kg⋅m/119 lb⋅in) 2. Radiator assembly
3. Radiator lower hose
1
5. Install the upper hose.
Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)
NOTE:
Make sure the head of the clamp bolt does not protrude
above the hose.
6. Install the intercooler hose (1).

• Tighten a clamp bolt.
MFW71CSH000701 Tightening torque

8 N⋅m (0.8 kg⋅m/69 lb⋅in)
2. Install the fan.
Specifications Tightening torque

Full cab 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
Wide cab 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
3. Install the reserve tank hose.

MFW71CSH000901
7. Close the drain plug, and fill with cooling water.

Drive Belt
Inspection • Securely tighten each bolt after the adjustment.
• Inspect the drive belt for wear or damage, and
Generator drive belt tension adjustment value
replace it as necessary.
• Inspect the belt tension, and adjust it as necessary.
Amount Frequency Tension
of flex of N
(in) (Hz)
When 980 – 1176
4–5
using new 191 – 209 (100 – 120 /
(0.16 – 0.2)
belt 221 – 265)
706–804
When 6–7
162 – 172 (72 – 82 /
readjusted (0.24 – 0.28)
159 –181)
A/C drive belt tension adjustment value
Amount Frequency Tension

of flex of N
MFW71CSH001401
(in) (Hz)
Inspection guidelines When 392–588

10 – 13
using new 115 – 141 (40 – 60 /
• Press the middle section of each belt with the force (0.39 – 0.51)
belt 88 – 132)
of approx. 98 N (10 kg / 22 lb), and inspect the
amount of flex / frequency of vibrations of the belt. 294 – 392
When 13 – 15
101 – 115 (30 – 40 /
readjusted (0.51 – 0.59)
66 – 88)
1 2
MFW71CSH002501
Reference 3
MFW71CSH001301
NOTE:
Legend
• Since a V-rib belt is used for the generator drive
1. Adjust bolt
belt and it is necessary to adjust the tension more
2. Installation nut
accurately than conventional V belts, use a sonic
3. Mounting bolt
tension meter to confirm that the measured
frequency of vibrations is within the adjustment
values and readjust the tension if the value is
improper.

Adjustment
When adjusting the tension of the drive belt, do so for
both the generator drive belt and the A/C compressor
drive belt.
Adjusting generator drive belt

1. Loosen the adjust plate lock nut and through bolt.
2. Turn the adjust bolt to adjust the generator drive
belt.
3. After the adjustment, tighten the adjust plate lock
nut and through bolt at the specified torque.
Tightening torque
Through bolt 127 N⋅m (12.9 kg⋅m/93 lb⋅ft)
Adjusting A/C compressor drive belt

1. Loosen the lock nut of the idle pulley.
2. Turn the adjust bolt of the idle pulley to adjust the
belt.
3. Tighten the lock nut at the specified torque after
the adjustment.
Tightening torque

c
MFW71CMF000601
(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 127 N⋅m (12.9 kg⋅m / 93 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
Thermostat
Component Parts
MFW61CLF000601
Legend
1. Water outlet pipe 4. Without thermostat
2. Gasket 5. Spacer
3. Thermostat 6. Sealing cup
Removal 4. Remove the thermostat. (Spacer is removed for

the specification without thermostat)
1. Drain the cooling water. Prepare a receptacle, and
drain at a rate so that the cooling water does not
spill onto the thermostat housing. Inspection
2. Remove the radiator air extraction hose from the
1. Inspect the water outlet pipe for corrosion etc.
radiator side.
2. Inspect the thermostat.
• Remove the radiator upper hose at the radiator
side. • Inspect the thermostat pellet, spring, shaft,
jiggle valve and caulking section for damage.
1
1
MFW41CSH001301 MFW41CSH001401
Legend Legend
1. Jiggle valve 1. Wood chippings
2. Stirring rod
• Inspect the operation of the thermostat.

• Place the thermostat into water, and gradually 3. Inspect the gasket for cracks and damage.
raise the water temperature to inspect the
temperature at which the it starts opening,
temperature at which it is fully open, and
Installation
amount of lift. 1. Install the gasket.
NOTE:
Temperature at which it Replace the gasket as it can cause water leakage.
80 to 84°C (176 to 183°F)
starts to open
2. Install the thermostat. (Install the spacer)
Temperature at which it
More than 95°C (203°F) • Install the gasket to the thermostat, and install it
is fully open
as shown in the diagram.
Amount of lift More than 8 mm (0.315 in)
NOTE:
• As the heat capacity for wax type thermostats is Do not install in the wrong location or in the wrong
great, there is some difference between the direction.
valve operation with changes in water
temperature.
NOTE:
To avoid direct heat on the thermostat, either cover the
bottom of the container with a plate, or suspend it. At
this time, continue to stir the water to ensure a constant
water temperature.

Tightening torque
5 N⋅m (0.5 kg⋅m/43 lb⋅in)
5. Install the radiator air extraction hose.

6. Fill with cooling water.
MFW91BSH000801
Legend
1. Jiggle valve position
Tightening torque
24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
NOTE:
If you install the thermostat in the wrong position, you
will not be able to install the water outlet pipe.
MFW41CSH001601
Legend
1. Water outlet pipe
2. Positioning stopper
3. Thermostat
Fan Drive
Inspection
This diagram shows a vehicle with a day cab model.
MFWA1CLF000101

1. Fan coupling
• Inspect for abnormal noises and oil leaks.
• Rotate by hand to inspect for abnormal noises.
4 3
MFW61CMH000101
Legend
1. Cooling fan
2. Fan drive
3. Bimetal
4. Cooling fin

MFW71CLF000601
(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 36 N⋅m (3.7 kg⋅m / 27 lb⋅ft)
Water Pump
Component Parts
12
11
10
6
5
MFW81CLF000501
Legend
1. Pulley 7. Washer
2. Dust cover 8. Shaft
3. Snap ring 9. Water pump body
4. Bearing 10. O-ring
5. Spacer 11. Seal unit
6. Bearing 12. Impeller
Removal
3. Remove the O-ring (water duct).
4. Remove the O-ring (water pump).
5. Remove the water pump.
1 3
MFW61CLF000401
Legend
1. Water pump assembly 4. O-ring (water pump)
2. O-ring (water duct) 5. Plate
3. Water duct
Disassembly
If more than 10cc/100 hours of water is leaking from
the water drain hole when the pump assembly is
assembled, disassemble and adjust.
1. Remove the impeller.

2. Use a puller (Puller: 1-8521-0050-0) to remove the 6. Use a press to remove the bearing.
pulley.
MFW41CSH002401
MFW61CSH000501
7. Remove the spacer.

3. Remove the dust cover. 8. Remove the washer.
4. Remove the snap ring. 9. Push the seal unit out from the pulley side to
5. Remove the shaft. remove it.
• Remove the snap ring from the pulley side, and 10. Remove the O-ring.
gently tap the shaft from the impeller side with a 11. Only for the water pump body.
hammer to remove it.
Inspection
1. Inspect the impeller for wear etc.
2. Inspect the pulley for abrasion and wear.
3. Inspect the dust cover for deformation and
damage.
4. Inspect the snap ring for damage.
5. Inspect the shaft.
• Inspect the shaft oil seal striking surface for
wear or damage.
MFW41CSH002301
BLW71CSH000801
• Measure the inner diameter of the pulley shaft 7. Inspect the spacer for damage.
insertion section and the outer diameter of the 8. Inspect the washer for damage.
shaft, and inspect to make sure that the
9. Replace the seal unit with a new seal unit.
interference is within the standard value.
10. Replace the oil seal with a new oil seal.
11. Replace the o-ring with a new O-ring.
12. Inspect the water pump body for rust and damage.
Reassembly
1. Set the water pump body.
3. Install the washer.
4. Install the bearing.
• Apply engine oil to the shaft.
• Assemble the washer, bearing, spacer and
bearing in order to the shaft, and use a press to
press-fit them.
NOTE:
MFW71CSH001901 2 bearings are placed at the front side.
Pulley and shaft interference

0.048 – 0.078 mm
Assembly standard
(0.0019 – 0.0031 in)
6. Inspect the bearing.

• Inspect the bearing for breakaway, wear, and
abnormal noises.
• Inspect the entire periphery from the ball gap to
the lace for scratches and breakaway.
• Inspect the ball and race sections for abnormal
looseness caused by wear.
• Rotate the bearing by hand to check whether or
not its movement is smooth, and if there are
any abnormal noises.
MFW41CSH002401
NOTE:
The spacer is placed between the bearings.
5. Install the spacer.

6. Install the shaft to the water pump body.
• Fill the bearing with grease (BESCO L-3 or
BESCO L-2 grease or equivalent).
• Install the shaft to the water pump body, put a
pipe, etc. against the bearing outer race, and
use a press to press-fit it.
NOTE:
Make sure you do not damage the oil seal.
MFW41CSH002701
MFW61CSH000801 MFW61CSH000301
Legend
1. Impeller insertion section
7. Install the snap ring.
8. Install the dust cover to the water pump body in the
direction shown in the diagram.
10. Install the seal unit.
• Install the seal unit to the water pump body.
• Using a press, press-fit the seal unit (Seal unit
setting tool: 1-8522-0047-0) until its collar
section hits the pump body.
Seal unit press-fit dimensions

11 – 11.6 mm
Assembly standard
(0.43 – 0.46 in)
• The seal unit has liquid gasket burned-on to the

water pump body and shaft striking surface.
• To make a seal unit setting tool, refer to the
diagram on the left.
MFW61CSH000601
9. Install the pulley to the shaft.

• Use a press to press-fit the pulley, while taking
care not to damage the dust cover.
NOTE:
In order to prevent damage to the bearing, use the tip
a
of the impeller side shaft to press-fit it.
BLW51CSH000601
(a) 11.0 to 11.6 mm (0.43 to 0.46 in)
2
2
4
MFW61CSH000201
5
12. Inspect after reassembly.
• Rotate the pump, and check that it rotates
MFW41CSH003301 smoothly.
Legend • Perform a pressure test with water pressure
1. Dia 17 mm (0.67 in) 100 kPa (1.0 kg/cm2 / 14 psi) equivalent, and
2. 11.2 to 11.4 mm (0.44 to 0.45 in) check the seal unit section for water leaks.
3. 50 mm (1.97 in)
4. Dia 33 mm (1.30 in)
5. Dia 44 mm (1.73 in) Installation
1. Install the water pump assembly.
• Uniformly apply a bead of liquid gasket
11. Install the impeller. (ThreeBond 1207B) approx. 2 to 3 mm (0.0787
to 0.1181 in) in width as shown in the diagram.
• Using a press, press-fit until the shaft tip (1) and
impeller edge surface (2) become the same NOTE:
level. Install within 5 minutes of applying the liquid gasket.
NOTE:
In order to prevent damage to the bearing, use the tip
of the pulley side shaft to press-fit it.
Gap between body and impeller

0.4 – 1.2 mm (0.02 – 0.05 in)
MFW61CSH000101
Legend
1. Do not apply gasket even if there is a groove

• Install the water pump assembly. • Press in the duct while taking care not to
damage the O-ring.
Tightening torque
19 N⋅m (1.9 kg⋅m/14 lb⋅ft) Tightening torque
• Temporarily install the bolt to the plate M16 bolt 103 N⋅m (10.5 kg⋅m/76 lb⋅ft)
attachment section (1) bolt.
MFW61CSH001001
MFW61CSH001201
Legend
1. Water duct
2. Install the O-ring (water pump).
2. Plate
• After installing the O-ring, apply soapy water to
the outer perimeter of the O-ring. 5. Install the plate.
1 Tightening torque
M8 bolt 19 N⋅m (1.9 (kg⋅m/ 14lb⋅ft)
M10 bolt 36 N⋅m (3.9 (kg⋅m/ 28lb⋅ft)
MFW61CSH001101
Legend
1. Soapy water
3. Install the O-ring (water duct).

4. Install the water duct.
MEMO
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ENGINE
Engine Fuel
(6HK1)
TABLE OF CONTENTS
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1D-2
Explanation of Functions and Operations . . . . . 1D-2
Function Inspection: . . . . . . . . . . . . . . . . . . . . . 1D-6
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1D-7
Phenomenon: Starting difficulties . . . . . . . . . . . 1D-8
Phenomenon: Hunting when idling . . . . . . . . . . 1D-9
Phenomenon: Lack of output . . . . . . . . . . . . . 1D-10
Phenomenon: Engine does not stop . . . . . . . . 1D-11
Phenomenon: Exhaust gas is blue or black . . 1D-12
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1D-12
Fuel Pressure Sensor (Common Rail) . . . . . . . . 1D-13
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-14
Pressure Limiter (Common Rail) . . . . . . . . . . . . 1D-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-15
Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . 1D-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-16
Fuel Filter Element Replacement Procedure . . . 1D-17
Precautions for Servicing . . . . . . . . . . . . . . . . 1D-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-17
Water Sedimenter Switch. . . . . . . . . . . . . . . . . . 1D-19
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-19
Fuel Temperature Sensor. . . . . . . . . . . . . . . . . . 1D-20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-20
Fuel Rail Pressure (FRP) Regulator . . . . . . . . . 1D-21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-21
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-23
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-23
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-25
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-32
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-33
Tightening Torque Table . . . . . . . . . . . . . . . . . 1D-35
Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-38
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-40
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1D-43
Fuel System
Precautions for Servicing Work procedure
All of the holes and gaps in the fuel lines within the fuel • When removing the fuel pipe, injection pipe,
system injectors are made to extremely precise injector, supply pump, and common rail, seal all of
specifications. These parts are highly sensitive to dust the fuel openings immediately.
or debris, and dust or debris entering these parts may • Store eyebolts and gaskets in a parts box with a lid
cause damage to the fuel lines. Therefore, you should so that debris and foreign matter do not adhere to
aim to completely prevent any dust or debris from them.
entering these parts. The injector ID plate is unique to • As fuel leaks can cause fire, always clean up any
that particular injector. Do not confuse it with a different spilled fuel after completing work, and after starting
injector ID plate. When the injector assembly is the engine, always check that there are no fuel
replaced, use a scan tool to write the ID code to the leaks.
ECM. Refer to “Engine control section” for the writing
procedure. Furthermore, as fuel water removing
agents cause diesel fuel to absorb water, which in turn
may cause rust, do not use water removing agents in
the fuel tank.

Fuel system diagram
2 5
3
1
11
9
10 8 6
7
BLW71DMF000101
Legend
1. Common rail (Fuel rail) 7. Fuel filter assembly (Sedimenter assembly)
2. Common rail pressure sensor 8. Recirculation valve (with a built-in fuel filter)
3. Leak-off pipe 9. Supply pump
4. ECM 10. Suction control valve
5. Injector 11. Fuel temperature sensor
6. Fuel tank

Common rail
BLW71DMF000201
Legend
1. Common rail (Fuel rail) assembly 3. Fuel inlet
2. Pressure limiter 4. Pressure sensor

Supply Pump
1 1
4
2
7
6
MFWB1DMF000201
Legend
1. Fuel outlet (return) 5. Camshaft
2. Fuel rail pressure (FRP) regulator / Suction 6. Supply pump assembly
control valve (SCV) 7. High pressure pipe
3. Fuel inlet 8. High pressure fuel outlet
4. Fuel temperature sensor

Injectors Fuel filter assembly
1
1 2
8
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00 0 0
00 0 0 00
7 3
6 4 6
3
5 4
5
MFW71DMH000201 MFW61DMH000101
Legend Legend
1. ID plate 1. Priming pump
2. Terminal stud 2. Element
3. Injector drive section 3. Drain plug
4. Injector assembly 4. Float
5. Gasket 5. Switch connector
6. O-ring 6. Case
7. Fuel outlet port 7. Body assembly
8. Recirculation valve

Air bleeding • Insert a vinyl hose into the drain plug tip and
1. Loosen the fuel filter air removal plug. prepare a container to receive the water.
2. Move the priming pump and pressure feed fuel. • Loosen the drain plug.
Check that fuel mixed with bubbles comes out of • In order to drain the water, operate the priming
the air removal plug. pump a few times.
3. When bubbles stop coming out, tighten the air • After draining, tighten the drain plug.
removal plug. • Operate the priming pump a few times, and check
that there are no fuel leaks.
• Check that the warning lamp in the meter has gone
Tightening torque
out.
7 N⋅m (0.7 kg⋅m/61 lb⋅in)
NOTE:
4. After tightening the plug, move the priming pump • The drained water contains fuel. Therefore, follow
until it becomes heavy enough or approx. 150 processing regulations established by your local
times. area when discarding the water.
5. Wipe up any spilt fuel. • If fuel sticks to the vehicle body etc, wipe it clean.
Check that there are no fuel leaks. If it does not
start, repeat from procedure 1.
MFW81DMH000101
Legend
1. Priming pump
2. Air removal plug
Water drain
If there is more water than the specified amount in the
sedimenter, a warning lamp lights. In this situation,
follow the procedure below to remove the water.

• Starting difficulties
• Hunting when idling
• Engine top speed is too slow
• Engine does not stop
• Exhaust gas is blue or black

Phenomenon: Starting difficulties

Starting difficulties Fuel tank is empty Fill the tank
Air in the fuel system Remove the air
Clogging or damaged fuel line. Loose Repair or replace the fuel line. Re-
fuel line connection tighten the connection
The fuel is frozen (wax blocked) Pour hot water on the fuel pump or fuel
filter to heat it up, or wait for the
temperature to rise
Clogging of the fuel filter element Replace the cartridge
Feed pump malfunction Replace the supply pump
Regulating valve is open Replace the supply pump
Injector nozzle fixing Replace the injector

Phenomenon: Hunting when idling

Hunting when idling Air in the fuel system Remove the air from the fuel system
Leak or clogging of the fuel system Repair or replace the fuel system
Water in the fuel system Replace the fuel
Low injector opening valve pressure, Replace the injector
poor injection condition
Incomplete supply pump functioning Replace the supply pump

Phenomenon: Lack of output

Lack of output Clogging of the fuel tank breather Clean the fuel tank breather
Air in the fuel system Remove the air from the fuel system
Blockage or leak in the fuel system Repair or replace the fuel system
Water in the fuel system Replace the fuel
Engine control fault Diagnose the engine control system

Phenomenon: Engine does not stop

Engine does not stop Engine control system fault Diagnose the engine control system

Phenomenon: Exhaust gas is blue or black

Exhaust gas is blue or black Low injector opening valve pressure, Replace the injector
poor injection condition
Main Specifications
Fuel system
Item Specifications
Engine type 6HK1-TC
Electronically controlled fuel injection system (common
Fuel system
rail type)
Fuel Pressure Sensor (Common Rail)

Component Parts
Common rail
BLW71DMF000201
Legend
1. Common rail (Fuel rail) 3. Fuel inlet
2. Pressure limiter 4. Pressure sensor
Maintenance Precautions NOTE:

Do not re-use sensors that have been removed.
Maintenance precautions
• Put cleansing fluid into a steam cleaner and
carefully clean around the sensors and common
rail.
• Remove water completely using compressed air.
• Confirm that foreign materials have all been
removed before starting work.
• After replacement of any of the sensors, use the
scan tool to erase trouble codes and check if the
sensor is operating correctly.
Removal
• Remove the fuel pressure sensor (1) using a
socket wrench 30 mm (1.1811 in).
BLW71DSH000101
Installation
• Apply grease (1) to the threads and seat area of
the sensor and then install it.
• Install the connector terminals so that the terminals
do not interfere each other.
Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft)
NOTE:
Do not allow foreign material to stick to the threaded
area. In addition, make sure there is not foreign
material on the mounting area and then install the
sensor.
HCW31DSH000901
Pressure Limiter (Common Rail)

Removal
Pressure limiter
• Remove the pressure limiter using a socket
wrench 19 mm (0.75 in).
NOTE:
• Do not re-use pressure limiter or gaskets that have
been removed.
• Do not damage the seat surface when taking off
the gasket.
BLW71DSH000201
Legend
1. Pressure limiter (socket width across flats of 19
mm (0.75 in))
Installation
Pressure limiter
• Install the pressure limiter with a copper gasket.
Tightening torque
172 N⋅m (17.5 kg⋅m/127lb⋅ft)
NOTE:
• Confirm that there is not any foreign material on
the mounting area.
• Tighten the pressure limiter using the area with a
width across flats of 19 mm (0.748 in).
Fuel Filter Assembly

Component Parts
2
1
3
4
5
MFW81DMF000101
Legend
1. Fuel filter assembly 4. Fuel return hose
2. Air removal plug 5. Water sedimenter switch connector
3. Fuel feed pipe (Than a fuel tank)
1. Remove the filler cap. 1. Install the fuel filter assembly.
2. Disconnect the wiring connector of the sedimenter
switch.
Tightening Torque
3. Extract the feed hose and return hose from the fuel
filter assembly, and cork it so that fuel does not 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
leak.
2. Install the feed hose and the return hose.
WARNING: 3. Connect the sedimenter switch wiring connector.
Make sure that foreign material does not enter the fuel
feed hose (engine side) when it is removed, as this 4. Install the filler cap.
may cause the supply pump to fail. (Inserting a rusty 5. Remove the air bleeding.
bolt, etc. is strictly prohibited) • Refer to “Fuel System”.
4. Remove the fuel filter mounting bolt.

5. Remove the fuel filter assembly.
Fuel Filter Element Replacement Procedure

• Replace the fuel filter element every 30,000 km
(18,000 miles) or once every 9 months. 1
2
Removal
3
1. Remove the fuel in the element case.
a. Loosen the drain plug at the bottom of the
4
element case.
b. When the air removal plug of the body is
loosened, the fuel is run out from the drain plug.
5
2. Remove the harness of the water warning switch.
3. Remove the element case from the body by
rotating the case in a counterclockwise direction,
using a socket (width of double socket (a) : 29 mm
(1.142 in). After removing the case, confirm that
the float at the inside bottom can move up and 6
down smoothly. 9
NOTE:
Check that the float in the element case moves
smoothly. 7
8
4. Remove the O-ring of the body by pulling out the
element downward. a
5. If foreign material is attached on the surface of the
BLW61DMH000101
body inner circumference, wipe it with clean cloth.
Legend
NOTE: 1. Cap
Do not use an air blower to remove foreign materials. If 2. Air removal plug
you do, they can be blown into the path of the clean 3. Filter body
side and cause failure of the supply pump. 4. O-ring
5. Fuel filter element
6. Element case
7. O-ring
8. Drain plug
9. Switch connector
Installation
1. Place the O-ring, packaged with the element kit,
into the groove on the outer circumference of the
body.
Careful handling of the O-ring is needed to prevent
being damaged by the threaded area of the body.
2. Apply a thin layer of fresh diesel fuel on the
gaskets, inside and outside of the element, and
then insert the gasket until it hits the end.
NOTE:
Be careful not to insert any foreign materials into the
four holes (clean side) next to the inside gasket.

• Make sure to use a genuine Isuzu fuel filter and
replace the O-ring at the same time.
4. Tighten the element case with a torque wrench.
Tightening torque
33 N⋅m (3.4 kg⋅m/25 lb⋅ft)
5. Tighten the drain plug of the element case, and

reconnect the connector of the water warning
switch.
Tightening torque
1
2 0.4 N⋅m (0.04 kg⋅m/3.5 lb⋅in)
6. Remove the air in the fuel.

• Refer to "Air bleeding" in Fuel System.
7
7. Start the engine and confirm that the check light is
turned off.
6
NOTE:
4 Reset the fuel filter replacement schedule (mileage
5 count) of the multi-display item on the meter side.
MFWA1DLH000101
Legend
1. Salient for socket
2. Float
3. Outside gasket
4. Inside gasket
5. Clean side hole
6. Element kit
7. O-ring grove
3. Apply a thin layer of fresh diesel fuel on the inner

circumference of the element case (or the O-ring
section at the body side). Turn the element in a
clockwise direction until it hits to the body carefully.
Biting with the O-ring must be avoided.
No hitting of the element to the case means that
the element does not have compete insertion.
Turn the element and push it in again.
WARNING:
Be careful so as not to pinch the O-ring when installing
the element case.
If the O-ring gets stuck, fuel may leak causing fire.
Water Sedimenter Switch

Inspection If a fault is discovered as a result of the inspections,
replace the switch section, and repair the bad
1. Inspect the water sedimenter switch.
connections between circuits and broken wires.
• Remove the fuel filter assembly from the
bracket.
• Connect the sedimenter switch wiring
connector, and turn the key switch ON.
• Turn the fuel filter assembly over (move the
float), and it is normal if the warning lamp in the
meter lights.
2. If the warning lamp does not light in procedure 1,
inspect the following.
• Turn the fuel filter assembly over. The switch is 1
normal if there is conductance between the
connector terminals.
• Remove the sedimenter switch connector,
connect between the vehicle side connector
terminals, then turn the starter switch ON. At
this time, if the sedimenter warning lamp lights,
the circuit is normal.
2
5
4 3
MFW61DMH000201
Legend
1. Fuel filter assembly
2. Drain plug
5. Water sedimenter switch assembly
Fuel Temperature Sensor

Removal
1. Disconnect the fuel temperature sensor connector.
2. Remove the fuel temperature sensor (1).
MFWA1DSH000701
Installation
1. Install the fuel temperature sensor.
Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
2. Connect the wiring connector fuel temperature

sensor.

Component Parts
1
2
MFWB1DMF000301
Legend
1. Bolt 3. O-ring
2. Fuel rail pressure (FRP) regulator / Suction 4. Supply pump
control valve (SCV)
Maintenance Precautions Installation

• Add cleaning agent to the steam cleaner and 1. Install the O-rings to the supply pump
thoroughly clean the sensor and supply pump 2. Install the FRP regulator to the supply pump, and
areas. temporarily tighten 2 bolts.
• Completely remove the moisture with an air
blower. NOTE:
• Start work after checking that all foreign matter has • Be careful so as not to pinch the O-ring during
been removed. installation.
• After starting the engine, check to be sure that • Temporarily tighten by hand until the FRP regulator
there is no fuel leaking. adheres the supply pump.
• After replacing valves, use a scan tool to check
3. Tighten the FRP regulator to the specified torque.
that the trouble code is cleared and that operations
are normal.
Tightening torque
Removal 8.9 N⋅m (0.9 kg⋅m/78 lb⋅in)
1. Disconnect the connector from the FRP regulator.
4. Connect the connector to the FRP regulator.
2. Remove the FRP regulator.
3. Remove the O-rings from the FRP regulator.

Supply Pump Relearn
status Not Learned → Learned.
Injector
Removal
NOTE:
Seal the inlet duct hole, supply pump and other such
places so that debris cannot enter.
1. Remove the engine exterior parts. Refer to “Engine

Exterior Parts”.
2. Remove the injection pipe.
1
3. Remove the noise cover. 2
3
1
BLW71BSH008901
Legend
1. Bracket
2. Head cover
2 3. Bolt
5. Remove the head cover.
BLW71BSH008301 NOTE:
Legend Make sure you do not lose the collar that is inside the
1. Noise cover head cover.
2. Head cover
4. Remove the noise cover bracket.
NOTE:
If the bracket is not damaged, do not remove it.
BLW71BSH009001
7. Remove the harness assembly.

• Push the arrowed section of the connector with
your fingers to remove it.

NOTE: • Remove the harness bracket with the harness
Do not pull the wires or pry the connector with a still attached.
screwdriver.
2
1
MFW41BSH027101
Legend
MFW41BSH026201
1. Harness terminal
2. Harness bracket
• Take out the injector harness terminal.

8. If there are no malfunctions with the connector, do
3 not remove it.
9. Remove the injector leak-off pipe.
10. Remove the injector clamp.
• Loosen the injector clamp bolt using a torque
wrench (T-40).
LNW71DSH003601
Legend
1. Injector
2. Injector harness
3. Terminal nut
MFWA1BSH003101
11. Remove the injector assembly.

• Loosen the clamp, and use the replacer to
remove the injector.

• If it is difficult to remove the injector, set the
injector remover (5-8840-2826-0) on the
injector, tighten the bolt into the leak- off pipe
fitting, and using the sliding hammer small (5-
8840-0019-0) pull the injector out in an upward
direction.
NOTE:
• When removing the injector using this special tool,
make sure that the injector sleeve is not removed as
well.
• The ID plate is unique to each injector, so install a
number tag to it before storing it to ensure that it is
not used on a different injector.
• He injector and glow plug protrude from first to
prevent them from being damaged.
MFW71BSH005301
1 Installation
2
NOTE:
When injector replaced, fuel injector ID codes is written
in ECM with scan tool.
• Insert gasket into the tip of the injector and

insert it into the cylinder head.
• Insert the injector clamp at the same time.
NOTE:
3 • The injector ID plate is unique to that particular
injector. Do not confuse it with a different injector
ID plate.
• When the injector assembly is replaced, use a
scan tool to write the ID code to the ECM. Refer to
“Engine Control Section” for the writing procedure.
LNW46CMH000301
Legend
1. Sliding hammer small
2. Injector remover
NOTE:
• Indicate the cylinder No. on the removed injector
before storing the injector.
• Be careful not to strike the injection nozzle against a
hard surface.
MFW71BSH005301
2. Apply engine oil to the thread section and seating

section of the injector clamp bolt, and temporarily
tighten it.
1
1
1
2 3
1
4
a
1
1
MFW81BSH010001
6
4. Tighten the injector clamp (temporarily tightened

BLW71BSH020401 earlier) at the specified torque.
Legend
1. O-ring
Tightening torque
3. Injector clamp bolt 30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
4. Injector clamp
5. O-ring 5. Tighten the injection pipe at the specified torque.
6. Gasket
Tightening torque
3. Install the injection pipe.
• Thinly apply engine oil to the outer Common rail side 25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
and install it.
that it is airtight to the injector and common rail
side.
• Tighten the injection pipe clip (1) at the
specified torque.
Tightening torque
6 N⋅m (0.6 kg⋅m/52 lb⋅in)
7. Install the injector harness assembly.

• Install the harness bracket with the harness still
1 2 3 4 5 6
attached.
Tightening torque
22 N⋅m (2.2 kg⋅m/16 lb⋅ft)
• Install the terminal nut to the injector, and

tighten to the specified torque strength.
Tightening torque
2 N⋅m (0.2 kg⋅m/17 lb⋅in)
7
MFWA1BSH001501 NOTE:
Legend • As the terminal is a single unit, tighten the nuts 2 to
1. Injection pipe #1 3 turns each until fully tightened.
2. Injection pipe #2 • Over tightening the nuts will cause damage to the
3. Injection pipe #3 terminal stud. Therefore, they should never be over
4. Injection pipe #4 tightened.
•
2
1
6. Install the leak-off pipe to the injector.
Tightening torque
12 N⋅m (1.2 kg⋅m/104 lb⋅in)
NOTE:
• Always use brand new gasket.
• Re-check to make sure you didn’t forget to tighten
anything.
MFW71BSH007101
Legend
1. Harness terminal
2. Harness bracket
8. Install the gasket.

• Clean the head cover gasket attachment slot
and gasket, and install the gasket to the head
cover.
NOTE:
Check that the collar has not fallen out.
MFW41BSH023501

• Install the noise cover bracket to the cylinder
head cover.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
1
2
BLW71BSH009001
9. Install the head cover.

• After temporarily tightening all of the bolts,
tighten them in the order shown in the diagram.
BLW71BSH008901
Tightening torque
Legend
13 N⋅m (1.3 kg⋅m/113 lb⋅in) 1. Bracket
2. Head cover
NOTE: 3. Bolt
Check that there is no debris on the upper surface of
the cylinder head.
• Install the noise cover (1) to the head cover (2),
and tighten the nut and bolt.
Tightening torque
8 4 1 5 9 20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
11
7 3 2 6 10
1
MFW41BSH035801
10. Install the bracket. 2
BLW71BSH008301

• Refer to “Programming” in Section 1A, Engine
12. Paint out fuel injector ID codes of the cylinder that Control System.
replaced injector among the fuel injector ID codes
written in the code label. 2 1
• Only when injector are replaced, it does.
• Injector ID code label is on the surface of the
noise cover. 64DA A505
2F4C 0F36
FA17 25 00
0000 8C
1
SAMPLE
6HK1
2 64 05 4F 08 F5 F5 F5 DD 0A 00 00 14
64 F0 00 12 0E 04 16 00 0A 0A 20 BA
3 64 00 31 06 0A 14 00 10 FA 00 25 82
64 E5 00 00 10 12 0F 16 0C 11 23 A4
4 64 05 3A 0C F6 D9 FB DA 00 EE EC 5B
64 32 61 1B 1C 0C 0D FA 1D 0F 0C D5
LNW76ESH002601
5
6 Legend
7 1. Fuel injector ID plate
2. Fuel injector ID code
3. Fuel injector
MFW81ASH000601
Legend
7. Injector ID code label
13. Install the engine exterior parts.

• Refer to “Engine Exterior Parts”.
14. Pour in cooling water.
15. Program the injector ID code.
• After installing the injector, make sure to
program the ID code indicated on the injector.
Fuel Tank
Component Parts
200L (44 Imp.gal) - Tank type: W
1 2
3
5
6
MFW81DLF000101
Legend
1. Fuel tank bracket 6. Drain plug
2. Fuel tank band 7. Fuel tank
3. Fuel feed hose 8. Fuel return hose
4. Outlet breather hose 9. Fuel tank unit
5. Filler cap

200L (44 Imp.gal) - Tank type: N
2 4
1
7
8
MFW81DMF001001
Legend
1. Fuel return hose 6. Filler cap
2. Fuel feed hose 7. Drain plug
3. Outlet breather hose 8. Fuel tank
4. Fuel tank bracket 9. Fuel tank unit
5. Fuel tank band

400L (88 Imp.gal) tank
2
3
4
1
MFW81DLF001501
Legend
1. Fuel tank unit 5. Filler cap
2. Fuel tank bracket 6. Fuel tank
3. Fuel tank band 7. Drain plug
4. Insulator
Removal Drain plug

1. Disconnect the negative terminal of the battery Tightening torque
cable. Except 400L tank 73.5 N⋅m (7.5 kg⋅m/54 lb⋅ft)
2. Loosen the fuel filler cap. 400L tank 29 N⋅m (3.0 kg⋅m/22 lb⋅ft)
3. Drain the fuel from the drain plug.
4. After draining the fuel, tighten the drain plug to the 5. Remove the fuel tank unit connector.
specified torque strength. 6. Remove the fuel feed hose.
7. Remove the fuel return hose.
• Plug the hose so that fuel does not leak, and tie
it to the frame side pointing upwards.

8. Remove the fuel tank attachment band, and 400L (88 Imp.gal) tank
remove the frame side end of the band.
9. Extract the fuel tank to the outside.
1
NOTE:
If the fuel tank cannot be extracted, remove the 2
bracket, and extract the fuel tank from the bottom.
2 3
MFW81DSH001501
Legend
1. Fuel tank unit
2. Fuel tank
3. Band
MFW81DSH000101 Installation
Legend 1. Install the fuel tank temporarily.
1. Frame
2. Fuel tank unit NOTE:
3. Band • When removing the fuel tank, if the bracket was
removed, install the bracket to the frame at the
200L (44 Imp.gal) - Tank type: N specified torque strength.
• When supporting the fuel tank in the bracket, make
sure the rubber section stuck to the fuel tank is
firmly supported in the bracket.
1
Bracket
2
97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft)
MFW81DSH001401
Legend
1. Fuel tank unit
2. Fuel tank
3. Band

2. Install the band to the fuel tank, and tighten the
nuts to the specified torque strength.
a Band nut
Tightening torque

Tightening torque
MFW81DSH001301
(a) 855 mm (33.7 in)

47.1 N⋅m (4.8 kg⋅m/35 lb⋅ft)
1
a 2
4 3
MFW81BSH001801
Legend
1. Band
2. Bracket
3. Inside nut
4. Outside nut
3. Install the fuel return hose.

4. Install the fuel feed hose.
• Insert the hose more than 25 mm (0.9843 in)
MFW81DSH001201 into the pipe.
5. Connect the fuel tank unit connector.
(a) 1345 mm (53 in) 6. Fill the fuel tank with fuel, and tighten the fuel filler
cap.
400L (88 Imp.gal) tank 7. Connect the negative terminal of the battery cable.
Bracket tightening torque 8. After starting the engine, check all of the hose
connection sections to make sure there are no fuel
97.1 N⋅m (9.9 kg⋅m/71.6 lb⋅ft)
leaks.

d
c
b
MFW81DLF000201
(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)

b
c
MFW81DMF001101
(a) 47.1 N⋅m (4.8 kg⋅m / 35 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 73.5 N⋅m (7.5 kg⋅m / 54 lb⋅ft)

MFW81DLF001601
(a) 97.1 N⋅m (9.9 kg⋅m / 71.6 lb⋅ft)

(b) 17.7 N⋅m (1.8 kg⋅m / 13 lb⋅ft)
(c) 20.6 N⋅m (2.1 kg⋅m / 15.2 lb⋅ft)
(d) 29 N⋅m (3.0 kg⋅m / 22 lb⋅ft)
Fuel Tank Unit

Component Parts
MFWA1DMF000501
Legend

MFWA1DMF000601
Legend

MFWA1DMF000701
Legend
Removal 2. Check that the low fuel level warning light lights up
when the float is at the "E" position.
1. Disconnect the wiring connector from the fuel tank
If any abnormality is found in the inspection
unit.
results, replace the meter with a normal one.
2. Remove the installment screw, and remove the
fuel tank unit.
NOTE:
• When removing and replacing the fuel tank unit,
make sure there is no interference around the
perimeter, and be sure not to distort the shape of the
arm.
• After removing the fuel tank unit, cover it to ensure
debris does not enter the tank.
Inspection
The fuel tank unit changes the internal resistance by
the float position (the fuel level height) and operates the
fuel meter indicator.
1. While moving the float from "E" to "F", inspect the
resistance value between the connector terminals.

Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 77.2 157 248.7 330.7 421.9 437.8
mm (in)
flange (3.04) (6.18) (9.79) (13.02) (16.61)) (17.24)
182.8 144.5 100.4 60.8 17.2 9.8
(40.2) (31.8) (22.1) (13.4) (3.8) (2.2)
6.0 28 50 86 141 150
2
h1
3 1
F
h2
h3
3/4
h4
h5
h6
1/2
1/4
SE
MFW81ELF000101

Float position
(h1) (h2) (h3) (h4) (h5) (h6)
Distance from the 53.5 114.1 171.6 233.0 295.8 303.4
mm (in)
flange (2.11) (4.49) (6.76) (9.17) (11.65)) (11.94)
182.0 143.0 102.0 60.5 19.0 13.8
(40.0) (31.5) (22.4) (13.3) (4.2) (3.0)
6.0 28 50 86 141 150
3 2 1
h1
h2
F
h3
h4
3/4
h5
h6
1/2
1/4
SE
MFW81ELF000601

F point 3/4 point 1/2 point 1/4 point E point
Float position
(h1) (h2) (h3) (h4) (h5)
Distance from the 98 226 354 481 578
mm (in)
flange (3.86) (8.90) (13.94) (18.94) (22.76)
0 22.7 50 95.4 150
h1
2 1
h2
h3
3/4
h4
h5
1/2
1/4
MFW81DLF001801
Installation
Follow the disassemble procedure in reverse order to
reassemble.
1. Install the fuel tank unit.
2. Connect the wiring connector to the fuel tank unit.
MEMO
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ENGINE
Engine Electrical
(6HK1)
TABLE OF CONTENTS
Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1E-2
Explanation of Functions and Operations . . . . . 1E-2
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1E-4
Phenomenon: Starter does not operate even
if the starter is switched on . . . . . . . . . . . . . . . . 1E-5
Phenomenon: The pinion moves forwards
but does not engage the ring gear . . . . . . . . . . 1E-6
Phenomenon: The pinion engages and rotates
the motor but does not rotate the engine . . . . . 1E-7
Phenomenon: The pinion engages but
does not rotate the engine . . . . . . . . . . . . . . . . 1E-8
Phenomenon: After the engine starts,
the starter does not stop even though
the starter switch is switched off . . . . . . . . . . . . 1E-9
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1E-9
Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-10
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1E-10
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-12
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-15
Tightening Torque Table . . . . . . . . . . . . . . . . . 1E-19
Charge System . . . . . . . . . . . . . . . . . . . . . . . . . 1E-20
Precautions for Servicing . . . . . . . . . . . . . . . . 1E-20
Explanation of Functions and Operations . . . . 1E-20
Main Specifications . . . . . . . . . . . . . . . . . . . . . 1E-22
Function Inspection . . . . . . . . . . . . . . . . . . . . . 1E-23
Failure Phenomenon List . . . . . . . . . . . . . . . . 1E-24
Phenomenon: Does not charge at all . . . . . . . 1E-25
Phenomenon: Insufficient charge . . . . . . . . . . 1E-26
Phenomenon: Overcharge . . . . . . . . . . . . . . . 1E-27
Phenomenon: Charging current is unstable . . 1E-28
Phenomenon: Abnormal noises coming
from the generator. . . . . . . . . . . . . . . . . . . . . . 1E-29
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-30
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1E-30
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-31
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-33
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1E-35
Bench Testing:. . . . . . . . . . . . . . . . . . . . . . . . . 1E-37
Starting System
Precautions for Servicing Starter
When performing maintenance work on the electrical The starter is a magnetic shift type, and has a
system, check that the starter switch, headlight switch circumscription engagement type reduction starter.
etc. are OFF, and always disconnect the battery minus When the starter switch is switched ON, the magnetic
terminal before starting maintenance work. switch assembly contact closes, and the armature
rotates. At the same time, the plunger draws in through
the lever assembly, the pinion is pushed out of the front
Explanation of Functions and Operations and engages with the ring gear, which then rotates
Starting circuit causing the crank shaft to rotate and the engine to
start. After the engine has started and if the starter
The starting system consists of the battery, starter, switch is switched OFF, the plunger returns, the pinion
starter switch, starter relay etc. and these main parts disengages from the ring gear, and the armature stops
are wired as shown in the starting circuit diagram. rotating. If the engine r/min are faster than the pinion,
the pinion is conversely rotated. However, as the pinion
runs idle because of the effects of the clutch, the
armature is not driven.
Starter motor
24V 5.0kW
5
8
7
6
MFW51EMF000401
Legend
1. Brush holder 5. Clutch
2. Magnetic switch assembly 6. Internal gear
3. Lever assembly 7. Armature
4. Pinion 8. Yoke

Schematics
B M
B S S
SW L
M
K.S
MFW41EMH000101
Legend
1. Momentary current: 308.4A (24V20°C / 68°F),
Holding current: 15.7A (24V20°C / 68°F)

• Starter does not operate even if the starter switch
is switched on
• The pinion moves forwards but does not engage
the ring gear
• The pinion rotates the engagement motor but does
not rotate the engine
• The pinion engages but does not rotate the engine
• After the engine starts, the starter does not stop
even though the starter switch is switched off

Phenomenon: Starter does not operate even if the starter is switched on

Starter does not operate even if the Battery is completely discharged Replace the battery
starter is switched on Broken wire or bad connection in the Repair it
wiring circuit
Bad contact in the starter switch Repair or replace
contact, or poor tightening of the
terminal
Bad contact in the starter relay contact, Repair or replace
or bad contact in the insertion terminal
Short circuit or broken wire in the Replace
magnetic switch coil

Phenomenon: The pinion moves forwards but does not engage the ring gear

The pinion moves forwards but does Insufficient battery capacity Recharge the battery
not engage the ring gear Worn pinion or ring gear tooth tip Replace the pinion or ring gear
Dirt adhering to the pinion shaft Repair it

Phenomenon: The pinion engages and rotates the motor but does not rotate the engine

The pinion engages and rotates the Clutch slipping Replace the clutch or starter
motor but does not rotate the engine Reduction gear damage Replace the gear or starter

Phenomenon: The pinion engages but does not rotate the engine

The pinion engages but does not rotate Insufficient battery capacity Recharge the battery
the engine Bad terminal connection in the wiring Repair it
circuit
Short circuit in the armature or field coil Replace the starter
Dirt on the commutator Repair or replace the starter
Weak brush spring or worn brush Replace the brush spring or brush
Bearing lock Replace the bearing or starter
Bad contact in the magnetic switch Replace the magnetic switch
contact

Phenomenon: After the engine starts, the starter does not stop even though the starter
switch is switched off

After the engine starts, the starter does Bad return from the starter switch Replace the starter switch
not stop even though the starter switch contact
is switched off Bad return from the starter relay contact Replace the starter relay
Short circuit in the magnetic switch coil Replace the magnetic switch
Main Specifications
Model (Manufacturer) Mitsubishi

Voltage 24 V
Output 5.0 kW
Time 30 sec.
Pinion teeth count 11
Rotational direction (see from pinion side) Clockwise
Weight (approx.) 70.1 N (7.2 kg / 16.0 lb)
No-load characteristics
Voltage/Current 23.5 V / Max.85 A
Rotational speed Min. 3,300 r/min
Load characteristics
Voltage/Current 18.5 V / Max.400 A
Torque Min. 26 N⋅m (2.6 kg⋅m / 19lb⋅ft)
Rotational speed Min. 1,250 r/min
Locking characteristics
Voltage/Current 9 V / Max.1,400 A
Torque Min. 88 N⋅m (9.0 kg⋅m / 65 /lb⋅ft)
Starter Motor
Component Parts
10
21
20
19 22
18
6
17
9 23
7 8 24 30
5
16
15
4 13
14 29
3 26 27 28
12
1 2 25
11
MFW41ELF000101
Legend
1. Snap ring 16. Planetary gear
2. Stop ring 17. Ball
3. Pinion 18. Gasket
4. Pinion spring 19. Plate
5. Screw 20. Armature
6. Front bracket 21. Bearing
7. Lever 22. Through bolt
8. Plate 23. O-ring
9. Gasket 24. Lead wire with terminal
10. Magnet switch 25. O-ring
11. Overrunning clutch 26. Yoke assembly
12. Internal gear 27. Brush
13. Washer 28. Brush holder
14. E-form retaining ring 29. Rear bracket
15. Gear shaft 30. Screw

Disassembly
NOTE:
• Before disassembling the starter, attach
identification marks on the attachment sections
between the magnetic switch, yoke, front bracket,
SW1
and rear bracket, to make it easier to reassemble
SW2
them later.
• Remove the pinion first. If disassembly is 24V
performed without first removing the pinion, the
pinion will become un-removable, and you will not
be able to proceed with disassembly. However, the
motor section and magnetic switch can be
removed even if the pinion is not removed.

2. Remove the stop ring.
3. Remove the pinion. HCW51ESH001701
• Under normal circumstances, if the pinion or
stop ring is tapped to the front bracket side, the
front bracket will break. Therefore, tap the • Place a pipe that is the exact same size as the
stopper ring when the pinion is out to the stop ring against the stop ring, hit the pipe with
cranking position. a hammer and remove the stop ring to the
• Connect the starter to the battery as shown in pinion side. Next, remove the snap ring, then
the diagram. When switch SW1 and SW2 are remove the stop ring, pinion, and pinion spring.
closed, the pinion moves forward to the
cranking position, and the armature rotates. NOTE:
Then, switch SW2 opens and the armature Do not re-use the snap ring.
stops rotating.
NOTE:
If left with the power supply on, heat will be generated, 6
so the pinion should be removed within 10 seconds.
5
4 1
2
3
1 2 3
MFW41ESH000201
Legend
1. Clutch shaft
2. Pinion spring
3. Pinion
HCW31ESH000201
4. Snap ring
Legend 5. Stop ring
1. Snap ring 6. Pipe
2. Stop ring
3. Pinion gear
4. Remove the pinion spring.
5. Remove the lead wire with terminal.

6. Remove the screw. • Pull the brush spring upwards, and remove the
7. Remove the magnetic switch. brush from the brush holder. Next, remove the
brush holder.
• Remove the magnetic switch M terminal nut,
and remove the lead wire with terminal. Next, 14. Remove the armature.
remove the magnetic switch tightening screw, 15. Remove the ball.
and remove the magnetic switch. • Remove the armature. At the same time the
ball should also come out, but sometimes it
NOTE: sticks in the grease and does not move. The
The tightening screw is tight, so use a shock driver to bearing can generally be removed with a puller.
loosen it.
8. Remove the screw. 17. Remove the gasket.
9. Remove the through bolt. 18. Remove the gasket.
• Remove the brush holder tightening screw and 19. Remove the plate.
through bolt. • Remove the planetary gear section plate, and
Next, remove the rear bracket. At the same time, remove the gasket.
remove the O-ring. Next, remove the lever support section gasket
and plate.
NOTE:
Do not re-use the O-ring. 20. Remove the planetary gears.
• Remove the 4 planetary gears.
10. Remove the rear bracket. • Pull out the internal gears, gear shaft,
11. Remove the yoke assembly. overrunning clutch and lever as a set from the
12. Remove the O-ring. front bracket.
• Place a socket (outer diameter 38 mm / 1.5 in) 21. Remove the lever.
against the armature commutator.
Next, let the brush slide against the socket, and NOTE:
while allowing the brush to be supported on the Remember the direction of the lever.
socket, remove the yoke assembly. At the same
22. Remove the E-shaped retaining ring.
time, remove the O-ring.
• Remove the both E- shaped retaining rings.
Rotate the overrunning clutch one spline gear
1 tooth, then remove it from the gear shaft
assembly.
2
NOTE:
Do not re-use E-shaped retaining rings after they have
been removed once.
23. Remove the internal gear.

24. Remove the washer.
• Remove the internal gear. At this time, remove
the washer that adjusts gear shaft play in the
axial direction.
25. Remove the gear shaft.
3
26. Remove the front bracket.
5 4
27. Remove the bearing.
HCW31ESH000401
28. Remove the brush.
Legend
1. Armature
2. Through bolt Inspection
3. Rear bracket 1. Inspect the armature.
4. Brush holder
5. Yoke assembly
13. Remove the brush holder.


Growler test. Commutator inspection
• Inspect for armature coil internal short circuits • Inspect the outer circumference of the
with a growler tester. commutator for wear.
If an internal short circuit is found in the If the armature is worn beyond the limit, replace
armature, replace it. it.
HCW51ESH000701 HCW51ESH000901
Earth inspection • Measure the thickness (called “undercut”) of

• Inspect the armature coil earth (bad insulation) the commutator insulation mold. Remove the
with a circuit tester. brush wear grindings, and repair any faults.
If the armature is earthed, replace it.
1 a
2
HEW61ESH001201
HCW51ESH000801 Legend
1. Insulation mold
2. Commutator segment
3. Bad
4. Good
Gear inspection
• Inspect the gear section for damage and wear.
If a fault is found in the armature, replace it.

Bearing inspection • Inspect the wear of the brush length.
• Inspect the bearing for abnormal noises, If the brush is worn close to the limit, replace
looseness, and grease leakage. If a fault is the brush holder assembly for the brush holder
found in the bearing, replace it. side brush. Just replace the brush on the Yoke
assembly side.
2. Inspect the field coil.
Conduction inspection • Check that the brush moves smoothly in the
brush holder.
• Inspect the coil for broken wires with a circuit
Also inspect the pressure of the brush spring.
tester. If the there are broken wires, replace the
yoke assembly. • Inspect the brush holder earth (bad insulation)
with a circuit tester.
However, clean the brush holder before
inspection. Place one side of the circuit tester
probe against the brush holder plate (metal
section) and the other probe onto the insulated
holder (2). If there is conductance, the
insulation must be bad, so replace the brush
holder assembly.
HCW51ESH001101
Earth inspection
• Inspect the coil earth (bad insulation) with a
circuit tester. If it is earthed, either repair it, or
replace the yoke assembly.
HEW61ESH001301
Legend
1. Brush length
2. Insulated holder
4. Overrunning clutch and pinion.

Inspect the overrunning clutch.
• Hold the overrunning clutch housing section
with your hand, and when rotating the pinion by
hand, it should gently rotate in one direction
with a certain amount of resistance, but not
rotate at all in the opposite direction. If this is
not the case, replace the overrunning clutch.
Inspect the pinion, and replace the pinion if it is
damaged or worn.
HCW51ESH001201
NOTE:
3. Inspect the brush. The inside of the overrunning clutch is filled with
grease, so if it is washed using wash oil or oil removing
detergents, the grease may be washed out of it.
Therefore, simply wipe dirt off the overrunning clutch
using a cloth.

8. Inspect the magnetic switch.
• Inspect the conductance between the M
terminal and body, and if there is no
conductance, replace the magnetic switch.
Also check that there is no conductance
between the B terminal and M terminal. If there
is conductance, replace the magnetic switch.
3 2
HCW51ESH001401
5. Inspect the front bracket.

• Inspect the bearing and oil seal, and if there are
any faults, replace the front bracket assembly
(including the bearing and oil seal).
MFW51ESH000201
6. Inspect the internal gears and planetary gears.
• Inspect the gear teeth, and replace the internal Legend
gears or planetary gears if abnormal wear or 1. S terminal
damage is found. 2. B terminal
3. M terminal
7. Inspect the lever.
• If the section that rubs against the overrunning
clutch is worn, the pinion protrusion location is
incorrect. For pinion protrusion location Reassembly
adjustments, see the assembly section. Reassembly can be performed in the reverse order to
disassembly. However, the following precautions
should be followed.
NOTE:
The following parts should be replaced with brand new
parts.
• Snap ring (fixing the stop ring)

• E-shaped retaining ring
• O- ring (gasket on both sides of the yoke, and
each screw)
MFW41ESH001101
Legend
1. Worn section

1. The following sections require lubrication. We
recommend using MULTEMP 0A-171 grease
(manufactured by Kyodo Yushi Co., Ltd.) on
sections 1, 2, 3, 4, 5, and 9 in the diagram, and
Molykote RAG650 grease (manufactured by Dow
Corning Corporation) for sections 6, 7, and 8 on
the diagram.
2
3
4
8 7 6
MFW51EMF000501
Legend
1. Plunger surface (very small quantity) 6. Lever and overrunning clutch rotational
2. Gear shaft spline section and rotational movement sections
movement section 7. Sleeve bearing and ball
3. Clutch shaft rotational movement section 8. Armature shaft gear, planetary gear, internal
4. Oil seal gear
5. Bottom of the pinion 9. Surface of the armature bearing outer
circumference (very small quantity)
• Pass the gear shaft through the washer,

2. Tightening torque internal gear, and overrunning clutch. Next,
The torque is as per the list on the separate sheet. move the overrunning clutch one spline tooth
distance, check that the overrunning clutch
3. Armature shaft axial direction play
does not slip, then attach the E-shaped
• No need to adjust. Insert the ball in to the shaft retaining ring.
tip section.
4. Gear shaft axial direction play
• By inserting one washer between the internal
gear and gear shaft, the required gap is
automatically maintained.
6
1
1 2
5
4
2
3
3
4
5
HCW51ESH001501 MFW41ESH001401
Legend Legend
1. Washer 1. Push the pinion down and hook-on the puller
2. Gear shaft prongs
3. E-shaped retaining ring 2. Pinion spring
4. Internal gear 3. Pinion
5. Overrunning clutch 4. Clutch shaft
5. Snap ring
6. Stop ring
5. Pinion attachment
• Before attaching the magnetic switch to the
front bracket, attach the pinion. Attach the 6. Pinion protrusion position inspection
pinion spring, pinion, and stop ring in order onto After assembling the starter, inspect the pinion
the clutch shaft, then finally tightly attach the protrusion position. The measurement and
snap ring to the clutch shaft groove. Next, use a adjustment procedures are as follows.
gear puller to firmly pull the stop ring to the stop • Connect the starter to the battery as shown in
ring side, and fix both sides. the diagram. When switches SW1 and SW2 are
closed, the pinion moves forward to the
cranking position, and the armature rotates.
Then, switch SW2 opens and the armature
stops rotating.
SW1
SW2
24V
HCW51ESH001701

• Gently push the end of the crankshaft by hand
(push back), and measure the crankshaft
moving dimensions (return dimensions). This
value is OK if it is between 0.5 to 2.0 mm (0.02
to 0.08 in). If the measured value is outside this 2
range, either adjust by changing the number (2
or less) of gaskets (thickness 0.5 mm (0.02 in)) A SW B
between the magnetic switch and front bracket, S
1
or replace the lever. M
3
V
PWW010SH036201
Legend
1. Battery
2
2. Ammeter
3. Voltmeter
8. Maintenance standard
MFW41ESH001601
Legend
1. Gently push the Clutch shaft by hand Standard value or limit
Item
2. Amount of shaft movement value
Unloaded Voltage 23.0 V
7. No-load test characteristics Current Less than 85 A
• After adjusting the protrusion position of the
Rotation More than 3300 r/min
pinion, connect the starter as shown in the
diagram. Commutator Outer
38.7 mm (1.52 in)
diameter
NOTE: Wear limit 38.1 mm (1.50 in)
Use a wire of adequate thickness, and adequately
tighten the connection sections. Commutator Undercut 0.8 mm (0.031 in)
Limit 0.2 mm (0.008 in)
• Close the switch, and read the r/min, current,
Brush Length 23 mm (0.91 in)
and voltage. Compare with the maintenance
standard. If the value is different to the Wear limit 12 mm (0.47 in)
maintenance standard value, disassemble Brush spring 33 – 45 N (3.4 – 4.6 kg
them again and inspect them. Pressure
/ 7.5 – 10.1 lb)
Limit 20 N (2.0 kg/4.4 lb)
Pinion drive position 0.5 – 2.0 mm
(0.02 – 0.08 in)

b
a
MFW81EMF000301
(a) 23 N⋅m (2.3 kg⋅m / 17 lb⋅ft)

(b) 6 N⋅m (0.6 kg⋅m / 52 lb⋅in)
(c) 16 N⋅m (1.6 kg⋅m / 12 lb⋅ft)
(d) 10 N⋅m (1.0 kg⋅m / 87 lb⋅in)
(e) 3 N⋅m (0.3 kg⋅m / 26 lb⋅in)
Charge System
Be aware of the following precautions when handling
the generator.
• Connecting the plus and minus poles of the battery
to the opposite poles causes damage to the
generator diodes.
• Never disconnect the battery terminals and
charging circuit wires when the engine is running.
• The wiring for each terminal should be performed
accurately in accordance with the terminal codes.
• Do not perform a mega test on the semi -conductor
element.
• Always disconnect the battery terminal (-) when
inspecting the device.
• Do not open/close the battery relay switch when
the engine is running.
• When performing charging from external sources
such as a quick charge, always disconnect the
battery terminals first.
• Do not directly use a steam cleaner or water on the
device.
• After wiring, tighten B terminal and E terminal to
the torque strength shown below.
11 N⋅m
B terminal
50A (1.1 kg⋅m / 95 lb⋅in)
Specifications 4 N⋅m
E terminal
(0.4 kg⋅m / 35 lb⋅in)
11 N⋅m
B terminal
60A (1.1kg⋅m / 95 lb⋅in)
E terminal
(0.4 kg⋅m / 35 lb⋅in)
11 N⋅m
B terminal
90A (1.1 kg⋅m / 95 lb⋅in)
E terminal
(0.4 kg⋅m / 35 lb⋅in)
• Refer to the belt adjustment sections for details on

adjusting the tension of the V belt.

Multi-function IC regulator
• Trouble diagnosis function
Trouble diagnosis is added to turn on the charge light
when the feed coil circuit is open, and there is
excessive voltage.

Charging circuit
2 3
1 4
11
10
8
7 6
MFW61EMF000301
Legend
6. Front bracket

50A / 60A / 90A Specifications
1
2
7 L
B S L
P
3
F
6
MIC
4
E
E
MFW71EMF000101
Legend
1. Charge lamp (LED) 5. Generator
2. Key switch 6. Field coil
3. Battery 7. Stator coil
4. IC Regulator
Main Specifications
Official output 24V – 50A 24V – 60A 24V – 90A

Rated speed 5,000 r/min 5,000 r/min 5,000 r/min
Regulator type IC type
Adjustment voltage 28.0 to 29.0V
Mass 97 N (9.9 kg/21.83 lb) 97 N (9.9 kg/21.83 lb) 179 N (18.3 kg/40.35 lb)

Function Inspection
General vehicle inspection
The charge warning lamp indicates operating
malfunctions in the charge system. The warning lamp
lights when the starter switch is switched “ON”, and if it
goes out after the engine has started, operation is
normal. If the warning lamp indicates a malfunction, or
if there is suspicion that there is insufficient battery
charge or overcharging, perform fault diagnosis
according to the list.

• Does not charge at all
• Insufficient charge
• Overcharging
• Charging current is unstable
• Abnormal noises coming from the generator

Phenomenon: Does not charge at all

Does not charge at all Battery fault Replace
Broken wire in the wiring/ampere meter, Repair
short circuit, disconnected connection
section
Broken wire in one of the generator Replace
coils, earthed, short circuit and diode
damage
Regulator fault Replace
Regulator bad terminal connection Repair

Phenomenon: Insufficient charge

Insufficient charge Battery fault Replace
Broken wire in the wiring, short circuit, Repair
disconnected connection section
Loose generator drive belt Adjust the tension of the belt
Stator coil layer short-circuit Replace
Diode fault Replace
Bad connection in one of the terminals Repair

Phenomenon: Overcharge

Overcharging Regulator fault Replace

Phenomenon: Charging current is unstable

Charging current is unstable Wiring intermittent contact or partly Repair
broken wire
Loose generator drive belt Adjust the tension of the belt
Stator coil short circuit, partly broken Repair
wire
Bad contact in each terminal Repair

Phenomenon: Abnormal noises coming from the generator

Abnormal noises coming from the Loose belt tension Adjust the tension of the belt
generator Bearing fault Replace the bearing
Contact between the rotor core and Repair
stator core
Diode fault Replace
Stator coil short circuit, partly broken Replace
wire
Generator
Component Parts
50A ⋅ 60A Specifications
1
2
3
4
5
6
7
8
9
10
11
12
13
24
23
22
21
20
19 18
17 16
15
14
MFW61ELF000101
Legend
1. Nut 13. Nuts (for tightening the cover)
2. Pulley 14. Cover
3. Fan 15. Screw (for installing the regulator)
4. Through bolts 16. Screw (for tightening the regulator)
5. Collar 17. Clamp
6. Front bracket 18. Regulator
7. Front bearing 19. Nut (for fixing the rectifier)
8. Retainer 20. Rectifier
9. Screw (for tightening the retainer) 21. Screw (for fixing field coil)
10. Collar 22. Rear bracket
11. Rotor 23. Stator
12. Rear bearing 24. Field coil

90A Specifications
1
2 3
4
5
6
7 8
9
10
11
12
13
14
23
15
26
25
17
24
23
22
21
20 19
18
16
MFW61ELF000201
Legend
1. Nut 14. Rear bearing
2. Spring washer 15. Nuts (for tightening the cover)
3. Plain washer 16. Cover
4. Pulley 17. Screw (for installing the regulator)
5. Fan 18. Screw (for tightening the regulator)
6. Through bolts 19. Clamp
7. Collar 20. Regulator
8. Front bracket 21. Nut (for fixing the rectifier)
9. Front bearing 22. Rectifier
10. Retainer 23. Screw (for fixing field coil)
11. Screw (for tightening the retainer) 24. Rear bracket
12. Woodruff key 25. Stator
13. Rotor 26. Field coil
Disassembly front and rear bracket for easy reassembly.

NOTE: 1. Remove the through bolt.
Before disassembling, put an alignment mark to the
• Remove the 3 through bolts (50A&60A).

• Remove the 4 through bolts (90A). • Before separating, use a dryer etc. to warm up
2. Remove the cover from the rear side. the bearing housing and then dismantle.
• Remove the 3 nuts. • When separating, dismantle with a press using
the holes where the through bolts have been
• Remove the 2 B terminal nuts (90A).
removed from.
50A ⋅ 60A Specifications
NOTE:
1 Take care not to damage the stator coil.
5. Remove the pulley nut with an impact.

6. Remove the spring washer and plain washer
(90A).
7. Remove the pulley.
B 8. Remove the fan.
9. Remove the woodruff key (90A).
E 10. Remove the collar.
2
• When removing the rotor, use a pressing
4 3 machine etc.
• Do not put the rotor into a vice as it will become
distorted in shape.
MFW61ESH000501 12. Remove the collar from the rotor (50A&60A).
Legend 13. Remove the front bracket assembly’s bearing
1. Connector retainer screw.
2. B terminal 14. Remove the front bearing.
3. Nuts
• If it is necessary to remove the front bearing,
4. Cover
remove retainer fitting screw, and then use an
90A Specifications appropriate socket to push out the bearing.
NOTE:
1 Only remove the bearing if necessary.
Once the bearing has been removed, it cannot be
reused.
15. Remove the stator.

• Remove the stator lead wires from the 4 places,
and remove the stator from the rectifier.
• Remove the stator lead wires from the 7 places,
and remove the stator from the rectifier (90A).
2 NOTE:
4 When removing the stator lead wires, use the soldering
iron for a short time (not over 5 seconds) so that the
rectifier does not overheat and damage the diode.
3
16. Remove the field coil terminal lead.
MFW61ESH000701
• Remove the 2 screws (M4) that connect the
Legend lead to the rectifier.
1. Nuts
• Remove the solder from the place where the
2. B terminal
lead connects to the rectifier.
3. Cover
4. Nuts NOTE:
When removing the field coil terminal lead, use the
soldering iron for short time (not over 5 seconds) so
that the rectifier does not overheat to the rectifier.
3. Remove the B terminal (90A).
4. Separate the front and rear sides.

• Remove the lead on the side of regulator from 90A Specifications
the clamp.
2
17. Remove the regulator fitting screw.
18. Remove the regulator. 1
19. Remove the nut (1 place) that fixes the rectifier.
20. Remove the rectifier.
50A & 60A Specifications
7
2 3
1
6
7 4
5
3
MFW61ESH000901
6
Legend
4 1. Screw
2. Soldered part
3. Regulator
5
4. Rectifier
5. Nut
MFW61ESH000801
6. Screw
Legend 7. Clamp
1. Screw
2. Soldered part
3. Regulator
4. Rectifier 21. Remove the 3 field coil fitting screws (50A&60A).
5. Nut 22. Remove the 4 field coil fitting screws (90A).
6. Screw 23. Remove the field coil.
7. Clamp
24. Disconnect the rear bearing.
• If it is necessary to remove the rear bearing,
use a pressing machine.
NOTE:
Only remove the rear bearing if necessary.
Once the rear bearing has been removed, it cannot be
reused.
Inspection
Generator inspection and repair
Inspect the stator
• Perform a visual inspection for damage, slack
connections and discoloration of the stator coil.

• Inspect the conduction between the 2 stator coil Inspect the coil assembly
lead wires (1) with a circuit tester. • Measure the resistance between both terminals in
If there is no conduction, replace the stator. the terminal section using circuit tester. If the value
is outside the standard value, replace the coil
assembly.
MFW61ESH000301
MFW61ESH000101
• Inspect the conduction between the stator coil lead
wire (1) and core (2) with a circuit tester. Inspect the rectifier assembly
If there is conduction, replace the stator.
• Inspect the conductance between the 4 diode
terminals of the plus diode using a circuit tester. If
there is conductance in both directions, there is a
short circuit in the plus diode. In this case, replace
the rectifier assembly.
1 If there is not conductance in both directions, the
plus diode is open. In this case, replace the
rectifier assembly.
• Inspect the conductance between the 4 diode
terminals of the minus diode using a circuit tester.
If there is conductance in both directions, there is
short circuit in the minus diode. In this case,
replace the rectifier assembly. If there is not
conductance in both directions, the minus diode is
open. In this case, replace the rectifier assembly.
2
MFW61ESH000201
Inspect the rotor

• Inspect the bearing for abnormal noises,
looseness, and leaking grease (if a minute amount
of grease is present, simply wipe it off), and
replace the bearing if a fault is found. It is easier to
inspect the bearing for abnormal noises and
slackness when it is press fit into the shaft, than
inspecting it by itself.

Reassembly
As the assembly can be done in the reverse order to
disassembly, only the most important points will be
explained here. Also, pay attention to the next point.
1 1. The bearings are filled with grease and sealed,
3 therefore they do not need lubricating.
NOTE:
The bearing from the rotor shaft with resin band must
never be greased. If there is oil on the rear bracket
bearing box section, it may cause joint rotation of the
rear bearing, and must therefore be completely wiped
2 off.
2. Use high temperature solder (fusing point 230°C /

446°F specifications).
When soldering, use a 180 to 270 watt soldering
MFW61ESH000601 iron and work quickly (within approx. 5 seconds) so
as not to overheat the rectifier.
Legend
1. Positive heat sync 3. Tightening torque for each parts. Refer to the
2. One section of the negative heat sync tightening torque table.
3. Diode terminal
NOTE:
Be careful not to over tighten.
N⋅m (kg⋅m/
Tightening torque
lb⋅in)
50A & 60A 137 (14.0 /
specifications 101 lb⋅ft)
Pulley nut
245 (25.0 /
90A specifications
181 lb⋅ft)
50A & 60A
6 (0.6 / 52)
specifications
Through bolt
14 (1.4 /
90A specifications
122)
Bearing retainer 5 (0.5 / 43)
50A & 60A
Field coil 3 (0.3 / 26)
specifications
MFW61ESH000401 assembly
90A specifications 5 (0.5 / 43)
Inspect the front bearing Rectifier 3 (0.3 / 26)
• Inspect the bearing for abnormal noises, loosens Regulator 3 (0.3 / 26)
and leaking grease (if a minute amount of grease Regulator and a connection
is present, simply wipe it off), and replace the 2 (0.2 / 17)
screw of rectifier
bearing if fault is found. It is easier to inspect the
bearing for abnormal noises and slackness when it Cover 3 (0.3 / 26)
is press fit into bracket, rather than inspecting it by Terminal B nut 11 (1.1 / 95)
itself.
4. Rear bracket, stator assembly and front bracket
Inspect the regulator rotor assembly installation.
• The regulator cannot be inspected with a circuit • As the fit of the rear bearing and rear bracket is
tester. After re-assembling the generator, test the very tight, heat the bearing box section of the
generator and check that the regulator is rear bracket 50 to 60 ºC (122 to 140°F)
controlling the generator voltage. beforehand, then assembly the bearing and
bracket.

• After re-assembling the generator, rotate the
pulley by hand, and check that the rotor rotates
smoothly.

Bench Testing:
Generator bench test
Ammeter SW1
Voltmeter
Lamp(24V)
(3W or less)
SW2
Battery
(24V)
Generator
Resistor
MFW81EMF000201
Voltage regulation • Run the generator to about 5,000 r/min and read
• Connect the circuit as shown in the above the ammeter.
diagram. If 5 A or less, read the indication of the voltmeter.
Use an ammeter of a rated 100 A and a voltmeter This is the regulated voltage.
of a rated 30 V. If the ammeter indicates 5A or more, either
Use a variable resistor of a rated 50 A or higher. continue charging until current drops below 5A or
replace the battery with a fully charged battery.
• Close switch 1. Open switch 2.
If the regulated voltage is outside the specified
At this point, the lamp should light.
range, replace the regulator.
If it does not light, check terminal L voltage.
If voltage is near to the battery voltage, check the Output current
generator.
If voltage is low, the lamp or lamp circuit is The output current test determines whether the
disconnected. generator outputs the rated current or not.
• Gradually raise generator rotational speed. • After checking voltage regulation, lower generator
Check that the lamp goes out before reaching speed and stop the generator.
about 1,300 r/min. • Close switch 1. The lamp should light.
Watch the voltage. If voltage cannot be kept below • Set variable resistance to the highest value
30 V, the IC regulator may be damaged. (minimum current), and close switch 2.
If voltage does not exceed battery voltage, the
generator is not generating power.
Check the generator again.
If the lamp does not light, check the generator
again.

• Raise the generator rotational speed, and, with 90A specifications
speed maintained at 5,000 r/min, adjust variable
resistance so that output current is the maximum.
Run the generator in this state for 15 minutes to Rotational 2,500 5,000
raise generator temperature. speed r/min r/min
15 minutes later, set generator rotational speed so Output Voltage 27V 27V
that it matches the specified speed (2,500 and characteristics 80A 90A
5,000 r/min). Then, adjust variable resistance in (when hot) Current
or more or more
this state so that output current is the maximum.
If the ammeter indication is within the specified Field coil resistance
6.3 – 7.5Ω
range at this time, the generator is operating (At 20 °C / At 68°F)
correctly. Regulator regulated voltage 28 – 29V
If it is outside the specified range, recheck the
Rotational direction
generator as explained in “Inspection”. Clockwise
(Seen from pulley side)
Specifications
50A specifications
Rotational 2,500 5,000

speed r/min r/min
Output Voltage 27V 27V
characteristics 42A 50A
(when hot) Current
or more or more
8.3 – 9.1Ω
(At 20 °C / At 68°F)
Regulator regulated voltage 28 – 29V
Clockwise
60A specifications
Rotational 2,500 5,000

speed r/min r/min
Output Voltage 27V 27V
characteristics 45A 60A
(when hot) Current
or more or more
8.3 – 9.1Ω
(At 20 °C / At 68°F)
Regulator regulated voltage 28 – 29V
Clockwise
ENGINE
Engine Exhaust
(6HK1)
TABLE OF CONTENTS
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1G-2
Explanation of Functions and Operations . . . . . 1G-2
Function Inspection: . . . . . . . . . . . . . . . . . . . . . 1G-4
Failure Phenomenon List . . . . . . . . . . . . . . . . . 1G-5
Phenomenon: Vibrations and rattling
from the exhaust system . . . . . . . . . . . . . . . . . . 1G-6
Phenomenon: Clogging of the exhaust system. 1G-7
Phenomenon: Exhaust gas leak, noise. . . . . . . 1G-8
Phenomenon: Exhaust gas is mostly black
in large quantity. . . . . . . . . . . . . . . . . . . . . . . . . 1G-9
Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-12
Tightening Torque Table . . . . . . . . . . . . . . . . . 1G-15
Diesel Particulate Defuser (DPD). . . . . . . . . . . . 1G-16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-16
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Filter cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 1G-17
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-20
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-21
Exhaust Differential Pressure Sensor . . . . . . . . 1G-22
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-22
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1G-22
Exhaust System
As vibrations and looseness in the exhaust system are
often caused by positioning discrepancies when
assembling the system, temporarily tighten all bolts
until all of the parts have been positioned, then finally
tighten all bolts in order from the engine side to the rear
pipe side.

The exhaust brake assembly adjusts the exhaust
pressure to assist the brake, performs engine Quick
Warm-up System (QWS), etc.
The Diesel Particulate Defuser (DPD) unit is a single
unit construction of a filter and oxidation catalyst, which
cleans the exhaust gas. The silencing effect is obtained
from the post silencer integrated in the tailpipe.
The main parts consist of the exhaust brake assembly,
front exhaust pipes A, B and C, DPD, exhaust throttle
assembly, throttle – silencer exhaust pipe, silencer, and
rear exhaust pipe. (Include it post silencer)
MFW71GLF000101
Legend
1. Front exhaust pipe A 5. Diesel Particulate Defuser (DPD)
2. Front exhaust pipe B 6. Exhaust throttle assembly
3. Exhaust brake assembly 7. Silencer
4. Front exhaust pipe C 8. Rear exhaust pipe

• When inspecting or repairing the exhaust system,
check that there is enough space between the floor
and the body.
• Damage to the body panel from heat or vibration
may cause the exhaust gas to leak into the room.
• Inspect the connection sections for damage or
looseness, and check that there are no exhaust
gas leaks.
• Inspect the clamps and rubber for deterioration,
abrasion, and damage.
• If the pipes, DPD or silencer are either damaged or
dented, repair or replace them.
• Inspect for the presence of dents, damage, and
holes or splitting due to corrosion, and inspect for
the presence of abnormal noises while driving.
• If a DTC related to DPD is detected, inspect and
repair according to the DPD section of “Engine
Control System”.
CAUTION:
Before disassembling the DPD assembly, always use a
scan tool to check the status and inspection /
maintenance details of the DPD pressure difference.
For details, refer to “Engine Control System”.

• Vibrations and rattling from the exhaust system
• Clogging of the exhaust system
• Exhaust gas leak, noise
• Exhaust gas is mostly black in large quantity

Phenomenon: Vibrations and rattling from the exhaust system

Vibrations and rattling from the exhaust Component looseness, or mismatching Line up the connection areas and then
system re-tighten also, inspect the hanger,
attachment bracket, and clamp for
damage

Phenomenon: Clogging of the exhaust system

Clogging of the exhaust system The exhaust brake and exhaust throttle Refer to the engine control system
are ON section to inspect the electrical system,
then repair any malfunction
Inspect the exhaust brake and exhaust
throttle shaft for hesitant movement,
and replace if there is a fault
Blocked exhaust pipe Repair or replace the exhaust pipe
DPD related DTC detected Inspect and repair by following the DPD
related engine control section
troubleshooting section

Phenomenon: Exhaust gas leak, noise

Exhaust gas leak, noise Bad attachment, or mismatch Line up the connection areas and then
re-tighten
Damage or scorching in the exhaust Replace the damaged part
pipe silencer, or DPD
Bad exhaust system component Replace the defect part
(clamp, pipe, silencer)
Silencer internal damage Replace the silencer
DPD internal damage Replace the damaged section

Phenomenon: Exhaust gas is mostly black in large quantity

DPD failure Melted or broken filter Replacement
Clogging of the filter carbon Clean or replace
Exhaust Pipe
Removal 6. Remove the exhaust pipe adaptor.
1. Remove the rear exhaust pipe.
• Remove the clamp, then remove the rear
exhaust pipe. 4
3
2 2
1 1
5
6
MFW71GSH003701
Legend
1. Gasket
MFW41GSH000801
3. Gasket
Legend 4. Silencer
1. Rear exhaust pipe 5. Gasket
2. Post silencer 6. Exhaust throttle assembly
2. Disconnect the exhaust throttle air pipe. 7. Remove the 2 DPD exhaust temperature sensor
3. Remove the silencer bracket. connectors.
4. Remove the silencer. 8. Remove the 2 DPD differential pressure hoses.
5. Remove the exhaust throttle assembly.

9. Remove the DPD assembly from the front pipe.
3 4
2 1
1
6 5
MFW41GSH001601
7
MFW81GSH001101
Legend
Legend 1. Exhaust differential pressure sensor assembly
1. Exhaust temperature sensor 2 (catalyst inlet) 2. Tightening screw
2. Exhaust temperature sensor 1 (catalyst outlet)
3. Differential pressure hose (Front)
4. Differential pressure hose (Rear)
5. Exhaust silencer 10. Remove the front exhaust pipe A, B, and C.
6. Exhaust throttle assembly • Remove the clamp, then remove the front
7. DPD assembly exhaust pipe.
• Remove the exhaust brake assembly.
NOTE:
If the exhaust differential pressure sensor assembly
must unavoidably be removed, pay attention to the 1
following points.
• Never loosen the 4 sensor tightening screws (2). If 2
they are loosened, replace the sensor assembly.
• Do not re-use the sensor assembly if it is ever
dropped.
3
• Do not use a tool such as an impact wrench etc.,
which causes vibrations when installing and
removing the sensor.
MFW71GSH003501
Legend
1. Front exhaust pipe A
2. Front exhaust pipe B
3. Front exhaust pipe C
4. Exhaust brake assembly

Installation
NOTE:
1
• As vibrations and looseness in the exhaust system
are often caused by positioning discrepancies
2
when assembling the system, temporarily tighten
all bolts until all of the parts have been positioned,
then finally tighten all bolts in order from the engine
side to the tail pipe side.
3
• Do not re-use the removed gasket or nuts.
1. Install the front exhaust pipe A.

• Install the front exhaust pipe A to the exhaust
manifold, and tighten to the specified torque
strength. 4
Tightening torque
MFW71GSH003501
76 N⋅m (7.7 kg⋅m/56 lb⋅ft)
Legend
1. Front exhaust pipe A
NOTE: 2. Front exhaust pipe B
Tighten front exhaust pipe A equally, and make sure 3. Front exhaust pipe C
there are no gas leaks. 4. Exhaust brake assembly
2. Install the front exhaust pipe B.
• Install the front exhaust pipe B to the front
exhaust pipe A, and tighten to the specified 4. Install the DPD assembly to the front pipe.
torque strength.
Tightening torque
85 N⋅m (8.7 kg⋅m/63 lb⋅ft)
5. Install the differential pressure hose to the DPD
3. Install the exhaust brake assembly. differential pressure pipe.
• Install the exhaust brake assembly and front • Securely insert the differential pressure hose to
exhaust pipe C to the front exhaust pipe B, and the pipe bulge section.
tighten to the specified torque strength. • Securely fasten the hose clip.
NOTE:
Tightening torque
• Do not mistake the front and rear directions.
41 N⋅m (4.2 kg⋅m/30 lb⋅ft) • Do not use hoses that are cracked.
• Never tighten or loosen the exhaust differential
pressure sensor assembly tightening screw.
• If gas leaks from the coupling section, it may cause
control malfunction.
After starting the engine, always check that there
are no gas leaks.
3 4
1 2
4
6
5
6 5
7
MFW61GSH000801 MFW81GSH001101
Legend Legend
1. Exhaust differential pressure sensor assembly 1. Exhaust temperature sensor 2 (catalyser inlet)
2. Tightening screw (Never loosen) 2. Exhaust temperature sensor 1 (catalyser outlet)
3. Differential pressure hose (Rear) 3. Differential pressure hose (Front)
4. Differential pressure hose (Front) 4. Differential pressure hose (Rear)
5. Clip for differential pressure hose 5. Exhaust silencer
6. Bulge section 6. Exhaust throttle
7. DPD assembly
6. Install the DPD exhaust temperature sensor

connector. 7. Install the exhaust pipe adaptor to the DPD.
NOTE:
Do not mistake the front and rear directions. Tightening torque
37 N⋅m (3.8 kg⋅m/27 lb⋅ft)
8. Insert the exhaust throttle assembly into the

exhaust adaptor, and Install the silencer.
Tightening torque
41 N⋅m (4.2 kg⋅m/30 lb⋅ft)

9. Install the air pipe to the exhaust throttle air
cylinder.
4 2
1
3
2
1
5
6
MFW41GSH000801
Legend
MFW71GSH003701
1. Rear exhaust pipe
Legend 2. Post silencer
1. Gasket
NOTE:
3. Gasket
After assembling each part, start the engine and check
4. Silencer
that there are no gas leaks or vibration from each of the
5. Gasket
coupling sections. If the DPD assembly was
6. Exhaust throttle
disassembled, perform the following careful checks for
gas leakage.
• Sufficiently warm up the engine.
10. Install the rear exhaust pipe. • Raise the engine to its maximum r/min. In this
• Tighten the clamp. condition spray soapy water onto the differential
pressure hose connection section and sleeve nut
NOTE: connection section, and verify that there are no
• Tighten the clamp bolts in sequence, upper and gas leaks.
lower.
• Install the clamp on an even keel.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)

d
MFW71GMF000101
(a) 76 N⋅m (7.7 kg⋅m / 56 lb⋅ft)

(b) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(c) 25 N⋅m (2.5 kg⋅m / 18 lb⋅ft)
(d) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)
(e) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)
(f) 85 N⋅m (8.7 kg⋅m / 63 lb⋅ft)
(g) 41 N⋅m (4.2 kg⋅m / 30 lb⋅ft)

Removal a. Paint the arrow mark (1) on the filter case so
that exhaust gas flow direction may be
1. Remove the DPD assembly.
distinguished.
Disassembly
Disassemble the DPD assembly.
1
1. Loosen the sleeve nut that fixes the differential
pressure pipe.
2. Remove the differential pressure pipe clips (3
locations).
3. Remove the differential pressure pipe.
1 2 3
MFW81GSH004201
b. Loosen the oxidation catalyst section tightening

nut, and separate the oxidation catalyst section,
and filter section.
c. Loosen the filter section tightening nut, and
separate the filter section from the rear case.
NOTE:
5 4 Do not apply a strong impact to the DPD assembly or
drop it.
MFW61GSH000601
Legend
2. Differential pressure pipe (Rear) 4 5
3
3. Sleeve nut (Rear)
4. Clip
5. Sleeve nut (Front) 2
4. Remove the DPD exhaust temperature sensors 1

(catalyst inlet side and outlet side).
5. Disassemble the DPD assembly.
MFW41GSH001001
Legend
2. Gasket
3. Filter section
4. Gasket
5. Rear case

Inspection • The DPD lamp lights, then goes off after
approx. 30 seconds.
1. Perform an external inspection of the exhaust pipe
related parts. • After verifying that the DPD lamp has gone off,
turn the key OFF and leave for more than 15
• Damage to the body panel from heat or vibration
seconds.
may cause the exhaust gas to leak into the room.
• Inspect the connection sections for damage or NOTE:
looseness, and check that there are no exhaust Do not perform 0-point corrections within 2 hours after
gas leaks. regenerating DPD because the differential pressure
• Inspect the clamps and rubber for deterioration, sensor assembly is sensitive to heat.
abrasion and damage.
• Inspect the pipes and silencer for dents, and for Filter cleaning
cracks due to corrosion, and either repair or
replace the damaged sections. Ash cannot be regenerated by combustion unlike
particulate matter (PM).
2. Inspect the DPD related sections.
• Visually check the filter for melting damage, Because the ash is calcined (tightly stuck) to the DPD
damage, or blockages. filter.
In order to remove ash, use a DPD ash removal device.
• Shine a light from the opposite side of the filter.
Refer to DPD ash removal device handling manual for
If the light penetrates and can be seen, replace
the handling of DPD ash removal device.
the filter section.
1. Set the DPD filter to the DPD ash removal device.
• Visually check the catalyst section for melting
damage, damage, or blockages. NOTE:
Set the DPD assembly so that arrow mark, which was
NOTE:
painted at disassembly operation, face up.
Before disassembling the DPD assembly, always use a
scan tool to check the status and inspection/
maintenance details of the DPD differential pressure.
For details, refer to “Engine Control System”.
MFW81GSH004101
2
2. Supply air up to the given pressure of 0.4 MPa (4.0
kg/cm2 / 58 psi) in the air tank.
MFW41GSH001101 Stop supplying when the air is pressurized up to
given pressure.
Legend
1. Filter CAUTION:
2. Filter case Do not supply air exceed 0.5MPa (5.0 kg/cm2 / 73 psi)
to the tank as indicated by the manometer mounted on
the pressure regulator.
At this point, check for air leaks from the pipe without
3. If the differential pressure sensor assembly has
fail.
been replaced, perform the following actions (on
the vehicle). 3. Press the device’s mechanical valve for three
• Switch the key from OFF to ON (do not start the seconds. Implement backwashing and cleanse the
engine). DPD filter.

4. Repeat the work described in STEP2 and STEP3
three times.
CAUTION:
Ash may escape from the exhaust filter and
1
backwashing noises may be heard while in use.
Wear protective equipment, such as dust masks, safety
goggles and earplugs and operate the equipment while
keeping the face and hands at a safe distance.
Air-tightness check
Check for air-tightness when the DPD is disassembled
and reassembled (when installed to vehicle).
1. Warm up the engine and rev the engine to the
maximum speed with no load.
2. With the engine revved, check the pressure hoses
(1) connections, sleeve nuts (2) and (4)
connections, for gas leaks by spraying soapy MFW81GSH004301
water on them. 1. Insert a new gasket into the filter section and rear
case, and temporarily tighten with nuts and bolts.
2. Insert a new gasket into the filter section and
oxidation catalyst section, and temporarily tighten
with new nuts and bolts.
1 NOTE:
• If the DPD was disassembled, do not reuse old
gasket, nuts, and bolts (use gasket and fixing kit).
NOTE:
• Check the attachment positions of the filter section
and rear case, and the filter section and oxidation
catalyst section, and tighten both pipe brackets.
2
3. Tighten the nuts and bolts to their specified torque.
4 3
• Tighten each nut and bolt twice.
MFW81GSH004001
Legend Tightening torque

1. Pressure hoses 25 N⋅m (2.5 kg⋅m/18 lb⋅ft)
3. Clips NOTE:
4. Sleeve nut (Front) After tightening each nut and bolt, with specified
tightening torque be sure to tighten once again to the
same torque (tighten twice).
Reassembly
Reassemble the DPD assembly.
NOTE:
• The DPD assembly must be installed with arrow
mark (1), which was painted at disassembly
operation, in the opposite direction of exhaust gas
flow.
• Do not reuse the removed gasket, nut and bolt.

• Check for gas leakage and confirm that it is securely
sealed.
4 5
3
Screw sizes Connector
2
Color
Sensor
M12 / 1.75 mm
(catalyst inlet Dark grey
(0.47 / 0.069 in)
side)
1
Sensor
M12 / 1.25 mm
(catalyst outlet Light grey
(0.47 / 0.049 in)
side)
Tightening torque
30 N⋅m (3.1 kg⋅m/22 lb⋅ft)
MFW41GSH001001
Legend 5. Tighten the sleeve nut of the pressure pipe (front)

1. Oxidation catalyst section (rear) with your hand.
2. Gasket
3. Filter section NOTE:
4. Gasket • Clean off the old burning prevention agent from the
5. Rear case sleeve nut, and apply new burning prevention agent
(Bostik : Never-Seez High Temperature stainless
grade 5-87411-039-0).
4. Install the DPD exhaust temperature sensor 6. Fix the differential pressure pipe with the clip.
(catalyser inlet, catalyser outlet)
NOTE: Tightening torque

• Remove the old seizing-prevention agent from the 10 N⋅m (1.0 kg⋅m/87 lb⋅in)
threaded portion to the threaded portion of the
sensor and apply a new seizing-prevention agent
7. Tighten the differential pressure pipe sleeve nut to
(Bostik : Never- Seez High Temperature stainless
grade 5-87411-039-0).
• When the sensor is replaced with a new one, the
application of the seizing-prevention agent is Tightening torque
unnecessary since it has already been pre-applied
Sleeve nut front
to the sensor. 35 N⋅m (3.6 kg⋅m/26 lb⋅ft)
Sleeve nut rear
• When assembling, do not hit the tip of the sensor to
the other boss.
• Do not use a sensor which has scratches or dents NOTE:
made by dropping or hitting. • If the differential pressure pipe attachment
procedure is not followed correctly, the nuts may
• Do not hit the protruded section against something
become loose. Always follow the procedure
after assembling the sensor to the DPD.
precisely when attaching the pipe.
• Be careful not to mix up sensors (for catalyst inlet
side and outlet side) when assembling. • Do not reuse old gaskets, nuts and bolts if the DPD
is disassembled.
1 2 3
5 4
MFW61GSH000601
Legend
2. Differential pressure pipe (Rear)
4. Clip
5. Sleeve nut (Front)
Installation
1. Install the DPD assembly.

Inspection
Filter Inspection
Inspect the differential pressure.
Perform after installing the DPD to the vehicle.
1. Start the engine and confirm there is no exhaust
leakage from the DPD related parts (such as DPD
sensor, differential pressure sensor, and
connecting parts of hoses).
2. Inspect the differential pressure.
a. Observe the Exhaust Temperature 1 parameter
with a scan tool. Make sure the temperature is
less than 120°C (248°F). If more than 120°C
(248°F), let increase 1000 RPM without load.
(Rotate the idle up sensor clockwise.)
b. Accelerate the engine to W.O.T. (accelerator
to 150°C (302°F).
3. If the inspection value is higher than limit value,
replace the filter.
Limit; 3.3 kPa (0.034 kgf/cm2 /0.48 psi)
NOTE:
After replacement of the DPD filter, perform DPD status
resetting.
DPD Regenerate Programming Procedure

DPD regenerate data reset
• Carry out the following steps when changing the
DPD.
identification > Engine > 6HK1-TC (C/Rail) >
Programming > DPD Regeneration data reset.
4. Initiate the reset function in accordance with the
onscreen instructions.
5. After the reset is complete, if the “Programming
Completed Successfully” message is displayed,
follow the onscreen instructions to advance the
end procedure.

Removal 3. Connect the differential pressure hoses (2 pieces).
1. Disconnect the differential pressure hoses (2 NOTE:
pieces).
• Do not mistake the front and rear directions.
2. Disconnect the differential pressure sensor
• Do not use cracked hoses.
harness connector.
3. Remove the differential pressure sensor.
differential pressure sensor assembly tightening
• Remove the installation bolts (2). screw.
• Remove the differential pressure sensor. • There is the danger of the sensor mis-operation
when there is a gas leak from the joint sections.
1 After starting the engine, check that no gas is
leaking.
2 • Do not reuse the differential pressure sensor
• Do not use a tool such as an impact wrench, etc., to
3
pressure sensor.
F
MFW81GSH001401
Legend
1. Differential pressure sensor
2. Installation bolts
3. Differential pressure hoses
4
NOTE:
3 2
sensor (1), be careful of the following points.
LNW76FSH001801
• Absolutely never loosen the 4 differential pressure
sensor installation screws. If they are loosened, Legend
replace the differential pressure sensor. 1. Front mark
• Do not reuse the differential pressure sensor 2. Rear side differential pressure hose insertion
assembly if it was dropped. section
3. Front differential pressure hose insertion section
• Do not use a tool such as an impact wrench, etc., to 4. Bracket
pressure sensor.
Installation
1. Install the differential pressure sensor.
• Tighten installation bolt by rule torque.
Tightening torque
25 N⋅m (2.6 kg⋅m/19 lb⋅ft)
2. Connect the differential pressure sensor harness

connector.

0-point correction of the differential pressure
sensor
Perform 0-point correction on the differential pressure
sensor when the differential pressure sensor assembly
has been replaced. (on vehicle)
1. Turn the key from the OFF state to the ON state.
(Engine does not start.)
2. DPD light turns on, and then turns off after
3. After checking that the DPD light is extinguished,
turn the key off and leave for at least 15 seconds.
NOTE:
Performing 0-point correction tend to receive the
influence by heat easily. Do not perform corrections
until two hours after regenerating DPD.
MEMO
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ENGINE
Engine Lubrication
(6HK1)
TABLE OF CONTENTS
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . 1H-2
Precautions for Servicing . . . . . . . . . . . . . . . . . 1H-2
Explanation of Functions and Operations . . . . . 1H-3
Function Inspection . . . . . . . . . . . . . . . . . . . . . . 1H-5
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1H-6
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Component Parts . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-8
Tightening Torque Table . . . . . . . . . . . . . . . . . 1H-10
Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Maintenance Precautions . . . . . . . . . . . . . . . . 1H-11
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-11
Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-12
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-12
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-13
Tightening Torque Table . . . . . . . . . . . . . . . . . 1H-16
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Component Parts . . . . . . . . . . . . . . . . . . . . . . 1H-17
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-17
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-18
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1H-20
Lubrication System
• Every time section that use liquid gasket are
disassembled, use a scraper to completely remove
all of the old gasket from each part and their
matching parts, clean each part with a rag etc. To
ensure there is no oil, water, dirt etc.
Adhered to them, and apply a fresh quantity of the
specified type of liquid gasket to each location
when assembling.
• Do not over-apply or under-apply the liquid gasket.
Always apply a suitable amount. An excess of
liquid gasket may cause blockages in the oil
gallery or oil jet, causing burning. Furthermore,
under-application of liquid gasket may cause oil or
water leaks.
• Always overlap the liquid gasket when starting and
finishing application.

Lubrication system diagram
26
3 2
25
24 4
23
5
6
22 7
21
20
8 9
19 18
11 10
16
17
12
15
13
14
MFW71HLF000201
Legend
1. Rocker arm 15. Full flow oil filter
2. Gallery to cylinder head 16. Over flow valve
3. Idle gear C 17. Crankshaft
4. Idle gear B 18. Oil jet
5. Oil relief valve 19. Specialized gallery for oil jet
6. Air compressor 20. Idle gear (front)
7. Oil thermo 21. Oil cooler
8. Idle gear A 22. Bypass oil gallery (oil cooler)
9. PTO idle gear (only for PTO gear specifications) 23. Main oil gallery
10. Turbocharger 24. Oil pressure switch
11. Oil pump 25. PTO gear oil supply (only for PTO gear
12. Oil relief valve specifications)
13. Oil strainer 26. Camshaft
14. Oil pan

Oil pump structural diagram
2
MFWB1HLF000201
Legend
1. Driven gear assembly 3. Drive gear assembly
2. Oil pump body 4. Oil pump drive gear

Function Inspection
Oil pressure inspection
1. Inspect the engine oil level. Add more engine oil if
there is insufficient oil.
2. Remove the oil pressure switch.
3. Attach an oil pressure gauge. 1
4. Sufficiently warm up the engine.
5. Measure whether the oil pressure indicates more 7
than 210 kPa (2.1 kg/cm2 / 30 psi) at 1,400 r/min. 2
6. Stop the engine. 6 3
7. Remove the oil pressure gauge.
8. Attach the oil pressure switch.
5
9. Start the engine, and check for oil leaks. 4
NOTE:
Inspect the engine oil for abnormal dirt, or whether fuel
or water is mixed into it. If an abnormality is found,
LNW41HSH000101
investigate the cause, take the appropriate action to
remedy the cause, and replace the oil. Legend
1. Oil change is necessary
Engine oil used 2. Good oil level
3. The supplying is possible to MAX
• Grade (API) CD Class
4. The supplying is necessary
Viscosity (SAE) 10W-30 Besco Clean
5. An MIN level
(Oil compatible with DPD)
6. Supply purpose MAX
NOTE: 7. Inspection purpose MAX
Only use one of the engine oils listed above in this
engine. Engine oil leak
Amount of engine oil • Inspect the oil seal, cylinder head cover, oil pan,
etc. For oil leaks.
• Park the vehicle on a level surface, and inspect the
amount of engine oil using a level gauge after
more than 30 minutes has passed since the engine
was stopped. If engine oil adheres to the level
gauge at a level between the upper limit and lower
limit, the oil level is OK.
However, if the level of engine oil is below the
lower limit, add more oil. Also, check how dirty the
oil is.
• Vehicles installed with this engine are equipped
with DPD, and so the method in inspecting the
engine oil level is different.
When a fixed amount of particulate matter (PM)
accumulates in the DPD filter, the DPD vehicle
automatically performs regeneration (combustion).
To perform this regeneration, a slight amount of
fuel is injected into the fuel chamber after
combustion of the engine and is fed to the DPD
filter as exhaust-mixed gas.
A portion of the fuel is mixed into the engine oil, so
the engine oil increases from when it is filled, but
this is not a problem.
NOTE:
If the engine oil has increased in quantity, fuel or water
may have become mixed in it. The cause must be
investigated.

Main Specifications
Main Specifications
Item Specifications
Lubrication system Forced lubrication type
Type Gear type
Output volume
Pump r/min: 4,490r/min
Oil SAE #30, Oil temperature:
Oil pump 115 L (25.3 Imp⋅gal) / min
50°C (122°F)
Output pressure
400 kPa (4.1 kg/cm2/58 psi)
Relief valve opening pressure 800 kPa (8.2 kg/cm2 / 117 psi)
Oil gallery relief valve opening pressure 490 kPa (5.0 kg/cm2 / 71 psi)
Type Full flow, filter paper type
Oil filter Bypass valve opening pressure

(Inlet/outlet oil pressure 250 kPa (2.5 kg/cm2 / 36 psi)
differential)
Oil cooler type Water-cooled multi-plate type
Temperature at which it starts
90°C (194°F)
to open
Oil thermo valve
Bypass opening valve temperature 95°C (203°F)
(Oil thermostat)
Bypass opening valve amount
5 mm (0.197 in)
of lift
Shallow pan type: Max. 10.5 L (2.31 Imp⋅gal),
Min. 8 L (1.76 Imp⋅gal)
Oil pan capacity
Deep pan type: Max. 16.5 L (3.63 Imp⋅gal),
Engine oil Min. 13.5 L (2.97 Imp⋅gal)
6HK1-TCN 13.5 L (2.97 Imp⋅gal)
Total capacity
6HK1-TCC,TCS 19.5 L (4.29 Imp⋅gal)
Maintenance standard table
Item Nominal Assembly Limitations for

dimensions standard use
16 mm 15.9 mm
Driven gear shaft outer diameter —
(0.6 3in) (0.626 in)
Gap between the driven gear shaft, driven 0.04 – 0.07 mm
— —
shaft, and bushing (0.0016 – 0.0028 in)
Oil pump
Gap between body wall and gear tooth tip 0.125 – 0.221 mm
— —
(0.0049 – 0.0087 in)
Axial direction gap between body 0.064 – 0.109 mm
— —
attachment surface and gear (0.0025 – 0.0043 mm)
Oil Filter
Component Parts
1
6
MFWB1HLF000401
Legend
1. Over flow valve 4. Oil filter plug
2. Oil filter body 5. Oil filter
3. Harness bracket 6. O-ring
Disassembly
Disassembly
1. Remove the oil filter.
• As oil has collected inside the oil filter (1)
making it heavy, support it by hand and use an
oil filter wrench (1-8522-1097-0) to remove it.

Reassembly
2. Assembly the O-ring to the oil filter body, and
install it to the cylinder block.
Tightening torque
38 N⋅m (3.9 kg⋅m/28 lb⋅ft)
MFW81HSH001401
2. Remove the over flow valve.

4. Remove the oil filter body.
Inspection
1. Inspect the oil filter.
MFW81HSH000601
• Replace the oil filter if it is blocked.
• Inspect the oil filter for deformation etc.
2. Inspect the over flow valve for blockages.
4. Install the O-ring to the over flow valve, and install
it to the oil filter body.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MFW81HSH000501
3. Replace the over flow valve O-ring.

4. Replace the oil filter body attachment section O-
ring.
MFW81HSH000701

5. Install the oil filter (1).
• Apply a thin layer of oil to the oil filter seal
section and screw it into the oil filter body.
When the oil filter seal section is in the position
where it contacts with the oil filter body, tighten
it one more turn.
When clamping was short, I tighten it with an oil
filter wrench (1-8522-1097-0).
NOTE:
• If it is over tightened, the oil filter will distort causing
an oil leak.
• Completely wipe off any oil that has seeped out.
MFW81HSH001401

c
d
MFWB1HLF000301
(a) 20 N⋅m (2.0 kg⋅m / 14 lb⋅ft)

(b) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
(c) 27 N⋅m (2.8 kg⋅m / 20 lb⋅ft)
(d) 38 N⋅m (3.9 kg⋅m / 28 lb⋅ft)
Oil Separator
Maintenance Precautions 3. Blow-by gas rubber hose
Maintenance precautions
1
• Replace the oil separator element once a year.
2
Disassembly
1. Blow-by gas rubber hose
• Disconnect the IN and OUT ends of the rubber
hose on the oil separator side.
2. Remove the cap
3. Remove the element.
3
1
2
4
MFWA1BSH002201
Legend
1. Oil separator hose (OUT)
2. Oil separator hose (IN)
3. Oil separator
4. Oil drain hose
3
4
MFWA1BSH002201
Legend
1. Oil separator hose (OUT)
2. Oil separator hose (IN)
3. Oil separator
4. Oil drain hose
Reassembly
1. Element
• Install a new element.
2. Cap
• Fit an O-ring onto the cap and tighten the cap
securely.
Oil Pan
Component Parts
Shallow pan type
5
8
6
7
MFW71BLF001201
Legend
1. O-ring 5. Bracket
2. Oil strainer 6. Rubber
3. Gasket 7. Bracket
4. Oil pan 8. Rubber spacer

Deep pan type
6 3
MFW71BLF001501
Legend
1. O-ring 4. Bracket
2. Oil strainer 5. Rubber spacer
3. Oil pan 6. Bracket
1. Remove the rubber spacer. 1. Mount the O-ring in the oil strainer, and install it to
2. Remove the attachment bolt loosening bracket. the crankcase.
3. Remove the attachment bolt loosening rubber.
(shallow pan type only)
Tightening torque
5. Remove the oil pan gasket. (shallow pan type only)
6. Remove the oil strainer.

• Apply liquid gasket (ThreeBond 1207C) to the
oil pan flange with a thickness of approx. 1 to 2
mm (0.04 to 0.08 in), and a width of approx. 4 to
5 mm (0.16 to 0.2 in). (deep pan type)
NOTE:
• Clean the installation surface before applying
sealing agent.
• Assemble it within 5 minutes after applying the
sealing agent.
MFW41BSH004201
2. Install the oil pan gasket.

• Apply liquid gasket (ThreeBond 1207C) approx.
2 mm (0.08 in) thick and approx. 3 mm (0.12 in)
wide to the crankcase, flywheel housing and 1
gearcase joints.
• Line up the oil pan gasket with the stud, and
install it. (shallow pan type)
NOTE:
• Clean the mounting surfaces before applying the MFW71HSH000401
sealing compound.
Legend
• Install within 5 minutes of applying the sealing 1. Areas which you must remember to apply the
compound. agent to
• When the oil pan is installed, the P/S pipe

bracket (1) and A/C ⋅ Generator stay (2) be
1 tightening. (deep pan type)
2
3
1
MFW41BSH004301
Legend
1. Crankcase
2. Front gearcase
3. Flywheel housing
2
3. Install the oil pan. MFW61HSH000201

• Tightening procedure tightens others after
tightening at 1, 2, and 3, 4 points.
Oil pan
Tightening torque
Shallow pan type 11 N⋅m (1.1 kg⋅m/95 lb⋅in)
Deep pan type 24 N⋅m (2.4kg⋅m /17 lb⋅ft)
1 2
1 2
MFW61BSH001701
Legend
1. Oil pan
2. Flywheel housing
4 3
MFW61HSH000101
NOTE:
Check the tightness of the oil pan drain plug.
Drain plug
Tightening torque
78 N⋅m (8.0 kg⋅m/58 lb⋅ft)
4. Install the rubber. (shallow pan type)

• Install the rubber to the plate beforehand.
• Equally tighten it with the oil pan.
• Equally tighten it with the oil pan.
6. Install the rubber spacer.
• Line up the radius of the rubber spacer with the
oil pan cover and insert it, and fix the hole
sections on both sides to the protruding section
of the housing.

a b
c
e
d
MFW61BLF000501
(a) 24 N⋅m (2.4 kg⋅m / 17 lb⋅ft)

(b) 48 N⋅m (4.9 kg⋅m / 35 lb⋅ft)
(c) 78 N⋅m (8.0 kg⋅m / 58 lb⋅ft)
(d) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
(e) 11 N⋅m (1.1 kg⋅m / 95 lb⋅in) Shallow pan type
24 N⋅m (2.4 kg⋅m / 17 lb⋅ft) Deep pan type
Oil Pump
Component Parts
4
3
5
2
7
6
BLW71HLF000701
Legend
1. Oil pump body 5. Cotter pin
2. Oil relief valve 6. Driven gear
3. Spring 7. Drive gear
4. Spring seat
Removal 4. Remove the oil pan.

Refer to “Crankshaft” in the Engine Mechanical
section.
Refer to “Cylinder Head” in the Engine Mechanical
section.
2. Remove the air compressor.
Refer to “Air compressor” in Engine Exterior Parts.
3. Remove the supply pump assembly.
Refer to “Supply pump” in Engine Exterior Parts.

6. Remove idle gear A.
MFW41HSH000101
MFW41HSH002201
3. The oil pump body is a single unit.

7. Remove idle gear A shaft.
8. Remove the oil pump assembly.
Inspection
1. Measure the driven gear.
a. Measure the outer diameter of the driven gear
shaft and the gap between the shaft and
bushing.
Nominal Limitations for use

dimensions
Shaft outer 16 mm 15.9 mm
diameter (0.6299 in) (0.626 in)
Assembly standard
Gap between the shaft 0.04 – 0.07 mm
and bushing (0.0016 – 0.0028 in)
MFW41HSH002301
• Also measure the outer diameter and gap

for the drive gear side.
Disassembly
1. Remove the driven gear. NOTE:
Measure the bushing inner diameter on the cylinder
2. Remove the oil relief valve. body side in the same way.
• Remove the cotter pin, then extract the spring
seat, spring, and oil relief valve in order.
NOTE:
When the cotter pin is removed, the spring seat and
spring will spring out, so make sure you do not lose
them.

3. Inspect the oil relief valve and spring for damage.
MFW41HSH000301
MFW41HSH000601
Legend
b. Measure the gap between the oil pump body 1. Oil relief valve
and gear tooth tip. 2. Spring
Assembly standard
0.125 – 0.221 mm 4. Inspect the oil pump body for damage.
Gap
(0.0049 – 0.0087 in)
Reassembly
• Also measure the gap on the drive gear side
1. Set the oil pump body assembly.
in the same way.
2. Install the oil relief valve.
• Insert the oil relief valve, spring, and spring
seat, in that order, and secure them with a
cotter pin.
3. Install the driven gear.
• Apply oil to the driven gear, and install it to the
pump body.
NOTE:
• Be careful not to drop the driven gear.
• Turn it with your hand to confirm that there are no
abnormalities.
• Install the driven gear so that the stepped surface
on the side of the driven gear is touching the
cylinder block.
MFW41HSH000401
2. Inspect the spring seat for damage.


NOTE:
• Install within 5 minutes of applying the sealing
compound.
• Do not allow liquid gasket to get onto the gears or
arrow section hole.
• Make sure the driven gear does not fall out.
MFW41HSH000901
Installation
Completely remove the gasket from the flywheel
housing and cylinder block mounting surfaces.
1. Install the oil pump.
MFW41BSH005201
• Apply oil to the oil pump gear insertion section.
• Remove any liquid gasket that has overflowed
from the oil pump mounting surface, and apply
oil to the crankcase and cylinder block bushing. • Line up the dowel and install the oil pump.
NOTE:
Do not allow oil to get onto the oil pump mounting Tightening torque
surface. 24 N⋅m (2.4 kg⋅m/17 lb⋅ft)
NOTE:
• There are no alignment marks on the gears.
• Install the oil pump before installing idle gear A.
MFW41BSH005101
• Apply liquid gasket (ThreeBond 1201 and

1207C) to the oil pump mounting surface as
MFW41BSH005301
shown in the diagram.

2. Install idle gear A shaft and idle gear A. 6. Install the air compressor.
• Apply oil to the gear inner circumference Refer to “Air compressor” in Engine Exterior Parts.
section and thrust section.
• Insert the gear into the shaft, and fit in the
collar. Refer to “Cylinder Head” in the Engine Mechanical
section.
NOTE:
Rotate the crankshaft and set the #1 cylinder to the top
dead point.
• Line up the shaft knock pin and cylinder block

knock hole, and also line up the crank gear “L”
mark with the idle gear A “O” mark, and install
them.
• Apply molybdenum-disulfide paste to the
threaded section and seating section of the
bolts and the washer, and tighten them.
Tightening torque
134 N⋅m (13.6 kg⋅m/98.4 lb⋅ft)
MFW61BSH001801
Legend
1. Crank gear
2. Idle gear A
NOTE:
• After installing, re-check that the marks are in line.
• After installing the flywheel housing, tighten the idle
gear A shaft using 3 bolts.

Refer to “Crankshaft” in the Engine Mechanical section.
5. Install the supply pump assembly.
Refer to “Supply pump” in Engine Exterior Parts.
MEMO
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ENGINE
Engine Speed Control System
(6HK1)
TABLE OF CONTENTS
Accelerator Control Assembly . . . . . . . . . . . . . . . . 1I-2
Component Parts . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1I-3
Accelerator Control Assembly

Component Parts
1
4
MFW71IMF000201
Legend
1. Bolt 4. Pedal
2. Control link and bracket assembly 5. Pedal stopper bolt
3. Accelerator position sensor
Removal 2. Remove the control link and bracket assembly

installation nut.
NOTE:
When removing the harness connector, remove the
battery earth.
MFWB1ISH000101

3. Remove the accelerator pedal installation bolts. Installation
4. Remove the harness connector to the Accelerator 1. Install the Accelerator Pedal Position (APP) sensor
Pedal Position (APP) sensor. to the control link and bracket assembly.
5. Remove the Accelerator Pedal Position (APP)
sensor from the control link and bracket assembly.
LNW71FSH002501
LNW71FSH002401
LNW71FSH002401
2. Connect the Accelerator Pedal Position (APP)

LNW71FSH002501
3. Install the accelerator pedal installation bolt.
4. Install the control link and bracket assembly.
Tightening torque
20 N⋅m (2.0 kg⋅m/14 lb⋅ft)
MFWB1ISH000101
5. After installing the pedal, check that the gap (a) is

at the specified value when the pedal is fully
depressed.
Gap (a) [reference value]: 1.0 mm (0.039 in)
• If it needs adjustment, loosen the nut (2), turn
the bolt (1) to adjust, and then fix the nut (2).
1
2
a
MFWB1ISH000201
ENGINE
Induction
(6HK1)
TABLE OF CONTENTS
Supercharging System. . . . . . . . . . . . . . . . . . . . . .1J-2
Precautions for Servicing . . . . . . . . . . . . . . . . . .1J-2
Explanation of Functions and Operations . . . . . .1J-2
Failure Phenomenon List . . . . . . . . . . . . . . . . . .1J-3
Phenomenon: If there is a fault or vibration . . . .1J-4
Phenomenon: If the turbocharger is thought
to be generally normal but the output is low . . . .1J-5
Phenomenon: Oil leak in the exhaust pipe or
intake pipe, and the exhaust gas color is white. .1J-6
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-7
Component Parts . . . . . . . . . . . . . . . . . . . . . . . .1J-7
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-7
Intercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-9
Component Parts . . . . . . . . . . . . . . . . . . . . . . . .1J-9
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-9
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-10
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-10
Air Cleaner Element . . . . . . . . . . . . . . . . . . . . . . .1J-11
Component Parts . . . . . . . . . . . . . . . . . . . . . . .1J-11
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-11
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-14
MAF (Mass Air Flow) Sensor . . . . . . . . . . . . . . . .1J-15
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1J-15
Supercharging System
Precautions for Servicing • When performing maintenance work, you should
aim to completely prevent any dust or debris from
• The turbocharger is designed to rotate at high
entering these parts.
speed (approx. 100,000 r/min), therefore if the fin,
housing, or other parts are damaged or bent just a CAUTION:
small amount, or if other faults are discovered, In order not to cause malfunction or trouble, do not
replace the turbocharger assembly. loosen the bolts and nuts of the turbocharger assembly,
or disassembly or remove the components of
turbocharger assembly.
1
2
3
8
7
6 5
MFW61JLF000101
Legend
1. Actuator 5. Center housing assembly
2. Oil inlet 6. Oil outlet
3. Rod end assembly 7. Compressor housing assembly
4. Turbine housing assembly 8. Connector

• If there is a fault or vibration
• If the turbocharger is thought to be generally
normal but the output is low
• Oil leak in the exhaust pipe or intake pipe, and the
exhaust gas color is white

Phenomenon: If there is a fault or vibration

If there is a fault or vibration Caused by a damaged bearing or Replace
contact between the rotating section
and its periphery Neglecting to change
the oil, debris entering the oil supply
pipes, blocked oil filter or driving
If there are no abnormalities in the Replace
lubrication system, and damage is
found to be caused by contact between
the rotating section and its periphery, it
is probably caused by poor balance in
the rotating section, or a bent shaft This
is because a worn bearing is being
used, or because debris has flown
inside and damaged the turbine wheel
or compressor wheel

Phenomenon: If the turbocharger is thought to be generally normal but the output is low

If the turbocharger is thought to be Gas leak from various parts of the Repair or replace
generally normal but the output is low exhaust
Carbon deposits or distortion in the Repair or replace
exhaust pipe silencer etc. can cause
excessive exhaust resistance
Air leak from the compressor output Clean or replace
side, dirty air cleaner
Compressor interior dirty Clean

Phenomenon: Oil leak in the exhaust pipe or intake pipe, and the exhaust gas color is white

Oil leak in the exhaust pipe or intake Dirty air cleaner, oil leak due to Clean or replace
pipe blockage
The exhaust gas color becomes white Blocked, crushed, or deformed drain oil Repair or replace
pipe
Wear or damage in the turbine shaft Repair or replace
section
Close type PCV; blocked air breather Clean or replace
Closed type PCV; Oil suction in the Repair or replace
turbocharger compressor side due to a
faulty air breather slinger
Turbocharger
Component Parts
1
2
3
8
7
6 5
MFW61JLF000101
Legend
1. Actuator 5. Center housing assembly
2. Oil inlet 6. Oil outlet
3. Rod end assembly 7. Compressor housing assembly
4. Turbine housing assembly 8. Connector
Inspection NOTE:
It is not a malfunction if oil is adhering to the
Inspect each part of the turbocharger, and only
compressor port inner surface. The engine blow-by gas
exchange it if an abnormality is found.
is returned to the compressor inlet, so the oil content
that is slightly contained in the blow-by gas may adhere
to the inner wall of the compressor inlet and outlet, but
this is not a failure of the turbocharger.

A. External inspection of each part
1. Perform a visual inspection on each of the parts for
cracks, interference, damage, distortion, oil leaks
from the seal section, gas leaks etc.
2. Rotate the turbine shaft by hand to see if it rotates
smoothly, and at the same time inspect the turbine
shaft play in the axial direction and rotational
direction.
B. Turbine shaft play measurement

1. Turbine shaft axial direction measurement.
• Set the dial gauge in the turbine shaft axial
direction, and adjust the gauge to zero.
• Move the turbine shaft forwards and
backwards, and read off the axial direction play.
The clearance should be within the table below.
BLW71JSH001001
Axial direction clearance

0.043 –0.094 mm
6HK1-TCN, TCC, TCS
(0.0017 – 0.0037 in)
BLW71JSH001101
2. Turbine shaft diameter direction measurement.

• Set the dial gauge including offset pin into the
turbine shaft, and adjust the gauge to zero.
• Move the turbine shaft up and down, and read
off the diameter direction play. The clearance
should be within the table below.
Diameter direction clearance

0.086 – 0.140 mm
6HK1-TCN, TCC, TCS
(0.0034 – 0.0055 in)
NOTE:
If the turbine shaft play is outside the specified value,
and if a malfunction is discovered in the center housing
assembly, replace the turbocharger assembly.
Intercooler
Component Parts
4
3
7 6
10
MFW71JLF000201
Legend
1. Intercooler 6. Radiator hose (lower)
2. Rubber hose (IN side) 7. Drain cock
3. Nuts 8. Radiator stay
4. Radiator assembly 9. Rubber hose (OUT side)
5. Radiator hose (upper) 10. Bolts
Removal Inspection
1. Remove the radiator assembly. 1. A distorted intercooler fin may lead to a reduction
in heat dissipation effectiveness, which may in turn
Refer to “Radiator” in Engine Cooling.
cause reduced engine performance.
2. Remove the 4 intercooler fixing bolts from the Therefore, the fin must be repaired. Take care not
radiator assembly and remove the intercooler. to damage the joint section of the fin when
repairing it.
2. Inspect inside the intercooler for dirt. Clean it if it is
particularly dirty.

Cleaning Installation
Washing the intercooler core 1. Install the intercooler to the radiator.
CAUTION:
Tightening torque
radiator, intercooler and surrounding parts when they
are still installed on the vehicle. 19.1 N⋅m (1.95 kg⋅m/14 lb⋅ft)
1. Seal the hose connecting section with a cap or 2. Install the radiator assembly.
fabric tape.
Refer to “Radiator” in Engine Cooling.
intercooler.
• Adhering matter which easily comes off with a
NOTE:
Do not use a high-pressure washer or brush.

NOTE:
corrosion.

washer.
• Start washing from the engine side of the
intercooler.
NOTE:
• Apply the high-pressure water in a direction
perpendicular to the fins.
• Do not bring the high-pressure water too close to
the fins.
6. After washing is finished, inspect the fins to

• If washing is not sufficient, wash them again.
NOTE:
the fins can be seen.
7. Rinse off the detergent constituents on the fins and

sufficiently.
Air Cleaner Element

Component Parts
1 2 3 4
7 6
MFW81JMF000101
Legend
1. Body assembly 5. Match mark
2. Outer element 6. Inner element
3. Wire clamp 7. Water drain valve
4. Air cleaner cover
Removal
1. Tilt the cab.
2. Remove the air cleaner cover.
• Remove the clamps (1) at 4 locations by
pressing them inside to remove the air cleaner
cover (2).

•
2
2
MFW81JSH000201
Legend
1. Air cleaner assembly
2. MAF (Mass Air Flow) sensor
2. Inspect the air cleaner.

• Inspect the element on a regular basis or when
the air cleaner warning light turns on.
3. Clean the element.
MFWB1JMH000101
• When it is dirty with dry dust, etc., clean it by
3. Remove the element. blowing the compressed air to it.
• Do not remove the inner element when the • Blow the compressed air from inside the
outer element is cleaned. element while rotating the element.
• Never clean the inner element. Replace the
NOTE:
inner element at the same time of replacing the
Do not hit or strike the element to clean.
outer element.
Do not exceed an air pressure of 690 kPa (7.0 kgf/cm2
NOTE: / 100 psi).
• Make sure to use a genuine dry type element
because an MAF sensor is used.
Do not use a wet type element because it may make
the sensor dirty.
• Use a genuine air cleaner element.
If other element is used, it may cause the sensor to
output a wrong signal.
Inspection
1. Inspection for MAF (Mass Air Flow) sensor.
Refer to Section 1A, “Engine Control System” for
MAF sensor inspection and replacement.
NOTE:
Do not touch the sensing section of the sensor with
hand because it is heated to 170 to 300 °C (338 to
572°F) when the sensor is turning on electricity. HCW310SH000101

• When blackened by oily smoke such as soot. 5. Inspect the water drain valve (1) at the lower side
Dissolve a mild detergent in water and soak the of the air cleaner for clogging.
element for approximately 30 minutes. Moreover, it checks whether the adhesion of water
Then rinse the element well with running tap drain valve is good.
water, etc.
After washing the element, allow it to dry
naturally without using flames (for two to three
days).
Do not exceed a water pressure of 275 kPa (2.8
kgf/cm2 / 40 psi).
1
MFW71JSH002201
HCW31BSH057501
4. Inspect the element for breakage or damage.

• Place a light in the element to inspect the
element for damage or pin hole, and inspect the
seal section for breakage.
NOTE:
• Make sure to replace the element if there is an
abnormality found.
• Replace the element after using it for 12 months or
after washing it 6 times, whichever is earlier, and
when it is damaged.
HCW31BSH057601

Installation
1. Install the element.
2. Install the air cleaner cover.
• Face the “ISUZU” mark on the cover upward
and engage the concave and convex sections
(3) at the left side of the cover.
• Hook the wire clams to the body assembly (1)
at 4 locations, and pull it towards you to install
the air cleaner cover (2).
1
2
3
MFW71JMH000401
MAF (Mass Air Flow) Sensor

Removal
3. Remove the MAF (Mass Air Flow) sensor.
MFW81JSH000101
Installation
1. Install the MAF (Mass Air Flow) sensor.
Tightening torque
1.5 N⋅m (0.15 kg⋅m/13 lb⋅in)
2. Install the harness connector.

MEMO
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ENGINE
Pre-Heating System
(6HK1)
TABLE OF CONTENTS
Pre-Heating System . . . . . . . . . . . . . . . . . . . . . . . 1K-2
Maintenance Precautions . . . . . . . . . . . . . . . . . 1K-2
Description of Functions and Operation . . . . . . 1K-2
Functional Inspection . . . . . . . . . . . . . . . . . . . . 1K-3
List of Trouble Symptoms . . . . . . . . . . . . . . . . . 1K-5
Symptom: Glow indicator lamp does not turn on1K-6
Symptom: Preheating does not work . . . . . . . . 1K-7
Symptom: Preheating period is either too long
or too short . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1K-8
Main Specifications . . . . . . . . . . . . . . . . . . . . . . 1K-8
Pre-Heating System
Over tightening glow plugs can cause damage to them.
Description of Functions and Operation

The QOS II system has been adopted for the pre-
heating system. Also, the electricity supply controls are
performed by the ECM.

Functional Inspection
Inspection and correction of QOS II • If the results of the measurement show that the
1. System inspection. resistance value is outside specifications,
replace the glow relay.
• Disconnect the of the engine coolant
Glow relay resistance value :
temperature sensor (1) connector.
approximately 51.5Ω
4 1
4 3
1
2 2 1
3
MFW61KSH000201
HCW31KSH000101
• Connect a voltmeter between the glow plug and
• Glow relay (1) attachment location :
engine ground.
Chassis relay box(fix the left side of cab
• Turn the ignition switch to ON (without starting mounting).
engine) and check for the following items.
- The glow indicator turns on for 3.5 seconds.
- The voltmeter indicates the power supply
voltage for approximately 18 seconds.
• If there are any abnormalities with the
inspection, inspect the glow relay, water thermo
sensor and the glow plugs. If normal, inspect 1
the engine control system.
MFW81ESH000101
3. Inspect the engine coolant temperature sensor.

• Place the sensor part of engine coolant
temperature sensor into water, and check that
the resistance value changes as shown in the
graph when the water temperature is changed.
HCW31KSH000201 NOTE:
Be careful not to allow water in the terminal section.
2. Inspection of the glow relay.
Also, wipe off the water droplets on the sensor after the
• Using a circuit tester, measure the resistance inspection.
value (between 1 and 2) of the glow relay.

4. Inspection of the glow plug.
• Measure the resistance value of the glow plugs
using a circuit tester.
• If the results of the measurement show that the
resistance value is outside specifications,
replace the glow plug.
Glow plug resistance value :

approximately 6.0Ω (normal temperature)
NOTE:
Use a 6-piece set of genuine glow plugs.
MFW71KSH000201
Resistance value at a certain temperature

(approximate value)
Remarks Resistance value
– 20°C (– 4°F) Approx 15.48 kΩ
0°C (32°F) Approx. 5.79 kΩ
20°C (68°F) Approx. 2.45 kΩ
40°C (104°F) Approx. 1.15 kΩ
60°C (140°F) Approx. 0.59 kΩ
80°C (176°F) Approx. 0.32 kΩ MFW61KSH000401
100°C (212°F) Approx. 0.19 kΩ
Thermistor characteristic
30
20
10
7.0
)
5.0
Resistance value(k
3.0
2.0
1.0
0.7
0.5
0.3
0.2
0.1
-20 0 20 40 60 80 100 120
MFW81CSH000901

List of Trouble Symptoms
• Glow indicator lamp does not turn on
• Preheating does not work
• Preheating period is either too long or too short

Symptom: Glow indicator lamp does not turn on

Glow indicator lamp does not turn on. Slow blow fuse melts Replace the slow blow fuse
Fuse blows Replace the fuse
Burnout of indicator valve Replace the indicator valve

Symptom: Preheating does not work

Preheating does not work. Slow blow fuse melts Replace the slow blow fuse
Connection failure of the glow relay Re-install or replace the glow relay
connector

Symptom: Preheating period is either too long or too short

Preheating period is either too long or Thermo-switch failure or open or short Replace the thermo-switch. Repair the
too short. in the circuit circuit
Glow plug failure Replace or tighten the glow plug
Main Specifications
Item Model
Model with pre-heater Glow plug QOS timer
Glow plug rated voltage and current 20.5V - 4.6A
ENGINE
Power Take-Off (PTO)
(6HK1)
TABLE OF CONTENTS
Flywheel PTO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-2
Functional and Operational Description . . . . . . 1L-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-3
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-6
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-7
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 1L-8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1L-11
Tightening Torque Table . . . . . . . . . . . . . . . . . 1L-15
Flywheel PTO
Functional and Operational Description
The PTO crank gear is added to the end of the
crankshaft, and the flywheel PTO is tightened to the
crankshaft together with the flywheel.
Motive energy is outputted from the PTO gear located
in the upper section of the flywheel housing, from the
PTO crank gear via the idle gear. There is no
mechanism for turning the motive power ON/ OFF
partway; motive power is output by direct coupling to
the engine, regardless of the clutch and transmission
being ON/OFF.

Components
3 4
2
5
1
6
14
10
13
11
12
MFW71LLF000401
Legend
1. Front bearing 8. Idle gear
2. PTO gear 9. Idle gear shaft
3. O-ring 10. Idle gear bearing
4. Bearing case 11. PTO crankshaft gear
5. Rear bearing 12. Flywheel housing (PTO specifications)
6. PTO shaft 13. Crankshaft
7. Oil seal 14. Idle gear A

Removal
Removal of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000701
Legend
1. Flywheel housing (PTO specifications) 12. Idle gear cover
11. Nut
1. Remove the oil pipe of the PTO gear section. • Loosen the assembly case tightening bolt, and
• Remove the clip. remove the O-ring, oil seal, rear bearing, PTO
gear, front bearing inner race in an assembled
2. Remove the PTO assembly.
state.

Removal of the PTO idle gear assembly
2 3
1 2
1
4
6
3
10
MFW71LMH000101
9
Legend MFW71LMH000501
1. PTO gear assembly Legend

2. Oil pipe 1. Idle gear A
3. Idle gear cover 2. Bearing (front)
3. Idle gear
4. Bearing (rear)
5. Lock washer
6. Shaft
7. Bolt
Removal of the PTO crank shaft gear assembly
8. Nut
1. Remove the transmission. 9. Inner spacer
• Refer to "Transmission ASM" in Section 5C, 10. Thrust collar
Manual Transmission (MLD) or "Transmission
ASM" in Section 5C, Manual Transmission
(MZW).
• Refer to "Timing Gears, Flywheel, and Flywheel
Housing" in Section 1B, Engine Mechanical.
• Refer to "Timing Gears, Flywheel, and Flywheel
4. Remove the PTO crankshaft gear.

1. Remove the idle gear cover (1).
Use 2 replacer holes (M10 / 1.5) (2) to remove it.
1 1
2 3
2 4
5
6
7
8
9
10
11
MFW71LSH000201
Legend
MFW71LSH000101
1. Front bearing
2. PTO gear
3. PTO shaft
2. Remove the flywheel housing. 4. Rear bearing
3. Loosen the idle gear shaft bolt. 5. Oil thrower
4. Remove with the shaft and idle gear assembly in 6. O-ring
one piece. 7. Bearing case
8. Oil seal
9. Flange
Disassembly 10. O-ring
11. Nut
Disassembly of the PTO gear assembly
1. Remove the O-ring from the bearing case.
2. Remove the PTO gear assembly from the bearing Disassembly of the PTO idle gear assembly
case. 1. Remove the bearing tightening nut to remove the
3. Remove the oil seal from the bearing case. lock washer.
4. Remove the front bearing and rear bearing from 2. Use the press to pull the shaft out from the idle
the PTO gear assembly. gear assembly, then remove the inner bearing.
3. Remove the outer races (both front and back) from
the idle gear.
4. Remove the inner spacer (shim) and the outer
spacer (snap ring) from the idle gear.
1
2
3
4
5
6
7
8
MFW71LSH001101 MFW41LSH000201
Legend 2. Inspect the PTO gear.

1. Shaft • Inspect the gear tooth surfaces for damage and
2. Idle gear wear.
3. Front bearing
3. Inspect the idle gear bearing.
4. Inner spacer
5. Outer spacer • Inspect the bearing for peeling, wear and
6. Rear bearing abnormal sounds.
7. Lock washer • Inspect the entire circumference from between
8. Nut the roller and ball bearing cage to the inner race
• Inspect the roller and ball bearing cage for any
Inspection abnormal looseness caused by wear.
1. Inspect the PTO bearing. • Rotate the bearing to manually inspect for
• Inspect the bearing for peeling, wear and irregularities in movement.
abnormal sounds.
• Inspect the entire circumference from between
the roller and ball bearing cage to the inner race
• Inspect the roller bearing cage for looseness
caused by wear.
• Rotate the bearing to manually inspect for
irregularities (such as bumpiness) in
movement.
MFW41LSH000301
4. Inspect the idle gear.

• Inspect the gear tooth surface for wear and
damage, and the inner circumference for
damage.

• Firmly fit by pushing the inner race.
NOTE:
There should be no gaps between the bearing end
surface and shaft surface.
3. Install the O-ring to the bearing case and firmly fit

the rear bearing.
NOTE:
• Apply engine oil to the ball area before firmly fitting
the rear bearing.
• There should be no gaps between the bearing end
surface and case surface.
4. Firmly fit the PTO gear assembled at Procedure 2.

5. Press the oil thrower all the way in until it touches
MFW41LSH000501
the rear bearing.
6. Apply engine oil to the lip area of the oil seal, and
Reassembly use oil seal installer (9-8522-1310-0) to fit it firmly
Reassembly of the PTO gear assembly
7. Insert and fasten the O-ring with a nut after
assembling the flange to the PTO shaft.
Tightening torque
1
2 3 480 N⋅m (48.9 kg⋅m/353.7 lb⋅ft)
4
5
6
7 Reassembly of the PTO idle gear
8
9
10
11
1
2
3
4
5
MFW71LSH000201 6
7
Legend 8
1. Front bearing
2. PTO gear
3. PTO shaft
4. Rear bearing
5. Oil thrower
6. O-ring
7. Bearing case MFW71LSH001101
8. Oil seal Legend

9. Flange 1. Shaft
10. O-ring 2. Idle gear
11. Nut 3. Front bearing
4. Inner spacer
5. Outer spacer
6. Rear bearing
1. Firmly fit the PTO gear into the PTO shaft. 7. Lock washer
• Bake fit at below 250 °C (482°F). 8. Nut
2. Firmly fit the front bearing into the PTO shaft.

a. Measure the gap in the idle gear bearing axis
1. Use the snap ring pliers to insert the outer spacer direction. Assemble the inner race of the idle
(snap ring) into the idle gear. gear bearing without the inner spacer, and
direction on a level block.
MFW41LSH000601
LNW71LSH001001
2. Fit the outer race of the tapered roller bearing

firmly into the outer space until they touch.
b. Next, assemble the inner spacer (2) and
direction in the same way.
LNW71LSH000201
LNW71LSH001101
3. Select the inner spacer.
• Select spacers so that the measurements

above satisfy 0 mm (0 in) < (3) - (1) < 0.07
mm (0.0028 in).
• Note that there are 21 spacer sizes in
increments of 0.07 mm (0.0028 in), ranging
from 6.05 (0.2382 in) to 7.45 mm (0.2933
in).
4. Install the front side inner race to the shaft.

NOTE:
5. Install the PTO idle gear.
MFW71LSH000801
8. Tighten the nut (2) via the lock washer (1).

MFW71LSH000601
Tightening torque
6. Install the inner spacer (1). 196 N⋅m (20 kg⋅m/145 lb⋅ft)
• After tightening the nut, measure the clearance

in the PTO idle gear axis direction.
- If the clearance is not within specifications,
1 replace the spacer and readjust it.
0 – 0.05 mm
Clearance in the axis direction
(0 – 0.002 in)
Friction starting torque

0.2 N⋅m (0.02 kg⋅m / 1.74 lb⋅in)
NOTE:
MFW71LSH000701 • Apply engine oil to the bearing for assembly.
• The clearance value in the direction of the axis is
important. Make adjustments so that it always falls
7. Install the rear side inner race (1). within the specified range.
• After tightening, bend the lock washer to fasten the
NOTE: nut.

Installation
Installation of the PTO idle gear assembly
2 3
1
1
4
6
2
MFW71LSH000301
10
9
MFW71LMH000501
Legend
1. Idle gear A
2. Bearing (front)
3. Idle gear
4. Bearing (rear)
5. Lock washer
6. Shaft
7. Bolt
8. Nut
9. Inner spacer
10. Thrust collar
1. Install the idle gear assembly.

• The idle gear A and crank gear should be
aligned.
NOTE:
• The idle gear assembly should be securely installed
to the cylinder block installation section.
• Apply engine oil to the bearing just before
installation.
• Apply engine oil to the inner circumference of the
bushing and the thrust contact surface of idle gear
A.
• Take sufficient care to ensure that the thrust collar
does not come off.

2. Apply molybdenum disulfide to the bolt seat
surface and thread section, then tighten it at the 1
specified torque.
Tightening torque
98 N⋅m (10 kg⋅m/72 lb⋅ft) →
angle method 60° to 90°
• Confirm that the bolt is tightened at 156.8 N⋅m

(16 kg⋅m / 116 lb⋅ft) or more in the tightening
direction.
3. Install the flywheel housing. 2
• Refer to "Timing Gear, Flywheel, and Flywheel
4. Install the idle gear cover.
• Apply a thin layer of grease to the O-ring (1) to
install it.
• Apply liquid gasket (ThreeBond 1207C) to
seven places on the flange surface (2) and the
bolt seat surface (3).
• Tighten the bolt at the specified torque.
3
Tightening torque N⋅m (kg⋅m / lb⋅ft)
4
40 N⋅m (4.1 kg⋅m/30 lb⋅ft) MFW71LMH000301
NOTE: Installation of the PTO crank shaft gear assembly

After firmly fitting it in, do not hammer the cover section 1. Position the crankshaft gear to the crankshaft
(4). knock pin, then tap with a rubber hammer to set it.
2. Install the oil seal retainer.
• Apply liquid gasket (ThreeBond 1207C) when
installing the part.
3. Install the slinger oil seal set to between the crank
shaft gear and oil seal retainer.
5. Install the transmission.
• Refer to "Transmission ASM" in Section 5C,
Manual Transmission (MLD) or "Transmission
ASM" in Section 5C, Manual Transmission
(MZW).

Installation of the PTO assembly
2
3
4
5
6
7
8
9
1 10
11
21
20
19 18
17
16
15 14
13
12
MFW71LLF000701
Legend
1. Flywheel housing (PTO specifications) 12. Idle gear cover
11. Nut
1. Apply a thin layer of engine oil to the O-ring and 3. Install the PTO assembly to the flywheel housing
install to the bearing case. and tighten the bearing case at the specified
2. Firmly fit the front bearing outer into the gearcase. torque.
• Apply engine oil to the ball part of the bearing
before firmly fitting it in.
Tightening torque
42 N⋅m (4.3 kg⋅m/31 lb⋅ft)

4. Install the oil pipe of the PTO gear unit.
• Install the clip.
• Tighten the oil pipe and clip at the specified
torque.
Tightening torque
(1) 27.5 N⋅m (2.8 kg⋅m/20 lb⋅ft)
(2) 8.8 N⋅m (0.9 kg⋅m/78 lb⋅in)
(3) 23.5 N⋅m (2.4 kg⋅m/17 lb⋅ft)
(4) 41.2 N⋅m (4.2 kg⋅m/30 lb⋅ft)
2
1
MFW71LSH001201

e d
MFW71LLF000301
(a) 42 N⋅m (4.3 kg⋅m / 31 lb⋅ft)

(b) 480 N⋅m (48.9 kg⋅m / 353.7 lb⋅ft)
(c) 98 N⋅m (10 kg⋅m / 72 lb⋅ft) → Angle method 60° to 90°
(d) 196 N⋅m (20 kg⋅m / 145 lb⋅ft)
(e) 40 N⋅m (4.1 kg⋅m / 30 lb⋅ft)
MEMO
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First Edition
WORKSHOP MANUAL
ENGINE
(6HK1 model)
0-XXXKI
2011MY
2011MY

WORKSHOP MANUAL
ENGINE
(6HK1 model)
No.MG6HK-WE-1101AU
2011MY
2011MY
WORKSHOP MANUAL ENGINE CONTROL SYSTEM (6HK1 model)

WORKSHOP MANUAL
ENGINE CONTROL SYSTEM

(6HK1 model)
No.MG6HKED-WE-1101AU
MG6HKED-WE-1101AU_67015_前書 2010.11.5 3:30 PM ページ 1
Section Sub Section
1C Engine Cooling
1D Engine Fuel
1F Emission Control
1G Engine Exhaust
1J Induction
2B Front Suspension
2C Rear Suspension
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4D Parking Brake
5E Clutch
9C Entertainment
9D Wiring System
9F Body Structure
9G Cab
9H Seats
9L Cab Mounting
MG6HKED-WE-1101AU.book 1 ページ２０１０年１１月２５日　木曜日　午前１０時４３分
Engine Control System (6HK1) 1A-1
ENGINE
(6HK1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 DTC P0335 (Flash Code 15). . . . . . . . . . . . . 1A-138
Temperature vs. Resistance . . . . . . . . . . . . . . . 1A-3 DTC P0336 (Flash Code 15). . . . . . . . . . . . . 1A-141
Altitude vs. Barometric Pressure. . . . . . . . . . . . 1A-4 DTC P0340 (Flash Code 14). . . . . . . . . . . . . 1A-143
Diagnostic Trouble Code (DTC) Type DTC P0341 (Flash Code 14). . . . . . . . . . . . . 1A-146
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 DTC P0380 (Flash Code 66). . . . . . . . . . . . . 1A-148
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6 DTC P0381 (Flash Code 67). . . . . . . . . . . . . 1A-150
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0401 (Flash Code 93). . . . . . . . . . . . . 1A-153
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0404 (Flash Code 45). . . . . . . . . . . . . 1A-155
Routing Diagrams . . . . . . . . . . . . . . . . . . . . . . . 1A-11 DTC P0409 (Flash Code 44). . . . . . . . . . . . . 1A-158
Fuel System Routing Diagram . . . . . . . . . . . . 1A-11 DTC P0426 (Flash Code 143). . . . . . . . . . . . 1A-161
Component Locator . . . . . . . . . . . . . . . . . . . . . . 1A-12 DTC P0427 or P0428 (Flash Code 48) . . . . . 1A-163
Engine Controls Component Views . . . . . . . . 1A-12 DTC P042B (Flash Code 145) . . . . . . . . . . . 1A-167
Engine Control Module (ECM) Connector DTC P042C or P042D (Flash Code 49) . . . . 1A-169
End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-18 DTC P0477 or P0478 (Flash Code 46) . . . . . 1A-173
Engine Control Connector End Views. . . . . . . 1A-20 DTC P0500 (Flash Code 25). . . . . . . . . . . . . 1A-176
Diagnostic Information and Procedures . . . . . . . 1A-31 DTC P0502 or P0503 (Flash Code 25) . . . . . 1A-179
Engine Control System Check Sheet . . . . . . . 1A-31 DTC P0560 (Flash Code 155). . . . . . . . . . . . 1A-184
Diagnostic Starting Point - Engine Controls . . 1A-32 DTC P0563 (Flash Code 35). . . . . . . . . . . . . 1A-187
Diagnostic System Check - Engine Controls . 1A-33 DTC P0571 (Flash Code 26). . . . . . . . . . . . . 1A-188
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-36 DTC P0601 (Flash Code 53). . . . . . . . . . . . . 1A-191
Scan Tool Data Definitions . . . . . . . . . . . . . . . 1A-40 DTC P0602 (Flash Code 154). . . . . . . . . . . . 1A-192
Scan Tool Output Controls . . . . . . . . . . . . . . . 1A-46 DTC P0604, P0606 or P060B
Scan Tool Does Not Power Up . . . . . . . . . . . . 1A-47 (Flash Code 153, 51 or 36) . . . . . . . . . . . . . . 1A-194
Scan Tool Does Not Communicate with DTC P0633 (Flash Code 176). . . . . . . . . . . . 1A-195
CAN Device. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-48 DTC P0638 (Flash Code 61). . . . . . . . . . . . . 1A-196
Engine Cranks but Does Not Run . . . . . . . . . . 1A-51 DTC P0641 (Flash Code 55). . . . . . . . . . . . . 1A-199
DTC P0016 (Flash Code 16). . . . . . . . . . . . . . 1A-54 DTC P0650 (Flash Code 77). . . . . . . . . . . . . 1A-202
DTC P0079 or P0080 (Flash Code 38) . . . . . . 1A-58 DTC P0685 or P0687 (Flash Code 416) . . . . 1A-208
DTC P0087 (Flash Code 225). . . . . . . . . . . . . 1A-61 DTC P0697 (Flash Code 57). . . . . . . . . . . . . 1A-211
DTC P0088 (Flash Code 118). . . . . . . . . . . . . 1A-66 DTC P0700 (Flash Code 185). . . . . . . . . . . . 1A-214
DTC P0091 or P0092 (Flash Code 247) . . . . . 1A-73 DTC P1261 or P1262 (Flash Code 34) . . . . . 1A-220
DTC P0101 (Flash Code 92). . . . . . . . . . . . . . 1A-81 DTC P1455 (Flash Code 132). . . . . . . . . . . . 1A-223
DTC P0102 or P0103 (Flash Code 91) . . . . . . 1A-84 DTC P1471 (Flash Code 149). . . . . . . . . . . . 1A-225
DTC P0112 or P0113 (Flash Code 22) . . . . . . 1A-88 DTC P161B (Flash Code 179) . . . . . . . . . . . 1A-228
DTC P0116 (Flash Code 23) . . . . . . . . . . . . . . 1A-92 DTC P1621 (Flash Code 54). . . . . . . . . . . . . 1A-229
DTC P0117 or P0118 (Flash Code 23) . . . . . . 1A-94 DTC P1664 (Flash Code 76). . . . . . . . . . . . . 1A-230
DTC P0182 or P0183 (Flash Code 211) . . . . 1A-102 DTC P2002 (Flash Code 127). . . . . . . . . . . . 1A-238
DTC P0192 or P0193 (Flash Code 245) . . . . 1A-106 DTC P2122 or P2123 (Flash Code 121) . . . . 1A-241
DTC P0201, P0202, P0203, P0204, DTC P2127 or P2128 (Flash Code 122) . . . . 1A-245
P0205 or P0206 (Flash Code 271, 272, DTC P2138 (Flash Code 124). . . . . . . . . . . . 1A-249
273, 274, 275 or 276) . . . . . . . . . . . . . . . . . . 1A-110 DTC P2146 or P2149
DTC P0217 (Flash Code 542). . . . . . . . . . . . 1A-123 (Flash Code 158 or 159) . . . . . . . . . . . . . . . . 1A-251
DTC P0219 (Flash Code 543). . . . . . . . . . . . 1A-125 DTC P215A (Flash Code 25) . . . . . . . . . . . . 1A-257
DTC P0299 (Flash Code 65). . . . . . . . . . . . . 1A-135 DTC P242F (Flash Code 131) . . . . . . . . . . . 1A-266
1A-2 Engine Control System (6HK1)

DTC P2453 (Flash Code 141). . . . . . . . . . . . 1A-268
DTC P2454 or P2455 (Flash Code 47) . . . . . 1A-271
DTC P2456 (Flash Code 47). . . . . . . . . . . . . 1A-276
DTC P2458 (Flash Code 139). . . . . . . . . . . . 1A-278
DTC P253A (Flash Code 28) . . . . . . . . . . . . 1A-281
DTC U0073 (Flash Code 84) . . . . . . . . . . . . 1A-287
DTC U0101 (Flash Code 85) . . . . . . . . . . . . 1A-290
DTC U0110 (Flash Code 87). . . . . . . . . . . . . 1A-292
DTC U0167 (Flash Code 177) . . . . . . . . . . . 1A-295
EGR Control System Check . . . . . . . . . . . . . 1A-296
Glow Control System Check . . . . . . . . . . . . . 1A-300
Exhaust Brake Control System Check . . . . . 1A-303
Cruise Control System Check . . . . . . . . . . . . 1A-309
Control System Check . . . . . . . . . . . . . . . . . 1A-314
Symptoms - Engine Controls . . . . . . . . . . . . . . 1A-320
Symptoms - Engine Controls . . . . . . . . . . . . 1A-320
Intermittent Conditions . . . . . . . . . . . . . . . . . 1A-322
Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-325
Rough, Unstable, or
Incorrect Idle and Stalling . . . . . . . . . . . . . . . 1A-327
High Idle Speed. . . . . . . . . . . . . . . . . . . . . . . 1A-329
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-330
Surges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-331
Lack of Power, Sluggishness or Sponginess 1A-333
Hesitation, Sag or Stumble . . . . . . . . . . . . . . 1A-335
Abnormal Combustion Noise . . . . . . . . . . . . 1A-337
Poor Fuel Economy. . . . . . . . . . . . . . . . . . . . 1A-338
Excessive Smoke (Black Smoke) . . . . . . . . . 1A-340
Excessive Smoke (White Smoke) . . . . . . . . . 1A-342
DPD System Manual Regeneration
Frequently . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-344
DPD System Regeneration Long Time . . . . . 1A-346
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-348
Engine Control Module (ECM) Replacement 1A-348
Service Programming System (SPS)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-350
(Remote Procedure) . . . . . . . . . . . . . . . . . . . 1A-350
(Pass-Thru Procedure) . . . . . . . . . . . . . . . . . 1A-352
Description and Operation . . . . . . . . . . . . . . . . 1A-353
Engine Control Module (ECM) Description . . 1A-353
Engine Control Component Description . . . . 1A-356
Fuel System Description . . . . . . . . . . . . . . . . 1A-360
Fuel System Component Description . . . . . . 1A-361
Fuel Injection System Description. . . . . . . . . 1A-365
Exhaust Gas Recirculation (EGR)
System Description . . . . . . . . . . . . . . . . . . . . 1A-366
Turbocharger Description . . . . . . . . . . . . . . . 1A-368
Special Tools and Equipment . . . . . . . . . . . . . . 1A-372
Special Tools and Equipment . . . . . . . . . . . . 1A-372
Specifications
Temperature vs. Resistance 150 302 13900
Engine Coolant Temperature vs. Resistance 100 212 33600
°C °F Ohms 50 122 106000
Temperature vs. Resistance Value (Approximately)
Fuel Temperature vs. Resistance
120 248 115
°C °F Ohms
110 230 150
100 212 190
110 230 140
90 194 240
100 212 180
80 176 320
90 194 240
70 158 430
80 176 310
60 140 590
70 158 420
50 122 810
60 140 580
40 104 1150
50 122 810
30 86 1660
40 104 1150
20 68 2450
30 86 1660
10 50 3700
20 68 2450
0 32 5800
10 50 3700
-10 14 9300
0 32 5740
-20 -4 15480
-10 14 9160
-30 -22 26700
-20 -4 15000
Exhaust Temperature vs. Resistance -30 -22 25400
°C °F Ohms
Intake Air Temperature vs. Resistance
°C °F Ohms
1000 1832 120
950 1742 135
100 212 190
900 1652 155
90 194 240
850 1562 180
80 176 320
800 1472 205
70 158 430
750 1382 240
60 140 590
700 1292 290
50 122 810
650 1202 345
40 104 1150
600 1112 425
30 86 1650
550 1022 530
20 68 2430
500 932 675
10 50 3660
450 842 885
0 32 5650
400 752 1200
-10 14 8970
350 662 1710
-20 -4 14700
300 572 2580
250 482 4300
200 392 6900

Altitude vs. Barometric Pressure
Barometric
Altitude Measured Altitude Measured Pressure
in Meters (m) in Feet (ft) Measured in
Kilopascals (kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
4267 14000 56-64
3962 13000 58-66
3658 12000 61-69
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105

Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC • The ECM records the operating conditions at the
Action Taken When the DTC Sets - Type A time the diagnostic fails. The ECM stores this
information in the Failure Records.
• The ECM illuminates the malfunction indicator
lamp (MIL) when the diagnostic runs and fails. Conditions for Clearing the DTC - Type D
• The ECM records the operating conditions at the • A current DTC clears when the diagnostic runs and
time the diagnostic fails. The ECM stores this passes.
information in the Freeze Frame/ Failure Records.
• A history DTC clears after 40 consecutive warm-up
Action Taken When the DTC Sets - Type B cycles, if no failures are reported.
• Use a scan tool to clear the DTC.
• The ECM illuminates the MIL on the second
consecutive driving cycle when the diagnostic runs
and fails.
• The ECM records the operating conditions at the
time the diagnostic fails. The first time the
diagnostic fails, the ECM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive driving cycle, the
ECM records the operating conditions at the time
of failure and stores this information in the Freeze
Frame and updates the Failure Records.
Conditions for Clearing the MIL/ DTC - Type A or

Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail.
• A current DTC clears when the diagnostic runs and
passes.
cycles, if no failures are reported.
• Use a scan tool to clear the MIL and the DTC.
Non-Emissions Related DTCs

Action Taken When the DTC Sets - Type C
• The ECM illuminates the Service Vehicle Soon
(SVS) lamp when the diagnostic runs and fails.
time the diagnostic fails. The ECM stores this
Conditions for Clearing the SVS Lamp/ DTC - Type

C
• The ECM turns OFF the SVS lamp after 1 driving
cycle when the diagnostic runs and does not fail.
passes.
• Use a scan tool to clear the SVS lamp and the
DTC.
Action Taken When the DTC Sets - Type D

• The ECM will not illuminate the MIL or SVS lamp.

Diagnostic Trouble Code (DTC) List
DTC Flash Code DTC Type DTC Descriptor

P0016 16 A Crankshaft Position - Camshaft Position Correlation
P0045 33 A Turbocharger Boost Control Solenoid Circuit
P0079 38 A Exhaust Valve Control Solenoid Circuit Low
P0080 38 A Exhaust Valve Control Solenoid Circuit High
P0087 225 B Fuel Rail/ System Pressure Too Low
P0088 118 A Fuel Rail/ System Pressure Too High
P0089 151 B Fuel Pressure Regulator Performance
P0091 247 A Fuel Pressure Regulator Control Circuit Low
P0092 247 A Fuel Pressure Regulator Control Circuit High
P0093 227 B Fuel System Leak Detected
P0101 92 B Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A Mass Air Flow Sensor Circuit Low Input
P0103 91 A Mass Air Flow Sensor Circuit High Input
P0112 22 A Intake Air Temperature Sensor Circuit Low
P0113 22 A Intake Air Temperature Sensor Circuit High
P0116 23 B Engine Coolant Temperature Sensor Circuit Range/ Performance
P0117 23 A Engine Coolant Temperature Sensor Circuit Low
P0118 23 A Engine Coolant Temperature Sensor Circuit High
P0122 43 A Throttle Position Sensor Circuit Low
P0123 43 A Throttle Position Sensor Circuit High
P0182 211 A Fuel Temperature Sensor Circuit Low
P0183 211 A Fuel Temperature Sensor Circuit High
P0192 245 A Fuel Rail Pressure Sensor Circuit Low
P0193 245 A Fuel Rail Pressure Sensor Circuit High
P0201 271 A Injector Circuit Open - Cylinder 1
P0217 542 D Engine Coolant Over Temperature Condition
P0219 543 D Engine Overspeed Condition
P0234 42 A Turbocharger Overboost Condition
P0237 32 A Turbo Charger Boost Sensor Circuit Low
P0238 32 A Turbo Charger Boost Sensor Circuit High
P0299 65 B Turbocharger Underboost
P0335 15 A Crankshaft Position Sensor Circuit
P0336 15 A Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 A Camshaft Position Sensor Circuit

P0341 14 A Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C Glow Plug Circuit
P0381 67 C Glow Plug Indicator Circuit
P0401 93 A EGR Flow Insufficient Detected
P0404 45 A EGR Control Circuit Range/ Performance
P0409 44 A EGR Sensor Circuit
P0426 143 C Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1
P0427 48 A Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 48 A Catalyst Temperature Sensor Circuit High Sensor 1
P042B 145 C Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2
P042C 49 C Catalyst Temperature Sensor Circuit Low Sensor 2
P042D 49 C Catalyst Temperature Sensor Circuit High Sensor 2
P0477 46 A Exhaust Pressure Control Valve Low
P0478 46 A Exhaust Pressure Control Valve High
P0500 25 A Vehicle Speed Sensor
P0502 25 A Vehicle Speed Sensor Circuit Low Input
P0503 25 A Vehicle Speed Sensor Circuit High Input
P0560 155 A System Voltage
P0563 35 C System Voltage High
P0571 26 C Brake Switch Circuit
P0601 53 A Internal Control Module Memory Check Sum Error
P0602 154 C Control Module Programming Error
P0604 153 A Internal Control Module RAM Error
P0606 51 A ECM Processor
P060B 36 A Internal Control Module A/D Processing Performance
P0633 176 D Immobilizer not programmed
P0638 61 A Throttle Actuator Control Range/ Performance
P0641 55 A Sensor Reference Voltage 1 Circuit
P0650 77 A Malfunction Indicator Lamp (MIL) Control Circuit
P0685 416 C ECM Power Relay Control Circuit Open
P0687 416 C ECM Power Relay Control Circuit High
P0700 185 A Transmission Control System Emissions Related Malfunction
P1093 227 B Fuel Rail Pressure Too Low
P1261 34 A Injector Positive Voltage Control Circuit Group 1
P1404 45 A EGR Position Fault (Closed Position Error)
P1404 45 A EGR Position Fault (Learned Position Error)
P1455 132 A PM Over Accumulation
P1471 149 A DPD Insufficient Regeneration

P161B 179 D Immobilizer wrong response
P1621 54 A Control Module Long Term Memory Performance
P1664 76 C Service Vehicle Soon Lamp Control Circuit
P1669 75 C DPD Lamp Control Circuit
P2002 127 A Particulate Trap Efficiency Below Threshold
P2122 121 A Pedal Position Sensor 1 Circuit Low Input
P2123 121 A Pedal Position Sensor 1 Circuit High Input
P2138 124 A Pedal Position Sensor 1-2 Voltage Correlation
P2146 158 A Fuel Injector Group 1 Supply Voltage Circuit
P215A 25 A Vehicle Speed - Wheel Speed Correlation
P2227 71 B Barometric Pressure Sensor Circuit Range/ Performance
P2228 71 A Barometric Pressure Sensor Circuit Low
P2229 71 A Barometric Pressure Sensor Circuit High
P242F 131 A DPD Restriction
P2453 141 A DPD Differential Pressure Sensor Circuit Range/ Performance
P2454 47 A DPD Differential Pressure Sensor Circuit Low
P2455 47 A DPD Differential Pressure Sensor Circuit High
P2456 47 A DPD Differential Pressure Sensor Learned Position
P2458 139 A DPD Regeneration Duration
P253A 28 C PTO Sensor Circuit
P256A 31 C Engine Idle Speed Selector Sensor
U0073 84 B Control Module Communication Bus Off
U0101 85 A Lost Communication with TCM
U0110 87 A Lost Communication with VNT System
U0167 177 D Lost Communication With Vehicle Immobilizer Control Module
Overview Wirings
Overview Wirings
1/2
Cruise control switch

(Combination switch)
Cruise resume/accel. switch 65
Cruise set/coast switch
Cruise cancel switch
42
PTO throttle sensor 70 A
41
24 Ignition switch (on)
Idle up sensor 66 Ignition switch (start)
46
21 Key position
Main relay
40
Accelerator pedal position sensor 1 63 2
5 Dropping C
61 resistor
64 35
Accelerator pedal position sensor 2 Battery 24V
60 B
39 Case ground
81
BARO sensor 71 43 Signal ground
62 Signal ground
Power ground
1
23 3 Power ground
Mass air flow sensor 69 4 Power ground
22
Intake air temperature sensor 72 MIL A
6
7 Exhaust brake lamp
17 SVS lamp
11 Glow plug lamp
80
ECM 9 DPD lamp
Exhaust differential pressure sensor
67 Oil pressure lamp
79 16
Exhaust temperature sensor 1 Oil pressure switch
73
Exhaust temperature sensor 2 74 Glow relay
Vehicle speed sensor 10
19 C
Speed sensor C/U
Cruise control main switch Glow plug
25
DPD regeneration switch
47
Clutch pedal switch Starter cut relay

26 14 B
Starter relay
Exhaust brake switch
A 45 15
Exhaust brake solenoid valve
Heater & A/C Refrigerant
relay pressure switch
34
8 Tachograph
C
A/C unit
Condenser A/C switch
fan relay
1 2 3 4 5 6 7 8
Neutral switch 9 10 11 12 13 14 15 16
52
50
18
48 37
Parking brake switch
A PTO switch 44
EHCU TCM IP cluster BCM REA Air sus C/U
Oil level switch

53
55
Brake switch 2
Stop light relay
A 54
Brake switch 1
MFWB1AXF000101

2/2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
95
Crank shaft position sensor
107
58
109 Immobilizer
control unit
108 (ICU)
78
Boost pressure sensor 91 Transmission

CAN resistor
control module
ECM (TCM)
Intake throttle position sensor

85
112 M+
84 M Intake throttle
Engine coolant temperature sensor
M-
104
Fuel temperature sensor 83

121
Fuel injector 1 Cylinder #1
119
117
114
116
U 111 120
M V Fuel injector 4 Cylinder #6
EGR motor 103
W 118
110 Fuel injector 6 Cylinder #4
115
U 105
94 Fuel rail pressure regulator
V 113
EGR position sensor 93
W 89
99
97
Exhaust throttle solenoid valve
102 B
87
Camshaft position sensor
98
101
100
Ground
68
82
Fuel rail pressure sensor
90
MFWA1AXF000401
Routing Diagrams
Fuel System Routing Diagram
2 5
3
1
11
9
10 8 6
7
MFW81AMF002501
Legend
1. Fuel rail 7. Fuel filter (with water separator)
2. Fuel rail pressure (FRP) sensor 8. Recirculation valve (with a built in fuel filter)
3. Leak off pipe 9. Fuel supply pump
4. Engine control module (ECM) 10. Fuel temperature (FT) sensor
5. Fuel injector 11. Fuel rail pressure (FRP) regulator
6. Fuel tank
Component Locator
Engine Controls Component Views
MFW81ASF000701
Legend
1. Speed sensor control unit 3. Barometric pressure (BARO) sensor
2. Accelerator pedal position (APP) sensor
3 2
MFWB1AMF000101
Legend
1. Boost pressure sensor 3. Fuel rail pressure (FRP) sensor
2. Pressure limiter valve
MFWB1ASF000101
Legend
1. Camshaft position (CMP) sensor 3. Rotary electric actuator (REA)
2. Turbocharger
3 2
MFWB1AMF000201
Legend
1. Intake throttle valve 3. Engine coolant temperature (ECT) sensor
2. Exhaust gas recirculation (EGR) valve
MFWB1AMF000301
Legend
1. Fuel temperature (FT) sensor 3. Crankshaft position (CKP) sensor
2. Fuel rail pressure (FRP) regulator
1 2 3 4 5 6
MFW76ESF000301
Legend
1. Fuel injector No.1 cylinder 4. Fuel injector No.4 cylinder
4
1
2
3
MFW76ESF000201
Legend
1. Exhaust brake valve 4. Exhaust differential pressure sensor
2. Exhaust temperature sensor 2 (in front of oxidation 5. Exhaust throttle valve
catalyst) 6. DPD assembly
3. Exhaust temperature sensor 1 (in front of filter)
MFWA1ASF000101
Legend
1. Mass air flow (MAF) sensor/ intake air temperature
(IAT) sensor
MFW76ESF000701
Legend
1. Sensor cover 2. Vehicle speed sensor (VSS)
MFWB1ASF000501
Legend
1. CAN resistor
MFW71AMF000301
Legend
1. Engine control module (ECM) 2. Dropping resistor

Engine Control Module (ECM) Connector Connector No. FB24
End Views Connector color Black
Engine Control Module (ECM)
Test adapter No. J-35616-64A
Pin No. Wire color Pin function
20 – Not used
21 BLU/ WHT ECM main relay control
22 BLK MAF sensor low reference
23 RED MAF sensor 12 volts reference
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 24 BLK/ BLU Ignition voltage
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
3 25 RED/ WHT Cruise control main switch signal
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 2 1
Clutch pedal switch signal
26 WHT/ BLU
27 – Not used
28 – Not used
29 – Not used
30 – Not used
LNW76ESH001501
31 – Not used
32 – Not used
Connector No. FB24
33 – Not used
Connector color Black
34 BRN/ YEL A/C signal
35 GRN Dropping resistor
36 – Not used
1 BLK/ YEL ECM power ground
37 BLU CAN low signal
2 WHT/ RED Battery voltage
38 – Not used
APP sensor 1, APP sensor 2, PTO
39 GRY throttle sensor, idle up sensor and
5 WHT/ RED Battery voltage BARO sensor shield ground
6 YEL/ BLK MIL control 40 BLU/ WHT ECM main relay control
7 BRN/ GRN Exhaust brake lamp control APP sensor 1, idle up sensor,
41 BLK cruise control switch and PTO
8 LT GRN Engine speed signal output
throttle sensor low reference
LT GRN/
9 DPD amber lamp control APP sensor 1, idle up sensor and
BLK
42 WHT PTO throttle sensor 5 volts
10 WHT/ GRN Glow relay control reference
11 ORN/ BLU Glow plug lamp control 43 BLK/ YEL ECM signal ground
12 – Not used 44 VIO/ WHT PTO switch signal
13 – Not used LT GRN/

45 Exhaust brake switch signal
RED
14 BLK/ RED Starter cut relay control
46 BLK/ WHT Ignition switch signal
Exhaust brake solenoid valve
15 GRN/ RED 47 RED/ GRN DPD regeneration switch signal
control
16 BLU/ YEL Engine oil level lamp control 48 YEL Parking brake switch signal
17 BLU/ BLK SVS lamp control 49 – Not used
18 BLU/ WHT CAN high signal 50 BLK/ GRN Neutral switch signal
Vehicle speed signal from speed 51 – Not used

19 YEL/ GRN
sensor control unit
52 GRY/ WHT Diagnostic request switch
Connector No. FB24

53 VIO/ YEL Engine oil level switch signal
54 GRN/ BLK Brake switch 1 signal 121 120 119 113 112 111 110 109 108 107 106
105 104 103 102 101 100 99 98
55 GRN/ ORN Brake switch 2 signal 118 117
97 96 95 94 93 92 91 90
56 – Not used 116 115 114 89 88 87 86 85 84 83 82
57 – Not used
58 GRN/ WHT CAN high signal
59 – Not used
APP sensor 2, BARO sensor and
60 BLU
IAT sensor low reference
LNW76ESH001601
APP sensor 2 and BARO sensor 5
61 GRN
volts reference
62 BLK/ YEL ECM signal ground Connector No. E26
63 RED APP sensor 1 signal Connector color Black
64 YEL APP sensor 2 signal Test adapter No. J-35616-64A
65 BRN/ BLU Cruise control switch signal Pin No. Wire color Pin function
66 YEL/ BRN Idle up sensor signal 82 BLK FRP sensor signal
Exhaust differential pressure LT GRN/

67 RED 83 FT sensor signal
sensor signal WHT
68 BLK/ YEL Ground 84 GRN/ YEL ECT sensor signal
69 WHT/ BLK MAF sensor signal Intake throttle position sensor

85 VIO/ WHT
signal
70 RED PTO throttle sensor signal
86 – Not used
71 WHT/ RED BARO sensor signal
CMP sensor, FRP sensor and
72 GRN/ WHT IAT sensor signal 87 LT GRN EGR position sensor 5 volts
Exhaust temperature sensor 1 reference
73 YEL/ RED
signal 88 – Not used
Exhaust temperature sensor 2 89 GRN/ BLK FRP regulator low side
74 RED/ YEL
signal
90 BLK FRP sensor signal
75 – Not used
91 WHT Boost pressure sensor signal
76 – Not used
92 – Not used
77 – Not used
93 BRN EGR position sensor signal 2
78 GRN CAN low signal
94 BLU EGR position sensor signal 1
Exhaust differential pressure
sensor, exhaust temperature CKP sensor, intake throttle
79 BLK 95 YEL position sensor and boost
sensor 1 and exhaust temperature
sensor 2 low reference pressure sensor 5 volts reference
Exhaust differential pressure 96 – Not used

80 WHT
sensor 5 volts reference 97 GRN/ BLK FRP regulator low side
81 BLK/ YEL ECM case ground 98 WHT CMP sensor signal
99 GRY EGR position sensor signal 3
CMP sensor and FRP sensor
100 BLK
shield ground
Connector No. E26 Engine Control Connector End Views

Connector color Black Accelerator Pedal Position (APP) Sensor
101 YEL/ BLK EGR position sensor low
reference
102 GRN/ ORN
control
103 ORN EGR motor control 2 (PWM) 1 2 3
Intake throttle motor low side
104 GRN
(PWM)
4 5 6
FRP regulator control high side

105 WHT/ RED
(PWM)
106 – Not used
107 LT BLU CKP sensor signal
CKP sensor and boost pressure RTW76ESH001201
108 BLK
sensor shield ground
CKP sensor, intake throttle
position sensor, FT sensor, ECT Connector No. FL1
109 BLK
sensor and boost pressure sensor
Connector color Gray
low reference
Test adapter No. J-35616-33
110 BLK/ RED EGR motor control 3 (PWM)
LT GRN/
111 EGR motor control 1 (PWM)
RED APP sensor 2
1 GRN
5 volts reference
112 BLK/ BLU Intake throttle motor drive voltage
2 YEL APP sensor 2 signal
113 WHT/ RED
(PWM) 3 BLU APP sensor 2 low reference
114 BLK/ RED Cylinder #2 fuel injector control APP sensor 1
4 WHT
5 volts reference
115 BLK/ RED Cylinder #4 fuel injector control
5 RED APP sensor 1 signal
Common 2 (cylinder #4, #5 and
116 RED
#6) fuel injector charge voltage 6 BLK APP sensor 1 low reference
117 WHT/ BLU Cylinder #3 fuel injector control
Barometric Pressure (BARO) Sensor
118 BLK/ WHT Cylinder #6 fuel injector control
119 YEL Cylinder #1 fuel injector control
120 BLK/ BLU Cylinder #5 fuel injector control
Common 1 (cylinder #1, #2 and
121 WHT
#3) fuel injector charge voltage
1 2 3
RTW76ESH000901

Brake Switch 1
Connector No. FL52
1 BLU Sensor low reference
2 WHT/ RED Sensor signal
3 GRN Sensor 5 volts reference
1 2
MFW81ASH001001
Connector No. FU159

123 Connector color Black
1 GRN/ BLK Switch signal
2 BLK Switch ground
LNW46ESH001501 Brake Switch 2
Connector No. E54

1 WHT Sensor signal
2 BLK Sensor low reference
1 2
3 YEL Sensor 5 volts reference
MFW81ASH001001
Connector No. FB5

1 GRN/ ORN Switch signal
Connector No. FB5

Connector color Black Connector No. E48
Test adapter No. J-35616-42 Connector color Black
Pin No. Wire color Pin function Test adapter No. J-35616-33
2 BLK/ YEL Switch ground Pin No. Wire color Pin function
1 WHT Sensor signal
Clutch Pedal Switch
2 YEL/ BLK Sensor low reference
3 LT GRN Sensor 5 volts reference
Crankshaft Position (CKP) Sensor
1
2
1 2 3
LNW46ESH000801
Connector No. FU179

Connector color White RTW76ESH000701

Pin No. Wire color Pin function Connector No. E50
1 BLK/ ORN Ignition voltage feed Connector color Black
2 WHT/ BLU Switch signal Test adapter No. J-35616-33

Camshaft Position (CMP) Sensor
1 LT BLU Sensor signal
3 YEL Sensor 5 volts reference
1 2 3
RTW76ESH000701

Cruise Control Main Switch Data Link Connector (DLC)
1 2 3 4 5 6 7 8
1 2 3 4
5 6 7 8 9 10 9 10 11 12 13 14 15 16
LNW76ESH004201 LNW81ASH001401
Connector No. FU208 Connector No. FU23

Connector color Brown Connector color Light blue
Test adapter No. J-35616-33 Test adapter No. J-35616-2A
Pin No. Wire color Pin function Pin No. Wire color Pin function
1 – Not used 1 – Not used
2 – Not used LT GRN/ Class 2 serial data (EHCU [ABS
2
RED module])
Cruise control main switch
3 BLK/ ORN
ignition voltage feed 3 – Not used
4 RED/ WHT Cruise control main switch signal 4 BLK Ground
5 – Not used 5 BLK Ground
6 – Not used 6 GRN/ WHT CAN high
7 BLK Illumination lamp ground Keyword serial data (air
suspension control unit, SRS
LT GRN/ 7 LT BLU
8 Illumination lamp voltage feed control unit, ICU, BCM and IP
RED
cluster)
9 – Not used
Class 2 serial data (ABS control
8 PNK
10 – Not used unit)
Keyword serial data (HSA control
9 RED/ WHT
unit)
10 – Not used
11 – Not used
Diagnostic request switch (ECM,
12 GRY/ WHT air suspension control unit, SRS
control unit and IP cluster)
LT GRN/ Diagnostic request switch (EHCU
BLU [ABS module])
13
Diagnostic request switch (ABS
WHT/ VIO
control unit)
14 GRN CAN low
15 – Not used
16 RED Battery voltage

DPD Regeneration Switch EGR Valve
1 2 3 4 1 2 3 4
5 6 7 8 9 10 5 6 7 8
LNW76ESH004201 RTW76ESH002801
Connector No. FU142 Connector No. E45

Connector color Blue Connector color Black
1 BLK/ ORN Switch voltage feed 1 LT GRN Position sensor 5 volts reference
2 RED/ GRN Switch signal 2 GRY Position sensor signal 3
3 – Not used 3 BRN Position sensor signal 2
4 – Not used 4 BLU Position sensor signal 1
5 – Not used 5 YEL/ BLK Position sensor low reference
6 – Not used 6 BLK/ RED Motor control 3
7 BLK Illumination lamp ground 7 ORN Motor control 2
LT GRN/ LT GRN/
8 Illumination lamp voltage feed 8 Motor control 1
RED RED
9 – Not used
Engine Coolant Temperature (ECT) Sensor
10 – Not used
1 2
LNW46ESH001201

Connector No. E55
1 GRN/ YEL Sensor signal
Exhaust Brake Solenoid Valve 1 2 3
RTW76ESH001301
1 2 Connector No. FB66

2 RED Sensor signal
LNW66ESH001101
3 WHT Sensor 5 volts reference
Connector No. FB41 or J8 Exhaust Temperature Sensor 1

1 GRN/ BLK Ignition voltage feed
2 GRN/ RED Solenoid valve control
2 1
RTW76ESH001601

Exhaust Throttle Solenoid Valve
Connector No. FB67
Connector color Light gray
2 YEL/ RED Sensor signal
Exhaust Temperature Sensor 2 1 2
LNW66ESH001101

1 GRN/ BLK Battery voltage feed
2 GRN/ ORN Solenoid valve ground
RTW76ESH000301
Fuel Injector #1 to #6 Cylinder

Connector No. FB68
Connector color Dark gray
Pin No. Wire color Pin function 3 2 1
2 RED/ YEL Sensor signal
LNW46ESH001001
E71, E72, E73

Connector No.
E74, E75 and E76
1 #1, #2 and #3:
WHT
Charge voltage
2 #4, #5 and #6:
RED
E71, E72, E73 Fuel Rail Pressure (FRP) Sensor

Connector No.
E74, E75 and E76
#1: GRN
#2: BLU
#3: YEL
3 Fuel injector control
#4: BLK
#5: BRN
#6: VIO

123
LNW46ESH001501
1 2 Connector No.
Connector color
E49
Black
1 YEL/ BLK Sensor low reference
2 BLK Sensor signal
LNW46ESH001101
3 LT GRN Sensor 5 volts reference
Connector No. E47 Fuel Temperature (FT) Sensor

Regulator control high side
1 WHT/ RED
(PWM)
2 GRN/ BLK Regulator low side
1 2
LNW46ESH001201

Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor
Connector No. E30
LT GRN/
2 Sensor signal
WHT
Glow Plug 1 2 3 4 5
LNW46ESH001801
Connector No. J14 or FB128

LNW46ESH000701
3 WHT/ BLK MAF sensor signal
4 GRN/ WHT IAT sensor signal
Connector No. E31
5 BLU IAT sensor low reference
Connector color –
Pin No. Wire color Pin function Intake Throttle Valve
1 BLK/ RED Power Supply
1 2 3 4 5 6
RTW76ESH000401

PTO Throttle Sensor
Connector No. E46
1 GRN Motor control low side (PWM)
2 BLK/ BLU Motor drive voltage
3 – Not used
1 2 3
4 BLK Position sensor low reference
5 YEL Position sensor 5 volts reference
6 VIO/ WHT Position sensor signal
Idle Up Sensor
LNW81ASH001601
Connector No. FB129

1 2 3 1 BLK Sensor low reference

2 RED Sensor signal
Rotary Electric Actuator (REA)
LNW46ESH002601
Connector No. FL33

Connector color White
1 2 3
1 BLU/ RED Sensor low reference 4 5 6
2 YEL/ GRN Sensor signal
3 BLU Sensor 5 volts reference
MFW76ESH001601
Connector No. E10

1 RED CAN high
2 – Not used
3 GRN/ BLK Voltage feed
4 GRN CAN low
5 – Not used
6 BLK ground
Vehicle Speed Sensor (VSS)
1 2 3
RTW76ESH000701
Connector No. FB156 or J117

1 GRN Ignition voltage feed
3 GRY Sensor signal
Diagnostic Information and Procedures

Engine Control System Check Sheet
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name

Customers Name Model & Model Year
Drivers Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km
Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms
Incorrect Idle Rough idling

Other ( )
Hesitation, sag, stumble Surge Cut out
Poor Lack of power, sluggishness, sponginess
Driveability
Other ( )
Soon after starting After accelerator pedal depressed
Engine Stall During A/C operation After accelerator pedal released Shifting from N to D
Other ( )
Black smoke White smoke Poor fuel economy
Others Abnormal combustion noise DPD manual regeneration frequently
DPD regeneration long time
Other ( )
Dates problem occurred
Problem frequency Constant Intermittently ( times per day/month) Once only
Other ( )
Weather Fine Cloudy Rainy Snow
Various/Other ( )
Outside Hot (approx. ) Warm Cool Cold (approx. )
Condition When Problem Occurs
Temperature Any temperature

Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland
Condition of MIL or SVS lamp Remains On Intermittently turns On Does not turn On
Present Code Nothing P or U Code

No. ( )
Diagnostic Trouble
Code (DTC) or Flash
Code P or U Code
History Code Nothing No. ( )
DPD lamp or MID indicator Blinked Did not blink

DPD switch Pushed Did not push
DPD accumulation status 1 2 3 4 5
DPD System
DPD distance status 1 2 3 4
DPD incomplete regeneration status 0 1 2
DPD insufficient regeneration status 0 1 2
Exhaust differential pressure at instructed conditions kPa
Averaged MAF when exhaust differential pressure is measured g/s
MFWB1AXF000501

Diagnostic Starting Point - Engine Controls Reading Flash Diagnostic Trouble Codes (DTC)
Begin the system diagnosis with Diagnostic System The provision for communicating with the ECM is the
Check - Engine Controls. The Diagnostic System Data Link Connector (DLC). The DTC(s) stored in the
Check - Engine Controls will provide the following ECM memory can be read either through a hand-held
information: diagnostic scanner such as Tech 2 plugged into the
• The identification of the control modules which DLC or by counting the number of flashes of the
command the system. malfunction indicator lamp (MIL) or the service vehicle
soon (SVS) lamp when the diagnostic test terminal of
• The ability of the control modules to communicate the DLC is grounded. The DLC terminal "12"
through the serial data circuit. (diagnostic request) is pulled "Low" (grounded) by
• The identification of any stored diagnostic trouble jumped to DLC terminal "4", which is a ground wire.
codes (DTCs) and the their statuses. Once terminals "12" and "4" have been connected, turn
The use of the Diagnostic System Check - Engine the ignition switch ON, with the engine OFF. The SVS
Controls will identify the correct procedure for lamp will indicate a DTC three times is a DTC is
diagnosing the system and where the procedure is present and history. If more than one DTC has been
located. stored in the ECM's memory, the DTCs will be output
numerical order with each DTC being displayed three
Important: Engine Control System Check Sheet must times. The flash DTC display will continue as long as
be used to verify the customer complaint, you need to the DLC is shorted.
know the correct (normal) operating behavior of the
system and verify that the customer complaint is a valid
failure of the system.
Example:DTC 23 stored 2 3 Unit: Second
1.2 1.2 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 2.4
2nd digit number 1st digit number
Example:DTC 225 stored 2 2 5
0.3 0.3 1.2 1.2 0.3 0.3 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 2.4
3rd digit 2nd digit number 1st digit number

number
LNW76ESF000101

Diagnostic System Check - Engine Con- Diagnostic System Check Engine Controls
trols Important:
Description • DO NOT perform this diagnostic if there is not a
driveability concern, unless another procedure
The Diagnostic System Check - Engine Controls is an
directs you to this diagnostic.
organized approach to identifying a condition that is
created by a malfunction in the electronic engine • Before you proceed with diagnosis, search for
control system. The Diagnostic System Check must be applicable service bulletins.
the starting point for any driveability concern. The • Unless a diagnostic procedure instructs you, DO
Diagnostic System Check directs the service technician NOT clear the DTCs.
to the next logical step in order to diagnose the • If there is a condition with the starting system, refer
concern. Understanding and correctly using the to Starting System in Section 1E Engine Electrical.
diagnostic table reduces diagnostic time, and prevents
• Ensure the battery has a full charge.
the replacement of good parts.
• Ensure the battery cables (+) (-) are clean and
Test Description tight.
The numbers below refer to the step numbers on the • Ensure the ECM grounds are clean, tight, and in
diagnostic table. the correct location.
2. Lack of communication may be because of a partial • Ensure the ECM harness connectors are clean
or a total malfunction of the serial data circuit. and correctly connected. DO NOT attempt to crank
7. The presence of DTCs which begin with U, indicate the engine with ECM harness connectors
that some other module is not communicating. disconnect.
10. If there are other modules with DTCs set, refer to • Ensure the ECM terminals are clean and correctly
the DTC list. The DTC list directs you to the appropriate mating.
diagnostic procedure. If the control module stores • Ensure the fuel injector ID code data is correctly
multiple DTCs, diagnose the DTCs in the following programmed in to the ECM.
order:
• Ensure the immobilizer security information is
• Component level DTCs, such as sensor DTCs, correctly programmed into the ECM and
solenoid DTCs, actuator DTCs, and relay DTCs. immobilizer control unit (ICU).
Diagnose the multiple DTCs within this category in
numerical order. Begin with the lowest numbered • If there are fuel system DTC’s (P0087, P0088,
DTC, unless the diagnostic table directs you P0089, P0093 or P1093), diagnose sensor DTCs,
otherwise. solenoid DTCs, actuator DTCs and relay DTCs
first.
• If there are DPD system DTC's (P1455, P1471,
P242F, P2453 or P2458), diagnose sensor DTCs,
solenoid DTCs, actuator DTCs and relay DTCs
first.
Diagnostic System Check - Engine Controls
Step Action Value(s) Yes No

Install a scan tool.
1 — Go to Scan Tool
Does the scan tool turn ON? Go to Step 2 Does Not Power Up
2. Attempt to establish communication with the Go to Scan Tool
2 ECM. — Does Not
Communicate with
Does the scan tool communicate with the ECM? Go to Step 3 CAN Device
Notice: If an immobilizer system is active the ECM
will disable the fuel injection causing the engine to
stall immediately after starting and energize the
3 starter cut relay to disable cranking. Attempt to —
crank the engine.
Does the engine crank? Go to Step 4 Go to Step 5

Attempt to start the engine. Go to Engine
4 — Cranks but Does
Does the engine start and idle? Go to Step 6 Not Run

Does the scan tool display ECM DTCs P0633, Problem is relating
P161B or U0167? to starting system.
5 — Refer to Starting
Go to Applicable System in Section
DTC 1E Engine Electrical
Select the DTC display function for the following
control modules:
• ECM
• Transmission control module (TCM) (Smoother
6 only) —
• Electronic hydraulic control unit (EHCU) [ABS
module] or ABS control unit (If so equipped)
• Immobilizer control unit (ICU)
Does the scan tool display any DTCs? Go to Step 7 Go to Step 11

Does the scan tool display DTCs which begin with
7 U or other control module communication fault — Go to Applicable
DTCs? DTC Go to Step 8
Does the scan tool display ECM DTCs P0601, Go to Applicable
8 —
P0602, P0604, P0606, P060B or P1621? DTC Go to Step 9
Does the scan tool display ECM DTC P0563? Go to Applicable
9 —
DTC Go to Step 10
Is there any other code in any controller that has Go to Applicable
10 —
not been diagnosed? DTC Go to Step 11
Is the customer's concern with the transmission? Go to Diagnostic
System Check-
Transmission
11 —
Controls in Section
5A Transmission
Control System Go to Step 12
Is the customer's concern with the anti-lock brake Go to Diagnostic
system? System Check -
12 — ABS Controls in
Section 4C1 ABS/
ASR or 4C ABS Go to Step 13
Is the customer’s concern with the immobilizer Go to Diagnostic
13 — Immobilizer
Controls in Section
9I Security and Lock Go to Step 14

1. Review the following symptoms.
2. Refer to the applicable symptom diagnostic
table:
• Hard Start
• Rough, Unstable, or Incorrect Idle and
Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or
14 Sponginess —
• Hesitation, Sag or Stumble
• Abnormal Combustion Noise
• Poor Fuel Economy
• Excessive Smoke (Black Smoke)
• Excessive Smoke (White Smoke)
• DPD System Manual Regeneration
Frequently
• DPD System Regeneration Long Time
Go to Intermittent
Did you find and correct the condition? System OK Conditions

Scan Tool Data List • The Engine Controls - Diagnostic System Check is
completed.
The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool. • On-board diagnostics are functioning properly.
A given parameter may appear in any one of the data Scan tool values from a properly running engine may
lists, and in some cases may appear more than once, be used for comparison with the engine you are
or in more than one data list in order to group certain diagnosing. The Engine Scan Tool Data List represents
related parameters together. Use the Engine Scan Tool values that would be seen on a normal running engine.
Data List only after the following is determined: Only the parameters listed below are referenced in this
service manual for use in diagnosis.
Scan Tool Parameter Units Displayed Typical Data Value at Engine Idle Typical Data Value at 1400 RPM
Operating Conditions: Engine idling or 1400 RPM/ Engine coolant temperature is between 75 to 85°C (167 to 185°F)/
Accelerator pedal is constant/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level/ DPD is not under regeneration
Engine Speed RPM Nearly 525 RPM Nearly 1400 RPM
Desired Idle Speed RPM 525 RPM 525 RPM
Calculated Engine Load % Less than 25% Less than 20%
Coolant Temperature °C/ °F 75 to 85°C/ 167 to 185°F 75 to 85°C/ 167 to 185°F
Engine Coolant Temperature Volts 0.4 to 0.6 volts 0.4 to 0.6 volts
Sensor
Intake Air Temperature °C/ °F 20 to 40°C/ 68 to 104°F 20 to 40°C/ 68 to 104°F
Intake Air Temperature Sensor Volts 1.4 to 2.3 volts 1.4 to 2.3 volts
Fuel Temperature °C/ °F 20 to 60°C / 50 to 140°F 20 to 60°C / 50 to 140°F
Fuel Temperature Sensor Volts 0.8 to 2.3 volts 0.8 to 2.3 volts
Averaged MAF (Mass Air Flow) g/ s More than 20 g/ s at sea level More than 50 g/ s at sea level
MAF (Mass Air Flow) g /cyl More than 0.8 g/cyl at sea level More than 0.7 g/cyl at sea level
MAF Sensor (Mass Air Flow) Volts More than 1.5 volts at sea level More than 2.3 volts at sea level
Barometric Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Nearly 100 kPa/ 14.5 psi at sea
level level
Barometric Pressure Sensor Volts Nearly 2.3 volts at sea level Nearly 2.3 volts at sea level
Desired Turbocharger Position % 10 to 20% 25 to 35%
Desired Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure Sensor Volts Nearly 1.0 volt at sea level Less than 1.3 volts at sea level
Desired Fuel Rail Pressure MPa/ psi Nearly 32 MPa/ 4,600 psi More than 90 MPa/ 13,000 psi
Fuel Rail Pressure MPa/ psi 28 to 35 MPa/ 4,000 to 5,000 psi More than 90 MPa/ 13,000 psi
Fuel Rail Pressure Sensor Volts 1.4 to 1.6 volts More than 2.4 volts
FRP Regulator Command (Fuel % 30 to 45% 25 to 35%
Rail Pressure)
FRP Regulator Commanded Fuel mm3/sec 900 to 1100 mm3/sec More than 3500 mm3/sec
Flow
FRP Regulator Feedback Current mA 900 to 1100 mA 800 to 900 mA
(Fuel Rail Pressure)
Accelerator Pedal Position % 0% 23 to 30%
APP Sensor 1 (Accelerator Pedal Volts 0.3 to 0.7 volts 1.2 to 1.6 volts
Position)
Position)
Desired EGR Position % 0% Less than 35%
EGR Position 1 % 0% Less than 35%
EGR Position 1 Low/ High Low or High Low or High
Intake Throttle Solenoid % 0% 0%
Command
Desired Intake Throttle Position % More than 90% More than 90%
Intake Throttle Position % More than 100% More than 100%
Intake Throttle Position Sensor Volts More than 3.9 volts More than 3.9 volts
Idle-Up Sensor Volts 0.3 to 0.6 volts 0.3 to 0.6 volts
Fuel Compensation Cyl. 1 mm3/ stk -5.0 to 5.0 mm3 / stk (varies) 0.0 mm3/ stk
Fuel Supply Pump Status Not Learned/ Learned Learned
Learned
Rail Pressure Feedback Mode Wait Mode/ Feedback Mode Feedback Mode
Feedback Mode/
Shutoff Mode/ Wait
to Restart
Engine Running Status Off/ Ignition On/ Running Running
Cranking/ Running
Engine Runtime Time (hour: Varies Varies
minute: second)
Vehicle Speed km/h/ MPH 0 km/h/ 0 MPH 0 km/h/ 0 MPH
Starter Switch On/ Off Off Off
Ignition Switch On/ Off On On
Ignition Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Battery Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Brake Switch 1 Applied/ Released Released Released
Brake Switch 2 Applied/ Released Released Released
Clutch Pedal Switch Applied/ Released Applied or Released Applied or Released
Neutral Switch Neutral/ In Gear Neutral Neutral
Park Brake Switch Applied/Released Applied or Released Applied or Released
Exhaust Brake Switch On/ Off Off Off
Exhaust Brake Valve Command On/ Off Off Off
Exhaust Brake Cut Request from Inactive/ Active Inactive Inactive
ABS Module
TCM
ASR Commanded APP % 100% 100%
(Accelerator Pedal Position)
PTO Switch On/ Off Off Off
PTO Remote Throttle % 0% 0%
PTO Remote Throttle Sensor Volts Less than 0.4 volts Less than 0.4 volts
Engine Warm Up Switch On/ Off Off Off
A/C Request Signal (Air On/ Off Off Off
Conditioning)
Refrigerator Switch On/ Off Off Off
Oil Level Normal/ Low Normal Normal
Glow Plug Relay Command On/ Off Off Off
Malfunction Indicator Lamp (MIL) On/ Off Off Off
Distance While MIL is Activated km/ Miles 0 km/ 0 Miles 0 km/ 0 Miles
Engine Runtime With MIL Active minutes 0 0
Total Engine Overspeed Events Counter Varies Varies
Total Engine Coolant Counter Varies Varies
Overtemperature Event
Total Fuel Temperature Counter Varies Varies
Total Intake Air Temperature Counter Varies Varies
DPD Regeneration Switch On/ Off Off Off
DPD Mode Varies 30 30
DPD Accumulation Status 0/ 1/ 2/ 3/ 4/ 5 0, 1, 2, 3 or 4 0, 1, 2, 3 or 4
DPD Distance Status 0/ 1/ 2/ 3/ 4 0, 1, 2 or 3 0, 1, 2 or 3
DPD Incomplete Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
DPD Insufficient Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
DPD LLIR Condition On Varies Varies Varies
Particulate Matter
DPD Trip km Varies Varies
DPD DIL Trip km Varies Varies
Exhaust Differential Pressure kPa/ psi Varies Varies
Exhaust Differential Pressure Volts Varies Varies
Sensor
Exhaust Temperature 1 °C/ °F Varies Varies
Exhaust Temperature Sensor 1 Volts Varies Varies
Exhaust Throttle Status On/ Off Off Off
Vane Control Solenoid Error No/ Stuck/ Short No No
Circuit
Vane Position Sensor Error No/ All Low/ All No No
High
Turbocharger Control Module No/ High Voltage No No
Error
Cruise Main Switch On/ Off Off Off
Cruise Cancel Switch On/ Off Off Off
Cruise Resume/ Acceleration On/ Off Off Off
Switch
Cruise Set/ Coast Switch On/ Off Off Off
Immobilizer Signal Yes/ No Yes Yes
Wrong Immobilizer Signal Yes/ No No No
Immobilizer Function Yes/ No Yes Yes
Programmed
Security Wait Time Inactive/ Time Inactive Inactive
(hour: minute:
second)

Scan Tool Data Definitions Fuel Temperature Sensor
This parameter displays the voltage signal sent to the
This information will assist in emission or driveability
ECM from the fuel temperature (FT) sensor. FT sensor
problems. The displays can be viewed while the vehicle
is a range of value indicating a low voltage when the
is being driven. Always perform the Diagnostic System
temperature is high, and a high voltage when the
Check - Engine Controls first. The Diagnostic System
temperature is low.
Check will confirm proper system operation.
Averaged MAF (Mass Air Flow)
Engine Speed
This parameter displays the air flow averaged a second
This parameter displays the speed of the crankshaft as
as calculated by the ECM based on the mass air flow
calculated by the ECM based on inputs from the
(MAF) sensor input. The scan tool will display a high
crankshaft position (CKP) sensor or camshaft position
value at higher engine speeds, and a low value at lower
(CMP) sensor.
engine speed.
Desired Idle Speed
MAF (Mass Air Flow)
This parameter displays the idle speed requested by
This parameter displays the air flow into the engine as
the ECM. The ECM will change desired idle speed
calculated by the ECM based on the mass air flow
based on engine coolant temperature and other inputs.
Calculated Engine Load value at higher engine speeds, and a low value at lower
This parameter displays the engine load in percent engine speed.
based on inputs to the ECM from various engine
MAF Sensor (Mass Air Flow)
sensors. The scan tool will display a lower percentage
when the engine is at idle with little or no load. The
ECM from the mass air flow (MAF) sensor. MAF sensor
scan tool will display a higher percentage when the
is a range of value indicating a low voltage at lower
engine is running at high engine speed under a heavy
engine speed, and a high voltage at a higher engine
load.
speeds.
Coolant Temperature
Barometric Pressure
This parameter displays the temperature of the engine
This parameter displays the barometric pressure
coolant as calculated by the ECM using the signal from
(BARO) as calculated by the ECM using the signal from
the engine coolant temperature (ECT) sensor. The
the BARO sensor. The scan tool will display a low
scan tool will display a low temperature when the ECT
barometric pressure in high altitude area.
sensor signal voltage is high, and a high temperature
when the ECT sensor signal voltage is low. Barometric Pressure Sensor
ECM from the barometric pressure (BARO) sensor.
BARO sensor is a range of value indicating a low
ECM from the engine coolant temperature (ECT)
voltage in high altitude area, and a middle voltage in
sensor. ECT sensor is a range of value indicating a low
sea level.
voltage when the temperature is high, and a high
voltage when the temperature is low. Desired Turbocharger Position
This parameter displays turbocharger nozzle position
Intake Air Temperature
desired by the ECM based on current boost pressure.
This parameter displays the temperature of the intake
air as calculated by the ECM using the signal from the Desired Boost Pressure
intake air temperature (IAT) sensor. The scan tool will This parameter displays boost pressure desired by the
display a low temperature when the IAT sensor signal ECM based on current driving conditions. This can be
voltage is high, and a high temperature when the IAT compared to the actual boost pressure to determine
sensor signal voltage is low. sensor accuracy or turbocharger control problems.
Intake Air Temperature Sensor Boost Pressure
This parameter displays the voltage signal sent to the This parameter displays the boost pressure in the
ECM from the intake air temperature (IAT) sensor. IAT intake duct as calculated by the ECM using the signal
sensor is a range of value indicating a low voltage from the boost pressure sensor. The scan tool will
when the temperature is high, and a high voltage when display a low boost pressure when the low engine load,
the temperature is low. and a high boost pressure when the high engine load.
Note that the true boost pressure is determined by
Fuel Temperature
subtracting barometric pressure from the actual
This parameter displays the temperature of the fuel as
reading.
calculated by the ECM using the signal from the fuel
temperature (FT) sensor. The scan tool will display a
low temperature when the FT sensor signal voltage is
high, and a high temperature when the FT sensor
signal voltage is low.

Boost Pressure Sensor APP Sensor 1 (Accelerator Pedal Position)
This parameter displays the voltage signal sent to the This parameter displays the voltage signal sent to the
ECM from the boost pressure sensor. Boost pressure ECM from the accelerator pedal position (APP) sensor
sensor is a range of value indicating a low voltage 1 of the APP sensor assembly. APP sensor 1 is a range
when the boost pressure is low (idle or lower engine of value indicating a low voltage when the accelerator
load) and a high voltage when the boost pressure is pedal is not depressed, and a high voltage when the
high (higher engine load). accelerator pedal is fully depressed.
Desired Fuel Rail Pressure APP Sensor 2 (Accelerator Pedal Position)
This parameter displays fuel rail pressure desired by This parameter displays the voltage signal sent to the
the ECM based on current driving conditions. This can ECM from the accelerator pedal position (APP) sensor
be compared to the actual fuel rail pressure to 2 of the APP sensor assembly. APP sensor 2 is a range
determine sensor accuracy or fuel pressure control of value indicating a high voltage when the accelerator
problems. pedal is not depressed, and a low voltage when the
accelerator pedal is fully depressed.
Fuel Rail Pressure
This parameter displays the fuel rail pressure as Desired EGR Position
calculated by the ECM using the signal from the fuel This parameter displays EGR position desired by the
rail pressure (FRP) sensor. The scan tool will display a ECM based on current driving conditions. This can be
low pressure when the low engine load, and a high compared to the actual EGR position to determine
pressure when the high engine load. sensor accuracy or motor control problems.
Fuel Rail Pressure Sensor EGR Position 1
This parameter displays the voltage signal sent to the This parameter displays the EGR valve position
ECM from the fuel rail pressure (FRP) sensor. FRP calculated by the ECM using the signal from the
sensor is a range of value indicating a low voltage individual three EGR position sensors. The scan tool
when the fuel rail pressure is low, and a high voltage will display a low percentage when the EGR valve is
when the fuel rail pressure is high. closed, and a high percentage when the EGR valve is
opened.
FRP Regulator Command (Fuel Rail Pressure)
This parameter displays the fuel rail pressure (FRP) EGR Position 1
regulator control duty ratio based on inputs to the ECM This parameter displays the input state of the EGR
from various engine sensors. The scan tool will display position sensor 1 to the ECM. When the position
a lower percentage when the FRP regulator is sensor is opened, the scan tool displays Low. When the
controlled to open (fuel supply quantity to the fuel rail is position sensor is closed, the scan tool displays High.
increased). The scan tool will display higher
EGR Position 2
percentage when the FRP regulator is controlled to
This parameter displays the input state of the EGR
close (fuel supply quantity to the fuel rail is reduced).
position sensor 2 to the ECM. When the position
FRP Regulator Commanded Fuel Flow sensor is opened, the scan tool displays Low. When the
This parameter displays the commanded fuel flow position sensor is closed, the scan tool displays High.
quantity of the fuel rail pressure (FRP) regulator to the
EGR Position 3
fuel rail.
This parameter displays the input state of the EGR
FRP Regulator Feedback Current (Fuel Rail position sensor 3 to the ECM. When the position
Pressure) sensor is opened, the scan tool displays Low. When the
This parameter displays the fuel rail pressure (FRP) position sensor is closed, the scan tool displays High.
regulator control feedback current as measured by the
Intake Throttle Solenoid Command
ECM. The scan tool will display a low current when the
This parameter displays the intake throttle motor
FRP regulator is controlled to open (fuel supply
control duty ratio based on inputs to the ECM from
quantity to the fuel rail is increased). The scan tool will
various engine sensors. The scan tool will display a
display a high current when the FRP regulator is
lower percentage when the intake throttle motor is
controlled to close (fuel supply quantity to the fuel rail is
controlled to open. The scan tool will display a higher
reduced).
percentage when the intake throttle motor is controlled
Accelerator Pedal Position to close.
This parameter displays the angle of the accelerator
Desired Intake Throttle Position
pedal as calculated by the ECM using the signals from
This parameter displays intake throttle position desired
the accelerator pedal position (APP) sensors. The scan
by the ECM based on current driving conditions. This
tool will display linearly from 0 to 100% according to the
can be compared to the actual intake throttle position to
pedal operation.
determine sensor accuracy or motor control problems.

Intake Throttle Position Vehicle Speed
This parameter displays the intake throttle valve This parameter indicates the vehicle speed calculated
position calculated by the ECM using the signal from by the ECM using the signal from the vehicle speed
intake throttle position sensor. The scan tool will display sensor (VSS). The scan tool will display a low value at
a low percentage when the intake throttle valve is lower vehicle speeds, and a high value at higher
closed, and a high percentage when the intake throttle vehicle speeds.
valve is opened. Note that the intake throttle position
Starter Switch
indicates over 100% if the motor is commanded OFF.
This parameter displays the input status of the starter
Intake Throttle Position Sensor switch to the ECM. When the ignition switch is turned at
This parameter displays the voltage signal sent to the START position, the scan tool displays On.
ECM from the intake throttle position sensor. Intake
Ignition Switch
throttle position sensor is a range of value indicating a
This parameter displays the input status of the ignition
low voltage when the intake throttle valve is closed to a
switch to the ECM. When the ignition switch is turned
high voltage when the intake throttle valve is opened.
ON position, the scan tool displays On.
Idle-Up Sensor
Ignition Voltage
This parameter displays the ignition voltage measured
ECM from the idle up sensor. Idle up sensor is a range
at the ignition feed circuit of the ECM. Voltage is
of value indicating a low voltage when the idle up
applied to the ECM when the ignition switch is ON
sensor rotates in a counterclockwise direction to a high
position.
voltage when the idle up sensor rotates in a clockwise
direction. Battery Voltage
This parameter displays the battery voltage measured
Fuel Compensation Cyl. 1 to 6
at the ECM main relay switched voltage feed circuit of
This parameter displays the adjustment of fuel volume
the ECM. Voltage is applied to the ECM when the ECM
for each cylinder at low engine speed area as
main relay is energized.
calculated by the ECM. The scan tool will display a
negative value if the fuel volume is lowered. The scan Brake Switch 1
tool will display a positive value if the fuel volume is This parameter displays the input state of the brake
increased. If there is a cylinder that is excessively high switch 1 to the ECM. When the brake pedal is
or low value, it may indicate faulty fuel injector, weak or depressed, scan tool displays Applied.
slightly seized cylinder or an incorrectly programmed
Brake Switch 2
fuel injector ID code.
This parameter displays the input state of the brake
Fuel Supply Pump Status switch 2 to the ECM. When the brake pedal is
This parameter displays the learning state of the fuel depressed, scan tool displays Applied.
supply pump. Not Learned indicates initialized state
Clutch Pedal Switch
that is replaced to a new ECM or adjustment value is
This parameter displays the input state of the clutch
reset. After engine is warm upped, leaning will start at
pedal switch to the ECM. When the clutch pedal is
idle speed. Learned indicates learning process is
depressed, scan tool displays Applied. If the Smoother
completed state.
is installed, gearshift clutch input state from the TCM is
Rail Pressure Feedback Mode displayed.
This parameter displays the state of the fuel rail
Neutral Switch
pressure feedback to the ECM. Wait Mode indicates
This parameter displays the input state of the neutral
the ignition switch is turned ON position. Feedback
switch to the ECM. When the transmission gear is Park
Mode indicates the engine is during crank or run.
or Neutral, the scan tool displays Neutral.
Shutoff Mode indicates the ignition switch is turned
OFF position. Park Brake Switch
This parameter displays the input state of the park
Engine Running Status
brake switch to the ECM. When the park brake lever is
This parameter displays the state of engine. Ignition On
pulled, scan tool displays Applied.
indicates the ignition switch is turned ON position.
Cranking indicates the engine is during crank. Running Exhaust Brake Switch
indicates the engine is run. Off indicates the ignition This parameter displays the input state of the exhaust
switch is tuned OFF position. brake switch to the ECM. On indicates the exhaust
brake switch is closed and allows energizing the
Engine Runtime
exhaust brake solenoid valve and intake throttle
This parameter displays the time elapsed since the
depending upon driving condition. Off indicates the
engine start. The scan tool will display the time in
exhaust brake switch is open and exhaust brake will
hours, minutes and seconds.
not engage.

Exhaust Brake Valve Command Refrigerator Switch
This parameter displays the commanded state of the This parameter displays the state of the refrigerator
exhaust brake solenoid valve control circuit. On compressor engagement. On indicates the ECM
indicates the exhaust brake solenoid valve is being receiving a refrigerator compressor On signal. Off
grounded by the ECM, allowing air pressure to the indicates the ECM is not receiving a refrigerator
exhaust brake valve. compressor On signal.
Exhaust Brake Cut Request from ABS Module Oil Level
This parameter displays the state of the exhaust brake This parameter displays the state of the engine oil level
cut request to the ECM from the EHCU [ABS module] switch to the ECM. Normal indicators the engine oil
or ABS control unit. Active indicates the EHCU [ABS level is not too low for safe operation of the engine. Low
module] or ABS control unit is commanding to release indicators the engine oil level is abnormally low and has
the exhaust brake. opened the engine oil level switch.
Exhaust Brake Cut Request from TCM Glow Plug Relay Command
This parameter displays the state of the exhaust brake This parameter displays the commanded state of the
cut request to the ECM from the transmission control glow relay control circuit. On indicates the glow relay
module (TCM). Active indicates the TCM is control circuit is being grounded by the ECM, allowing
commanding to release the exhaust brake. voltage to the glow plugs.
ASR Commanded APP (Accelerator Pedal Position) Malfunction Indicator Lamp (MIL)
This parameter displays the controlled angle of the This parameter displays the commanded state of the
accelerator pedal calculated by the EHCU [ABS malfunction indicator lamp (MIL) control circuit. The
module] or ABS control unit when anti slip regulator MIL should be On when the scan tool indicates
(ASR) system operated. The scan tool will display command On. The MIL should be Off when the scan
100% when the ECM is not controlled to reduce fuel tool indicates command Off.
injection quantity. The scan tool will display a lower
Distance While MIL is Activated
percentage when the ECM is controlled to reduce fuel
This parameter displays the mileage since the
injection quantity to reduce drive wheels spinning.
malfunction indicator lamp (MIL) is turned ON.
PTO Switch
Engine Runtime With MIL Active
This parameter displays the state of the PTO switch to
This parameter displays the accumulated ignition
the ECM. When the PTO switch is operated by control
switch ON time elapsed since the malfunction indicator
lever or button, scan tool displays On.
lamp (MIL) is turned ON. The scan tool will display the
PTO Remote Throttle time in minutes.
This parameter displays the angle of the PTO remote
Total Engine Overspeed Events
throttle sensor as calculated by the ECM using the
This parameter indicates counter of engine overspeed
signal from the PTO remote throttle sensor. The PTO
event. Counter will be zero if any DTC is cleared.
remote throttle angle is a range of values indicating a
low percentage when the throttle sensor is not operated Total Engine Coolant Overtemperature Event
to a high percentage when the throttle sensor is This parameter indicates counter of engine overheat
operated. event. The counter is active if engine coolant is over
110°C (230°F). Counter will be zero if any DTC is
PTO Remote Throttle Sensor
cleared.
ECM from the PTO remote throttle sensor. PTO remote Total Fuel Temperature Overtemperature Event
throttle sensor is a range of values indicating a low This parameter indicates counter of fuel temperature
voltage when the throttle sensor is not operated to a excessively high condition. The counter is active if fuel
high voltage when the throttle sensor is operated. temperature is over 90°C (194°F). Counter will be zero
if any DTC is cleared.
Engine Warm Up Switch
This parameter displays the input state of the engine Total Intake Air Temperature Overtemperature
warm up switch to the ECM. On indicates the engine Event
warm up switch is closed and allows energizing the This parameter indicates counter of intake air
exhaust brake solenoid valve and intake throttle valve temperature excessively high condition. The counter is
depending upon engine condition. active if intake air temperature is over 60°C (140°F).
Counter will be zero if any DTC is cleared.
A/C Request Signal (Air Conditioning)
This parameter displays the state of the air conditioning
(A/C) compressor engagement. On indicates the ECM
receiving an A/C compressor On signal. Off indicates
the ECM is not receiving an A/C compressor On signal.

DPD Regeneration Switch Exhaust Differential Pressure Sensor
This parameter displays the input state of the DPD This parameter displays the voltage signal set to the
regeneration switch to the ECM. On indicates the DPD ECM from the exhaust differential pressure sensor.
regeneration switch is closed and allows entering the Exhaust differential pressure sensor is a range of value
regeneration process depending upon PM indicating a low voltage at a low differential pressure,
accumulation condition. such as small PM accumulation, and a high voltage at a
high differential pressure, such as large PM
DPD Mode
accumulation.
This parameter displays the state of the DPD. It mainly
indicates an action request or status to the user during Exhaust Temperature 1
regeneration event. 1 or 50 indicates DTC is set, which This parameter displays the temperature of the exhaust
is not allowing the DPD regeneration. 30 indicates gas in front of filter as calculated by the ECM using the
under normal engine operation. signal from the exhaust gas temperature sensor 1. The
scan tool will display a low temperature when the
DPD Accumulation Status
exhaust gas temperature sensor 1 signal voltage is
This parameter displays the state of the PM
high, and a high temperature when the exhaust gas
accumulations. It indicates that the PM accumulative
temperature sensor 1 signal voltage is low.
amount to the filter increases while parameter is
increasing from 0 to 5. This parameter uses together Exhaust Temperature Sensor 1
with DPD Distance Status parameter to determine This parameter displays the voltage signal sent to the
regeneration type manually. ECM from the exhaust gas temperature sensor 1.
Exhaust gas temperature sensor 1 is a range of value
DPD Distance Status
indicating a low voltage when the temperature is high,
This parameter displays the state of the distance since
and a high voltage when the temperature is low.
last regeneration. It indicates that the accumulative
distance without regeneration event increases while Exhaust Temperature 2
parameter is increasing from 0 to 4. This parameter This parameter displays the temperature of the exhaust
uses together with DPD Accumulation Status gas in front of oxidation catalyst as calculated by the
parameter to determine regeneration type manually. ECM using the signal from the exhaust gas
temperature sensor 2. The scan tool will display a low
DPD Incomplete Regeneration Status
temperature when the exhaust gas temperature sensor
This parameter indicates an error status of the DPD
2 signal voltage is high, and a high temperature when
regeneration. 1 or 2 indicates the frequency of the
the exhaust gas temperature sensor 2 signal voltage is
regeneration event that did not finish within a
low.
predetermined time.
Exhaust Temperature Sensor 2
DPD Insufficient Regeneration Status
ECM from the exhaust gas temperature sensor 2.
regeneration. 1 or 2 indicates the frequency of
incomplete filter purification after the regeneration
event.
DPD LLIR Condition On Particulate Matter
Exhaust Throttle Status
This parameter displays the amount of the PM
This parameter displays the commanded state of the
accumulations at idle.
exhaust throttle solenoid valve control circuit. On
DPD Trip indicates the exhaust throttle solenoid valve is being
This parameter displays the distance as calculated by grounded by the ECM, allowing air pressure to the
the ECM based on regeneration control. exhaust throttle valve.
DPD DIL Trip Vane Control Solenoid Error
This parameter displays the distance as one of the This parameter displays an error state of the
factor to determine the automatic regeneration or turbocharger nozzle control actuator from the rotary
manual regeneration. electric actuator (REA) control module. Stuck indicates
Exhaust Differential Pressure the REA control module detects an open circuit on the
This parameter displays the exhaust differential solenoid circuit or a sticking the nozzle control actuator.
pressure as calculated by the ECM using the signal Short Circuit indicates the REA control module detects
from the exhaust differential pressure sensor. The scan a short circuit on the solenoid circuit.
tool will display a low exhaust differential pressure at Vane Position Sensor Error
small PM accumulation, and a high exhaust differential This parameter displays an error status of the
pressure at large PM accumulation. turbocharger nozzle position sensor from the rotary
electric actuator (REA) control module. All High or All
Low indicates the REA control module detects all
nozzle position sensor signal are stuck low or high.

Turbocharger Control Module Error
This parameter displays an error status of the rotary
electric actuator (REA) control module system voltage.
High voltage indicates the REA control module detects
system voltage is too high.
Cruise Main Switch
This parameter displays the input state of the cruise
control main switch to the ECM. When the cruise
control main switch is pushed, the scan tool displays
On.
Cruise Cancel Switch
cancel switch to the ECM. When the cruise cancel
switch is pushed, the scan tool displays On.
Cruise Resume/ Acceleration Switch
resume/ accel. switch to the ECM. When the cruise
resume/ accel. switch is applied, the scan tool displays
On.
Cruise Set/ Coast Switch
set/ coast switch to the ECM. When the cruise set/
coast switch is applied, the scan tool displays On.
Immobilizer Signal
This parameter displays the input state of the response
signal to the ECM. When the ECM received any
response signal from the immobilizer control unit (ICU),
the scan tool displays Yes.
Wrong Immobilizer Signal
This parameter displays the input state of the received
response signal to the ECM. When the ECM received
wrong response signal from the immobilizer control unit
(ICU), the scan tool displays Yes.
Immobilizer Function Programmed
This parameter displays the state of the immobilizer
function programming in the ECM. The scan tool will
display Yes or No. Yes indicates the immobilizer
security information is correctly programmed in the
ECM. No indicates the ECM is not programmed or
ECM is reset.
Security Wait Time
This parameter displays the security wait time length in
the ECM. Inactive indicates not in security wait time.
Time indicates under security wait time. This wait time
stage will prevent any further attempts to enter the
security code until the wait time has elapsed. Note that
this parameter is not count downed. It keeps displaying
the same time until that wait time has elapsed. The
ignition switch must be kept at ON position during the
wait time period.

Scan Tool Output Controls
Scan Tool Output Control Descriptions

Fuel Pressure Control The purpose of this test is for checking whether the fuel rail pressure is changing when
commanded. Faulty fuel supply pump, fuel rail pressure (FRP) regulator, pressure limiter
valve or other fuel lines could be considered if the differential fuel rail pressure is large.
Pre Injection Control The purpose of this test is for checking whether the pre fuel injection is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine noise does not
change when commanded OFF.
Injection Timing Control The purpose of this test is for checking whether the main injection timing is changing when
commanded Retard/ Advance.
Injector Forced Drive The purpose of this test is for checking whether the fuel injector is correctly operating when
commanded ON. Faulty injector(s) could be considered if it does not create a clicking noise
(solenoid operating noise), contains an interrupted noise or has abnormal noise when
commanded ON.
Cylinder Balance Test Notice: If this test does not run, slightly increase the engine speed by pressing the
accelerator pedal.
The purpose of this test is for checking whether the fuel injector is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine does not change
speed when commanded OFF.
Intake Throttle Solenoid Control The purpose of this test is for checking whether the intake throttle valve is correctly moved
with command. Restricted valve movement by foreign materials, excessive deposits or a
faulty valve could be considered if the position difference is large.
EGR Solenoid Control The purpose of this test is for checking whether the EGR valve is correctly moved with
command. Restricted valve movement by foreign materials, excessive deposits or a faulty
valve could be considered if the position difference is large.
Turbocharger Solenoid Control The purpose of this test is for checking whether the turbocharger nozzle control solenoid is
correctly moved with command. Restricted actuator movement by foreign materials,
excessive deposits, damaged linkage, a faulty solenoid or a faulty position sensor could be
considered if the solenoid is not moved correctly.
Glow Relay Control The purpose of this test is for checking whether the glow relay is operating when
commanded ON. Faulty circuit(s) or a faulty glow relay could be considered if not
energizing when commanded ON.
Exhaust Brake Control The purpose of this test is for checking whether the exhaust brake control solenoid is
operating when commanded ON. Faulty circuit(s) or a faulty solenoid could be considered if
not energizing when commanded ON.
Exhaust Throttle Control The purpose of this test is for checking whether the exhaust throttle solenoid valve is
operating when commanded ON. Faulty circuit(s) or a faulty exhaust throttle solenoid valve
could be considered if not energizing when commanded ON.
Fuel Supply Pump Learn Important: The fuel supply pump relearn procedure must be done when the fuel supply
Resetting pump or engine is replaced, or an ECM from another vehicle is installed. Refer to Fuel
Supply Pump in Section 1D Engine Fuel.
The purpose of this test to reset the fuel supply pump adjustment value.
DPD Status Resetting Important: DPD status must be reset before regeneration with a scan tool.
The purpose of this function to reset the DPD status parameters.
DPD Normal Regeneration Important: Do Not perform this test if the exhaust differential pressure is more than a
Control threshold.
The purpose of this test is for DPD filter force regeneration.
DPD Slow Regeneration Control Important: Do Not perform this test if the exhaust differential pressure is more than a
threshold. And, engine oil must be replaced after DPD slow regeneration is completed.
The purpose of this test is for DPD filter force regeneration in case of excessively
accumulated PM. This very slow regeneration compared with another one.

Scan Tool Does Not Power Up • Scan tool power ground at terminal 4.
Circuit Description • Common signal ground at terminal 5.
The scan tool will power up with the ignition OFF. Some
The data link connector (DLC) is a standardized 16- modules however, will not communicate unless the
cavity connector. Connector design and location is ignition is ON.
dictated by an industry wide standard, and is required
to provide the following: Connector End View Reference: Engine Controls
• Scan tool power battery positive voltage at Connector End Views or ECM Connector End Views
terminal 16.
Circuit/ System Testing Scan Tool Does Not Power Up

Important: Make sure the scan tool and 24 volts
adapter works properly on another vehicle before
using this chart.
1 1. Turn OFF the ignition. —

2. Inspect the Dome Light (15A) fuse in the cabin
fuse block.
Is the Dome Light (15A) fuse open? Go to Step 2 Go to Step 3

Replace the Dome Light (15A) fuse. If the fuse
continues to open, repair the short to ground on
one of the circuits that is fed by the Dome Light
2 (15A) fuse or replace the shorted attached —
component.
Did you complete the repair? Go to Step 7 —

1. Check each circuit at the data link connector
(DLC) (FU23) for a backed out, spread or
missing terminal.
3 —
2. Repair the terminal as necessary.
Did you find and complete the repair? Go to Step 7 Go to Step 4

Connect a test lamp between the +B circuit (pin 16
4 of FU23) at the DLC and a known good ground. —
Does the test lamp illuminate? Go to Step 6 Go to Step 5
Repair the open in the battery voltage circuit to the
5 DLC. —
1. Test each ground circuit at the DLC (pins 4
and 5 of FU23) for an open circuit or high
resistance.
6 2. Repair the circuit(s), clean or tighten ground —
as necessary.
Go to Intermittent
Did you find and correct the condition? Go to Step 7 Conditions
1. Connect the scan tool to the DLC.
7 2. Attempt to turn ON the scan tool. —
Does the scan tool ON? System OK Go to Step 1

Scan Tool Does Not Communicate with Diagnostic Aids
CAN Device The following conditions will cause a loss of CAN serial
Circuit Description data communication between the scan tool and the
ECM.
The ECM communicates with the scan tool over the
• A CAN serial data circuit open
controller area network (CAN) link. The ECM, the
transmission control module (TCM) and the immobilizer • A CAN serial data circuit shorted to ground
control unit (ICU) communicate with each other over • A CAN serial data circuit shorted to voltage
the same CAN link. The ECM, the rotary electric • An internal condition within a module or connector
actuator (REA), the electric hydraulic control unit on the CAN serial data circuit, that causes a short
(EHCU) or ABS control unit, the body control module to voltage or ground to the CAN serial data circuit
(BCM) or the data recording module (DRM), the
instrument panel (IP) cluster and the TCM Connector End View Reference: Engine Controls
communicate with each other over the separated CAN Connector End Views or ECM Connector End Views
link that does not affect to the scan tool communication.
Circuit/ System Testing Scan Tool Does Not Communicate with CAN Device

Did you perform the Diagnostic System Check - Go to Diagnostic
1 Engine Controls? — System Check -
Go to Step 2 Engine Controls
Important: Make sure the CAN-di module is not
malfunctioning. When functioning properly, the
CAN-di module LED will be flashing. In the event of
a problem, the LED will be continually illuminated
or not illuminated.
2 1. Install a scan tool. —
3. Attempt to establish communication with the
ECM.
Go to Intermittent
Does the scan tool communicate with the ECM? Conditions Go to Step 3
1. Inspect for an intermittent, for poor
connections and for corrosion at the data link
connector (DLC) (pins 6 and 14 of FU23).
3 —
2. Repair the connection(s) as necessary.
Did you find and correct the condition? Go to Step 18 Go to Step 4

connections and for corrosion at the ECM E26
and FB24 connectors.
4 —

1. Check the ECM (40A) slow blow fuse and
ECM Main (15A) fuse in the chassis fuse
block, Engine Controller (10A) fuse in the
cabin fuse block. Replace and retest if open. If
any fuse continues to open, repair the short to
ground on each circuit fed by that fuse.
2. Turn OFF the ignition.
5 —
3. Disconnect the ECM FB24 harness connector.
5. Connect a test lamp to ground and check for
voltage at ignition voltage supply circuit at the
ECM (pin 24 of FB24).


Repair the open in the ignition voltage circuit to the
6 ECM. —
Notice: An open in a ground circuit at the ECM will
not cause a loss of communication.
1. Check ECM ground for corrosion and
7 tightness. —
2. Clean or tighten grounds as necessary.

2. Reconnect the ECM harness connector if
disconnected.
3. Replace the ECM main relay with the glow
8 relay or replace with a known good relay. —
ECM.
Does the scan tool communicate with the ECM? Go to Step 13 Go to Step 9
2. Remove the ECM main relay.
4. Using a test lamp, check for both voltage
9 —
supply circuit to the ECM main relay (pins 1
and 3 of X18).
5. Repair the open circuit(s) as necessary.

1. Reinstall the ECM main relay.
2. Turn the ignition ON and OFF while listening
of feeling for the ECM main relay click. Wait 7
10 seconds between transitions. —
Does the ECM main relay click when the ignition

switch is turned ON or OFF? Go to Step 12 Go to Step 11
Repair the ECM main relay ground circuit between
the ECM main relay (pin 5 of X18) and chassis
ground terminal (FB20) for the following conditions:
11 • An open circuit —
• High resistance or a poor connection at the ECM
main relay or ground terminal

1. Test the battery voltage circuit between the
ECM (pins 2 and 5 of FB24) and the ECM
main relay for the following conditions:
• An open circuit
12 • High resistance or a poor connection at —
the ECM or ECM main relay
2. Repair the circuit(s) as necessary.

Replace the ECM main relay.
13 —
Did you complete the replacement? Go to Step 18 —

2. Reconnect the ECM FB24 harness connector.
3. Disconnect the scan tool from the DLC if
connected.
4. Measure the resistance across the CAN Low
14 50 to 70 Ω
and High circuits by probing the DLC (pins 6
and 14 of FU23).
Is the resistance within the specified value (parallel

resistance of the 120 Ω resistor in the ECM and the
120 Ω CAN resistor should be 60 Ω)? Go to Step 16 Go to Step 15
2. Disconnect the ECM harness connector.
connections and corrosion at the harness
connector of the ECM (pins 58 and 78 of
FB24).
4. Test the CAN Low and High serial data circuits
between the DLC (pins 6 and 14 of FU23) and
the ECM (pins 58 and 78 of FB24), the
transmission control module (TCM) (pins 14
15 and 15 of FU108), the immobilizer control unit —
(ICU) (pins 5 and 6 of FL34) or the CAN
resistor (pins 1 and 2 of FU200) for the
following conditions:
• An open circuit
• A short circuit each other
• High resistance
5. Repair the connection(s) or circuit(s) as
necessary.

the ECM (pins 58 and 78 of FB24), the TCM
(pins 14 and 15 of FU108), the ICU (pins 5
and 6 of FL34) or the CAN resistor (pins 1 and
16 2 of FU200) for the following conditions: —
• A short to ground
• A short to voltage

Important: Replacement ECM must be
programmed and learned.
17 Replace the ECM. Refer to ECM Replacement. —

2. Reconnect all previously disconnected fuse,
relay or harness connector(s).
18 3. Turn ON the ignition, with the engine OFF. —
ECM.
Does the scan tool communicate with the ECM? System OK Go to Step 3

Engine Cranks but Does Not Run • Fuse and slow blow fuse are normal.
Description
Diagnostic Aids
The Engine Cranks but Does Not Run diagnostic table
• If an intermittent condition is suspected, refer to
is an organized approach to identifying a condition that
Intermittent Conditions in this section.
causes an engine to not start. The diagnostic table
directs the service technician to the appropriate system
Test Description
diagnosis. The diagnostic table assumes the following
conditions are met: The number below refers to the step number on the
• The battery is completely charged and terminals Circuit/ System Testing.
are cleaned and tight. 5. If the fuel rail pressure (FRP) regulator low side
circuits between the ECM and the FRP regulator are
• The engine cranking speed is normal. shorted to ground, FRP Regulator Feedback Current
• There is adequate fuel in the fuel tank. will be approximately 300 mA or more low as compared
• There is no fuel leak in the fuel line. with normal.
• There is no air in the fuel line.
Connector End View Reference: Engine Controls
• Filters (air, fuel) are clean.
Connector End Views or ECM Connector End Views
Circuit/ System Testing Engine Cranks but Does Not Run

2. Turn OFF the ignition for 30 seconds.
3. Crank the engine for the specified amount of
2 time. 15 seconds
4. Monitor the DTC Information with a scan tool.
Does the scan tool display any DTCs that failed this Go to Applicable
ignition? DTC Go to Step 3
2. Wait 2 minutes for the fuel pressure to bleed
down from the fuel rail.
3 3. Turn ON the ignition, with the engine OFF. 0 MPa (0 psi)
4. Observe the Fuel Rail Pressure parameter
with a scan tool.
Does the scan tool indicate the specified value? Go to Step 4 Go to Step 6
Notice: If the vehicle has run out of fuel, air may be
trapped in the fuel system.
1. Make sure the fuel tank have adequate fuel
and the fuel quality is good (take a sample).
2. Observe the Fuel Rail Pressure parameter on 25 MPa (3,600
4
psi)
the scan tool while cranking over the engine
for 5 seconds.
Does the scan tool indicate more than the specified

value during crank? Go to Step 9 Go to Step 5
Observe the FRP Regulator Feedback Current
parameter on the scan tool while cranking over the
engine for 5 seconds. Go to Fuel System
5 800 mA Check Chart in
Does the scan tool indicate more than the specified Section 1D Engine
value during crank? Fuel Go to Step 8

2. Disconnect the FRP sensor harness
connector.
connector of the FRP sensor (pins 1, 2 and 3
of E49).
6 5. Inspect for an intermittent, for poor —
connector of the ECM (pins 82, 87, 90 and
101 of E26).
6. Test for high resistance on each circuit.
necessary.

Replace the FRP sensor. Refer to Fuel Pressure
7 Sensor (Common Rail) in Section 1D Engine Fuel. —
Repair the short to ground between the ECM (pins
89 and 97 of E26) and the FRP regulator (pin 2 of
8 E47). —

1. Check for normal readings at key up for the
following sensor inputs: Use the Scan Tool
Data List or a known good vehicle to
determine nominal values.
• Engine Coolant Temperature Sensor
• Barometric Pressure (BARO) Sensor
9 —
• Boost Pressure Sensor
• Intake Throttle Position Sensor
2. Repair the circuit(s) or replace the sensor as
necessary.

1. Other possible causes for the no-start
condition:
• Engine mechanical timing
• Flywheel installed incorrectly causing the
crankshaft position (CKP) sensor to be
incorrectly timed to the engine.
Disconnect sensor and attempt to start
10 engine to verify. —
• Heavily restricted intake or exhaust
plugged solid.
• Poor engine compression.
• Water or gasoline contamination in fuel.
2. Repair as necessary.
Did you find and correct the condition? Go to Step 11 —

1. Reconnect all previously disconnected
harness connector(s).
11 2. Turn OFF the ignition for 30 seconds. —

3. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 12 Go to Step 2


Observe the DTC Information with a scan tool.
12 —
Are there any DTCs that you have not diagnosed? Go to DTC List System OK

DTC P0016 (Flash Code 16)
Crankshaft Position - Camshaft Position • The ignition switch is ON.
Correlation • The CKP sensor signal pulse is detected.
• The CMP sensor signal pulse is detected.
Circuit Description
The crankshaft position (CKP) sensor is located under Condition for Setting the DTC
the fuel supply pump. There are 56 notches spaced 6° • The ECM detects that the CKP sensor signal
apart and a 30° section that is open span. This open pulses and CMP sensor signal pulses are out of
span portion allows for the detection of top dead center synchronization during engine rotations.
(TDC).
The camshaft position (CMP) sensor is installed on the Action Taken When the DTC Sets
cylinder head at the rear of the camshaft gear. The
• The ECM illuminates the MIL when the diagnostic
CMP sensor detects total of seven projections per one
runs and fails. Refer to DTC Type Definitions for
engine cycle (six projections arranged equally every
Action Taken When the DTC Sets - Type A.
60° and one reference projection on the camshaft gear
surface).
Condition for Clearing the DTC
Detecting the open span portion from the CKP sensor
and one reference projection from the CMP sensor, the • Refer to DTC Type Definitions for Condition for
ECM determines cylinder #1 compression TDC to Clearing the MIL/ DTC - Type A.
ensure they correlate with each other. If the ECM
detects both signals are out of synchronization, this Diagnostic Aids
DTC will set. • This DTC is cause by an incorrect mechanical
timing condition, which is most likely caused by
Condition for Running the DTC wrong installation of timing gear, flywheel or
• DTCs P0335, P0336, P0340 and P0341 are not camshaft.
set.
Circuit/ System Testing DTC P0016 (Flash Code 16)

3. Start the engine. If the engine does not start,
2 crank over the engine for 10 seconds. —
Go to Applicable
Is DTC P0335, P0336, P0340 or P0341 also set? DTC Go to Step 3

1. Inspect the crankshaft position (CKP) sensor
and the camshaft position (CMP) sensor for
the following conditions:
• Physical damage of sensor
• Loose or improper installation of sensor
• Excessive air gap
• Foreign material passing between sensor
and sensor rotor or camshaft gear
• Physical damage of sensor rotor or
camshaft gear
3 —
rotor or camshaft gear
2. Inspect the engine mechanical timing for an
incorrectly installed timing gear or camshaft.
Notice: If the flywheel dowel pin is missing or

pushed in and the flywheel is incorrectly
installed, this DTC may set.
3. Repair or replace as necessary.

harness connector(s) if disconnected.
2. Clear the DTCs with a scan tool.
crank over the engine for 10 seconds.
4 —
5. Operate the vehicle within the Conditions for
Running the DTC. You may also operate the
vehicle within the conditions that you
observed from the Freeze Frame/ Failure
Records.
Did the DTC fail this ignition? Go to Step 2 Go to Step 5

5 —

Turbocharger Boost Control Solenoid Circuit • The REA detects the nozzle position is not at
predetermined value.
Circuit Description • The REA detects all of position sensor signals are
The position of the turbocharger nozzle is controlled by High or Low.
rotary electric actuator (REA) based on the command • The REA detects abnormal condition.
of the ECM. REA is installed on turbocharger. When
the engine is not under load, the turbocharger nozzles Action Taken When the DTC Sets
are in an open position. When the engine is under load, • The ECM illuminates the MIL when the diagnostic
the REA to close the turbocharger nozzles, thus runs and fails. Refer to DTC Type Definitions for
increasing the boost pressure. The ECM will vary the Action Taken When the DTC Sets - Type A.
target nozzle position dependent upon the boost
• The ECM inhibits EGR control.
requirements of the engine. If the REA senses an error
in the nozzle position signals, or abnormal condition, • The ECM inhibits cruise control.
the REA will send a message to the ECM via the
controller area network (CAN) communication bus and Condition for Clearing the DTC
the ECM will set this DTC. • Refer to DTC Type Definitions for Condition for
Clearing the MIL/ DTC - Type A.
Condition for Running the DTC
• The battery voltage is between 20 to 32 volts. Diagnostic Aids
• The ignition switch is ON. • If an intermittent condition is suspected, refer to
Condition for Setting the DTC • A sticking or intermittently sticking the REA may
Either of following condition is met: set this DTC.
• The REA detects the temperature around the DC
motor transistor is high.

2 3. Start the engine. —
Is DTC U0073 set? Go to DTC U0073 Go to Step 3

1. Inspect the turbocharger assembly for the
• Physical damage of turbocharger
• Turbocharger nozzle control linkage
3 damaged —
• Physical damage of REA

2. Disconnect the REA harness connector.
3. Connect a test lamp between the voltage feed
4 circuit (pin 3 of E10) and a known good —
ground.


Connect a test lamp between the voltage feed
5 circuit and the ground circuit (pins 3 and 6 of E10). —
1. Test the voltage and ground between the ECM
Main (15A) fuse and the REA (pin 3 of E10),
or between the REA (pin 6 of E10) and the
6 ground for an open circuit or high resistance. —

Repair the open circuit or high resistance between
the ECM Main (15A) fuse and the REA (pin 3 of
7 E10). Check the ECM Main (15A) fuse first. —

8 connections and corrosion at the harness —
connector of the REA (pins 3 and 6 of E10).

Replace the turbocharger. (REA is internal to
turbocharger). Refer to Turbocharger in Section 1J
9 Induction. —

10 5. Operate the vehicle within the Conditions for —
Records.

Observe the DTC information with a scan tool.
11 —

DTC P0079 or P0080 (Flash Code 38)
Exhaust Valve Control Solenoid Circuit Low or Action Taken When the DTC Sets
High • The ECM illuminates the MIL when the diagnostic
Circuit Description Action Taken When the DTC Sets - Type A.
The ECM controls the exhaust throttle solenoid valve
based on the diesel particulate defuser (DPD) system Condition for Clearing the DTC
regeneration status. The exhaust throttle solenoid valve • Refer to DTC Type Definitions for Condition for
energizes to apply air pressure to the exhaust throttle Clearing the MIL/ DTC - Type A.
valve that is installed rear of the DPD housing. If the
ECM detects an improper voltage level on the exhaust Diagnostic Aids
throttle valve control circuit, DTC P0079 or P0080 will • If an intermittent condition is suspected, refer to
set. Intermittent Conditions in this section.
Condition for Running the DTC Test Description

• The battery voltage is between 18 to 32 volts. The number below refers to the step number on the
• The ignition switch is ON. Circuit/ System Testing.
DTC P0080
Condition for Setting the DTC 3. If the exhaust throttle solenoid valve control circuit
• The ECM detects a low voltage condition on the between the ECM and the solenoid valve is normal,
exhaust throttle solenoid valve control circuit for voltage level low DTC P0079 will set.
longer than 3 seconds when the solenoid valve is
commanded OFF. (DTC P0079) Connector End View Reference: Engine Controls
• The ECM detects a high voltage condition on the
exhaust throttle solenoid valve control circuit for
commanded ON. (DTC P0080)

2. Perform the Exhaust Throttle Control with a
2 scan tool. —
3. Command the solenoid valve ON and OFF.
Go to Diagnostic
Does the solenoid valve click with each command? Aids Go to Step 3
2. Disconnect the exhaust throttle solenoid valve
harness connector.
3. Connect a test lamp between the ignition
3 voltage feed circuit (pin 1 of FB112) and a —
known good ground.

1. Connect a test lamp between the control
circuit (pin 2 of FB112) and battery voltage.
4 scan tool. —
Does the test lamp turn ON and OFF with each

command? Go to Step 9 Go to Step 5

Does the test lamp remain illuminated with each
5 —
the ECM Main (15A) fuse and the exhaust throttle
6 solenoid valve (pin 1 of FB112). Check the ECM —
Main (15A) fuse first.

1. Test the control circuit between the ECM (pin
102 of E26) and the solenoid valve (pin 2 of
FB112) for an open circuit or high resistance.
7 —

FB112) for a short to ground.
8 —

1. Inspect for an intermittent and for poor
connections at the harness connector of the
solenoid valve (pins 1 and 2 of FB112).
9 —

3. Inspect for an intermittent and for a poor
10 connection at the harness connector of the —
ECM (pin 102 of E26).

Replace the exhaust throttle solenoid valve.
11 —

13 3. Perform the Exhaust Throttle Control with a —
scan tool.
Does the solenoid valve click with each command? Go to Step 14 Go to Step 3
14 —


2 scan tool. —
Go to Diagnostic
harness connector.
Is DTC P0079 set, but not DTC P0080? Go to Step 5 Go to Step 4

FB112) for a short to battery or ignition
4 voltage. —

5 —

1. Reconnect all previously disconnected relay
or harness connector(s).
scan tool.
8 —

Fuel Rail/ System Pressure Too Low Action Taken When the DTC Sets
Description consecutive driving cycle when the diagnostic runs
The common rail fuel system is comprised of two fuel and fails. Refer to DTC Type Definitions for Action
pressure sections: a suction side between the fuel tank Taken When the DTC Sets - Type B.
and the fuel supply pump and a high-pressure side • The ECM limits fuel injection quantity.
between the fuel supply pump and the fuel injectors. • The ECM inhibits pre injection.
Fuel is drawn from the fuel tank via a feed pump and
then pumped into the fuel rail by three plungers, all of
which are internal to the fuel supply pump. This high • The ECM inhibits cruise control.
pressure is regulated by the ECM using the fuel rail
pressure (FRP) regulator dependant upon values from Condition for Clearing the DTC
the FRP sensor attached to the fuel rail. In case of fuel • Refer to DTC Type Definitions for Condition for
rail overpressure, a pressure limiter valve threaded into Clearing the MIL/ DTC - Type B.
the fuel rail will open to release overpressure and
return fuel back to the fuel tank. If the ECM detects that Diagnostic Aids
the fuel rail pressure went excessively high, then
• An intermittently sticking FRP regulator may have
sharply decreased, this DTC will set indicating high fuel
allowed the fuel pressure to become high enough
pressure, which activated the pressure limiter valve.
to open the pressure limiter valve.
Condition for Running the DTC • A skewed FRP sensor value can set this DTC. The
FRP Sensor on the scan tool should read 0.9 to
• DTCs P0192, P0193, P060B and P0651 are not 1.0 volt with the ignition switch ON and engine
set. OFF after the engine has stopped running for a
• The ignition switch is ON. minimum of 2 minutes.
• The engine is running.
Notice: If the fuel tank is empty or near empty, air
Condition for Setting the DTC might be allowed to go into the fuel system. With air in
the fuel system, smooth flow of fuel into the supply
• The ECM detects that the pressure limiter valve is
pump is interrupted and this DTC may set. Perform
activated with overpressure (more than 180 MPa
bleeding of fuel system after refilling.
[26,000 psi]) in the fuel rail.
Routing Reference: Fuel System Routing Diagram

2 —
Is DTC P0088, P0089, P0091, P0092, P0192, Go to Applicable

P0193, P0201 - P0206, P2146 or P2149 set? DTC Go to Step 3

2. Place the transmission in Neutral and set the
parking brake.
3 4. Accelerate the engine between idle and — An intermittent
W.O.T. (accelerator pedal full travel) many problem by foreign
times while observing the DTC Information material in the fuel
with a scan tool. system is
suspected. Go to
Does the DTC fail this ignition? Go to Step 4 Step 13
4 0.9 to 1.0 volt
4. Observe the Fuel Rail Pressure Sensor
parameter with the scan tool.
Does the scan tool indicate within the specified

value? Go to Step 5 Go to Step 12
2. Perform the Cylinder Balance Test with a scan
tool.
5 3. Command each injector OFF and verify an —
engine speed change for each injector.
Is there an injector that does not change engine

speed when commanded OFF? Go to Step 15 Go to Step 6
1. Inspect the fuel system line connections
between the fuel tank and the fuel supply
pump for tightness and all fuel hoses for cuts,
cracks and for the use of proper clamps.
Notice: The fuel system from the fuel tank(s)

to the fuel supply pump is under a slight
vacuum with the engine running. As a result,
air can enter the fuel system if these
connections are not tight. Air in the fuel
system will cause fuel rail pressure
fluctuations especially at high engine speed
6 and load, which may set this DTC. —
2. Pump the priming pump until it becomes firm.
If there is a leak on the suction side of the fuel
system between the priming pump and the
fuel supply pump, the priming pump will not
build up sufficient firmness and fuel leakage
may occur.
3. Start the engine and check for high side fuel
system leaks at the fuel supply pump and fuel
rail.
4. Repair any fuel system leaks as necessary.


1. Inspect the engine oil level.
Notice: Fuel may leak under the cylinder head

cover from the inlet high pressure line. In such
7 case, the engine oil level will rise. Inspect for —
fuel leakage into the engine oil.

1. Inspect the inlet high pressure joint to the fuel
injectors for fuel leaking from the sleeve
nut(s).
8 —

1. Inspect the fuel lines between the fuel supply
pump and fuel tank for being crushed or
kinked.
2. Inspect for a plugged fuel tank vent hose.
3. Inspect inside the fuel tank (if possible) for any
9 foreign material that may be getting drawn into —
the fuel line pickup causing a blocked
condition.

10 cracks and for the use of proper clamps. —

2. Disconnect the FRP regulator harness
connector.
connector of the FRP regulator (pins 1 and 2
of E47).
11 —
113 of E26).
necessary.


connector.
of E49).
101 of E26).
necessary.

Replace the fuel filter element. Refer to Fuel Filter
Element Replacement Procedure in Section 1D
13 Engine Fuel. —

Important: Replacement fuel injector must be
programmed.
Replace the appropriate fuel injector that does not
15 change engine speed when commanded OFF. —
Refer to Cylinder Head in Section 1B Engine
Mechanical.

Important: The fuel supply pump must be timed to
the engine and adjustment value must be learned
to the ECM.
Notice: Always replace the fuel filter element when

a fuel supply pump is replaced.
16 —
Replace the fuel supply pump and fuel filter
element. Refer to Engine Exterior Parts in Section
1B Engine Mechanical and Fuel Filter Element
Replacement Procedure in Section 1D Engine
Fuel.

Records.


18 —

Fuel Rail/ System Pressure Too High Action Taken When the DTC Sets
Description runs and fails. Refer to DTC Type Definitions for
The common rail fuel system is comprised of two fuel Action Taken When the DTC Sets - Type A.
pressure sections: a suction side between the fuel tank • The ECM limits fuel injection quantity.
and the fuel supply pump and a high-pressure side • The ECM inhibits pre injection.
between the fuel supply pump and the fuel injectors.
then pumped into the fuel rail by three plungers, all of • The ECM inhibits cruise control.
which are internal to the fuel supply pump. This high
pressure is regulated by the ECM using the fuel rail Condition for Clearing the DTC
pressure (FRP) regulator dependant upon values from • Refer to DTC Type Definitions for Condition for
the FRP sensor attached to the fuel rail. Clearing the MIL/ DTC - Type A.
If the ECM detects that during the same ignition cycle
the fuel pressure rose even higher than the amount to Diagnostic Aids
set DTC P0088 for a certain length of time, the MIL will
• An intermittently sticking FRP regulator may have
be illuminated. If the MIL is illuminated, the fuel
pressure was too high and the pressure limiter valve
to set this DTC.
did not active or did not active quick enough.
• Actual Fuel Rail Pressure and Desired Fuel Rail
Condition for Running the DTC Pressure parameter between idle and W.O.T.
(accelerator pedal full travel) in Park or Neutral
• DTCs P0192, P0193, P060B and P0651 are not should follow within ± 5 MPa (± 725 psi) quick
set. enough.
• The ignition switch is ON. • A skewed FRP sensor value can set this DTC. The
• The engine is running. FRP Sensor on the scan tool should read 0.9 to
1.0 volt with the ignition switch ON and engine
Condition for Setting the DTC OFF after the engine has stopped running for a
• The ECM detects that the fuel rail pressure is more minimum of 2 minutes.
than 198 MPa (28,700 psi) for longer than 5
seconds. Routing Reference: Fuel System Routing Diagram

2 —

P0201 - P0206, P2146 or P2149 set? DTC Go to Step 3
parking brake.
4. Accelerate the engine between idle and 180 MPa
3 An intermittent
W.O.T. (accelerator pedal full travel) many (26,000 psi)
times while observing the Fuel Rail Pressure problem by foreign
parameter with a scan tool. material in the fuel
system is
Does the Fuel Rail Pressure parameter ever suspected. Go to
exceed the specified value? Go to Step 4 Step 13

4 0.9 to 1.0 volt

tool.


may occur.
rail.



nut(s).
8 —


kinked.
condition.


connector.
of E47).
11 —
113 of E26).
necessary.

connector.
of E49).
12 —
101 of E26).
necessary.

13 Engine Fuel. —


programmed.
Mechanical.

to the ECM.

16 —
Fuel.

Records.

18 —

Fuel Pressure Regulator Performance Action Taken When the DTC Sets
and the fuel supply pump and a high-pressure side • The ECM inhibits EGR control.
between the fuel supply pump and the fuel injectors. • The ECM inhibits cruise control.
then pumped into the fuel rail by three plungers, all of Condition for Clearing the DTC
pressure is regulated by the ECM using the fuel rail • Refer to DTC Type Definitions for Condition for
pressure (FRP) regulator dependant upon values from Clearing the MIL/ DTC - Type B.
the FRP sensor attached to the fuel rail. If the ECM
detects that fuel pressure is a certain pressure higher Diagnostic Aids
than the desired pressure, this DTC will set. • An intermittently sticking FRP regulator may have
Condition for Running the DTC to set this DTC.
• DTCs P0091, P0092, P0192, P0193, P0201 - • Actual Fuel Rail Pressure and Desired Fuel Rail
P0206, P060B, P0651, P1261, P1262, P2146 and Pressure parameter between idle and W.O.T.
P2149 are not set. (accelerator pedal full travel) in Park or Neutral
• The battery voltage is between 18 to 32 volts. should follow within ± 5 MPa (± 725 psi) quick
enough.
• The ignition switch is ON.
• A skewed FRP sensor value can set this DTC. The
• The engine is running. FRP Sensor on the scan tool should read 0.9 to
Condition for Setting the DTC OFF after the engine has stopped running for a
• The ECM detects that the actual fuel rail pressure minimum of 2 minutes.
is more than 40 MPa (5,800 psi) over the desired
pressure for longer than 5 seconds. Routing Reference: Fuel System Routing Diagram

2 —
Is DTC P0091, P0092, P0192, P0193, P0201 - Go to Applicable

P0206, P2146 or P2149 set? DTC Go to Step 3
3 0.9 to 1.0 volt


connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
5 —
101 of E26).
necessary.

parking brake.
4. Accelerate the engine between idle and
W.O.T. (accelerator pedal full travel) many ± 5 MPa (± 725
6
times while observing the Fuel Rail Pressure psi)
and Desired Fuel Rail Pressure parameter
with a scan tool.
Does the Fuel Rail Pressure parameter follow

within the specified value quick enough (compare
with a similar unit if available)? Go to Step 7 Go to Step 9
Notice: An intermittent problem by foreign material
in the fuel is suspected.
7 Element Replacement Procedure in Section 1D —
Engine Fuel.


to the ECM.

9 —
Fuel.

Records.

11 —

Fuel Pressure Regulator Control Circuit Low Action Taken When the DTC Sets
or High • The ECM illuminates the MIL when the diagnostic
The fuel rail pressure (FRP) regulator is installed to the • The ECM limits fuel injection quantity.
fuel supply pump and controls the suction fuel quantity • The ECM inhibits pre injection.
into the fuel rail. The FRP regulator is fully opened in • The ECM inhibits EGR control.
the normal state and larger drive current results in
smaller opening. The ECM calculates desired fuel rail • The ECM inhibits cruise control.
pressure and fuel flow rate and it compares the
calculated desired fuel rail pressure to the actual value Condition for Clearing the DTC
to determine the FRP regulator position. When the • Refer to DTC Type Definitions for Condition for
actual fuel rail pressure is higher than the desired Clearing the MIL/ DTC - Type A.
value, the FRP regulator is closed to decease the flow
rate. If the ECM detects an excessively low or high FRP Diagnostic Aids
regulator solenoid feedback current, DTC P0091 or • If an intermittent condition is suspected, refer to
P0092 will set. Intermittent Conditions in this section.

• DTC P060B is not set. The number below refers to the step number on the
• The battery voltage is between 18 to 32 volts. Circuit/ System Testing.
• The ignition switch is ON. 7. If the FRP regulator high side circuit is shorted to
voltage, engine stalls and will not start.
Condition for Setting the DTC 8. If the FRP regulator low side circuit is shorted to
ground, this DTC may not set. This will cause engine
• The ECM detects that the FRP regulator feedback
stall or no engine start.
current is less than 50 mA, or more than 1000 mA
below the desired current. (DTC P0091)
• The ECM detects that the FRP regulator feedback Connector End Views or ECM Connector End Views
current is more than 2400 mA, or more than 1000
mA over the desired current. (DTC P0092)
Circuit/ System Testing DTC P0091 or P0092 (Flash Code 247)

Go to Diagnostic
Does the DTC fail this ignition? Go to Step 3 Aids
parameter with a scan tool.
3 300 mA
4 900 mA
value at Step 3? Go to Step 7 Go to Step 8

connector.
3. Connect a test lamp between the high side
ground.

2. Connect a test lamp between the low side
6 circuit (pin 2 of E47) and battery voltage. —

1. Test the high side circuits between the ECM
(pins 105 and 113 of E26) and the FRP
regulator (pin 1 of E47) for a short to battery or
7 ignition voltage. —

1. Test the low side circuits between the ECM
(pins 89 and 97 of E26) and the FRP regulator
(pin 2 of E47) for a short to ground.
8 —

regulator (pin 1 of E47) for the following
conditions:
• An open circuit
9 • A short to ground —
• A short to the low side circuit
• High resistance

Important: The ECM may be damaged if the FRP
regulator low side circuit is shorted to a voltage
source.
(pin 2 of E47) for the following conditions:
10 —
• An open circuit
• A short to battery or ignition voltage
• High resistance

FRP regulator (pins 1 and 2 of E47).
11 —


12 connections at the harness connector of the —
ECM (pins 89, 97, 105 and 113 of E26).

Replace the FRP regulator. Refer to Fuel Rail
Pressure (FRP) Regulator in Section 1D Engine
13 Fuel. —


Records.

16 —

Fuel System Leak Detected • The ECM inhibits EGR control.
• The ECM inhibits cruise control.
Description
The common rail fuel system is comprised of two fuel Condition for Clearing the DTC
pressure sections: a suction side between the fuel tank • Refer to DTC Type Definitions for Condition for
and the fuel supply pump and a high-pressure side Clearing the MIL/ DTC - Type B.
Fuel is drawn from the fuel tank via a feed pump and Diagnostic Aids
then pumped into the fuel rail by three plungers, all of • An intermittently sticking FRP regulator may have
which are internal to the fuel supply pump. This high allowed the fuel pressure to become low enough to
pressure is regulated by the ECM using the fuel rail set this DTC.
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. If the ECM • Actual Fuel Rail Pressure and Desired Fuel Rail
detects that the fuel rail pressure is certain pressure Pressure parameter between idle and W.O.T.
low as compared with the engine speed, this DTC will (accelerator pedal full travel) in Park or Neutral
set. should follow within ± 5 MPa (± 725 psi) quick
enough.
Condition for Running the DTC • A skewed FRP sensor value can set this DTC. The
• DTCs P0087, P0091, P0092, P0192, P0193,
P0201 - P0206, P060B, P0651, P1261, P1262,
OFF after the engine has stopped running for a
P2146 and P2149 are not set.
minimum of 2 minutes.
• The battery voltage is between 18 to 32 volts.
• The ignition switch is ON. Notice: This DTC most likely indicates a loss of fuel
• The engine is running. pressure by a fuel leak from the high pressure side.
Inspect the high pressure side fuel leakage between
Condition for Setting the DTC the fuel supply pump and fuel injector first.
• The ECM detects that the actual fuel rail pressure
is lower than 15 MPa (2,180 psi) for longer than 3
might be allowed to go into the fuel system. With air in
seconds.
Action Taken When the DTC Sets
consecutive driving cycle when the diagnostic runs Routing Reference: Fuel System Routing Diagram
and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type B.


1. Inspect the high pressure side between the
fuel supply pump and the fuel injectors for fuel
leakage. The following components may
contain an external leak.
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Fuel rail pressure (FRP) sensor
• Fuel pipe between the fuel supply pump
and fuel rail
• Fuel pipe between the fuel rail and fuel
injectors
2 • Each fuel pipe sleeve nuts —

case, the engine oil level will rise. Inspect for
Notice: Remove and inspect the inlet high

pressure joint to the fuel injectors for fuel
leaking from the sleeve nut(s). Replace the
fuel injector and injection pipe when foreign
material was in contact.

1. Remove each glow plug from the cylinder
head.
2. Inspect for fuel leakage into the combustion
3 chamber. —
Is there a cylinder that fuel leakage into the

combustion chamber? Go to Step 16 Go to Step 4
4 —

5 0.9 to 1.0 volt


parking brake.
6 tool. —
4. Command each injector OFF and verify an


may occur.
rail.



nut(s).
9 —

kinked.
condition.



connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
13 —
101 of E26).
necessary.

14 Engine Fuel. —

programmed.
Replace the appropriate fuel injector that was
leaking fuel found at Step 3 and inspect the engine
16 mechanical for any damage or poor engine —
compression. Refer to Cylinder Head in Section 1B
Engine Mechanical.


programmed.
Mechanical.

to the ECM.

18 —
Fuel.

Records.

20 —

Mass Air Flow Sensor Circuit Range/ • The intake throttle control is commanded OFF.
Performance • The DPD filter regeneration is inactive.
• The engine run time is longer than 5 seconds.
Circuit Description
The mass air flow (MAF) sensor is an air flow meter Condition for Setting the DTC
that measures the amount of air that enters the engine. • The ECM detects that the MAF sensor signal
It is fitted between the air cleaner and turbocharger. A voltage is not within a predetermined range of the
small quantity of air that enters the engine indicates calculated MAF value for longer than 5 seconds.
deceleration or idle speed. A large quantity of air that
enters the engine indicates acceleration or a high load Action Taken When the DTC Sets
condition. The ECM will calculate a predicted MAF
value and compares the actual MAF sensor voltage
signal to the predicted MAF value. This comparison will
determine if the signal is stuck, or is too low or too high
for a given operating condition. If the ECM detects that
the actual MAF sensor signal voltage is not within a • The ECM inhibits EGR control.
predetermined range of the calculated MAF value, this
DTC will set. Condition for Clearing the DTC
• Refer to DTC Type Definitions for Condition for
Condition for Running the DTC Clearing the MIL/ DTC - Type B.
• DTCs P0045, P0079, P0080, P0102, P0103,
P0112, P0113, P0116, P0117, P0118, P0122, Diagnostic Aids
P0123, P0234, P0237, P0238, P0404, P0409, • Any unmetered air that enters the engine
P0560, P060B, P0638, P0651, P0697, P1404, downstream of the MAF sensor will cause this
P2227, P2228, P2229, U0073 and U0110 are not DTC to set.
set. • High resistance in the MAF sensor circuit may set
• The battery voltage is between 18 to 32 volts. this DTC.
• The ignition switch is ON. • A short between the signal circuit of the MAF
AND following conditions are met longer than 3 sensor and the signal circuit of the intake air
seconds temperature (IAT) sensor will skew the MAF
• The engine speed is between 1200 to 2400 RPM. sensor lower than normal at higher air flows.
• The fuel injection is non injection state.
• The EGR control is commanded OFF. Connector End Views or ECM Connector End Views


1. Inspect the following conditions:
• Restricted air cleaner element, restricted
or collapsed air tubing between the air
cleaner and the intake manifold
• Any air induction leak
• Any contamination or objects that block
the MAF sensor inlet
• Skewed or slow MAF sensor
• Any water intrusion in the induction
system
• Any type of restriction in the exhaust
2 system —
• A sticking intake throttle valve
• A sticking EGR valve
• A sticking turbocharger nozzle control
actuator
• Exhaust throttle valve or exhaust brake
valve for stuck condition. Refer to
Exhaust System in Section 1G Engine
Exhaust.

2. Disconnect the MAF sensor harness
connector.
connector of the MAF sensor (pins 1, 2 and 3
of J14 or FB128).
3 4. Disconnect the ECM harness connector. —
connector of the ECM (pins 22, 23 and 69 of
FB24).

1. Test each sensor circuit between the ECM
(pins 22, 23 and 69 of FB24) and the MAF
sensor (pins 1, 2 and 3 of J14 or FB128) for
4 high resistance. —

Replace the MAF sensor. Refer to MAF (Mass Air
5 Flow Sensor) in Section 1J Induction. —

Records.

7 —

Mass Air Flow Sensor Circuit Low or High Condition for Setting the DTC
Input • The ECM detects that the MAF sensor signal
voltage is less than 0.1 volts for 3 seconds. (DTC
Circuit Description P0102)
The mass air flow (MAF) sensor is an air flow meter • The ECM detects that the MAF sensor signal
that measures the amount of air that enters the engine. voltage is more than 4.9 volts for 3 seconds. (DTC
It is fitted between the air cleaner and turbocharger. A P0103)
small quantity of air that enters the engine indicates
deceleration or idle speed. A large quantity of air that Action Taken When the DTC Sets
enters the engine indicates acceleration or a high load • The ECM illuminates the MIL when the diagnostic
condition. The sensor has the following circuits. runs and fails. Refer to DTC Type Definitions for
• 12 volts reference circuit Action Taken When the DTC Sets - Type A.
• Low reference circuit • The ECM uses a MAF substitution of default value.
• MAF sensor signal circuit • The ECM limits fuel injection quantity.
The ECM monitors the MAF sensor signal voltage. This • The ECM inhibits EGR control.
output voltage will display on the scan tool as a voltage
parameter and as a grams per cylinder (g/cyl)
parameter. If the ECM detects an excessively low or
high signal voltage, DTC P0102 or P0103 will set.
Condition for Running the DTC Clearing the MIL/ DTC - Type A.
• DTCs P0560 and P060B are not set.
Diagnostic Aids
• The ignition switch is ON. Intermittent Conditions in this section.

Is DTC P0560 also set? Go to DTC P0560 Go to Step 3

Observe the MAF (Mass Air Flow) Sensor
3 0.1 volts
Is the MAF Sensor parameter less than the Go to Diagnostic
specified value? Go to Step 4 Aids
connector.
3. Connect a test lamp between the 12 volts
4 reference circuit (pin 1 of J14 or FB128) and a —
known good ground.


Connect a 3-amp fused jumper wire between the
12 volts reference circuit and the signal circuit (pins
5 1 and 3 of J14 or FB128). 4.9 volts
Is the MAF Sensor parameter more than the
specified value? Go to Step 8 Go to Step 7
1. Test the 12 volts reference circuit between the
ECM (pin 23 of FB24) and the MAF sensor
(pin 1 of J14 or FB128) for an open circuit or

1. Test the signal circuit between the ECM (pin
69 of FB24) and the MAF sensor (pin 3 of J14
or FB128) for the following conditions:
• An open circuit
7 —
• A short to the low reference circuit
• High resistance

MAF sensor (pins 1 and 3 of J14 or FB128).
8 —

ECM (pins 23 and 69 of FB24).


Records.


13 —

2 4. Observe the MAF (Mass Air Flow) Sensor 4.9 volts
Is the MAF Sensor parameter more than the Go to Diagnostic

Monitor the DTC Information with a scan tool.
3 —
Is DTC P0560 also set? Go to Step 4 Go to Step 5
connector.
4 3. Turn ON the ignition, with the engine OFF. 0.1 volts
Is the MAF Sensor parameter less than the

specified value? Go to DTC P0560 Go to Step 7
connector.

Connect a test lamp between the low reference
6 circuit (pin 2 of J14 or FB128) and battery voltage. —
Important: The MAF sensor may be damaged if
the sensor signal circuit is shorted to a voltage
source.
69 of FB24) and the MAF sensor (pin 3 of J14
7 —
• A short to the 12 volts reference
• A short to any 5 volts reference


1. Test the low reference circuit between the
(pin 2 of J14 or FB128) for an open circuit or

connection at the harness connector of the
MAF sensor (pin 2 of J14 or FB128).
9 —



Records.

14 —

Intake Air Temperature Sensor Circuit Low or Condition for Setting the DTC
High • The ECM detects that the IAT sensor signal
The intake air temperature (IAT) sensor is fitted • The ECM detects that the IAT sensor signal
between the air cleaner and turbocharger. It is internal voltage is more than 4.85 volts for 3 seconds.
to the mass air flow (MAF) sensor. The IAT sensor is a (DTC P0113)
variable resistor and it measures the temperature of the
air entering the engine. The sensor has a signal circuit Action Taken When the DTC Sets
and a low reference circuit. The ECM supplies 5 volts to • The ECM illuminates the MIL when the diagnostic
the signal circuit and a ground for the low reference runs and fails. Refer to DTC Type Definitions for
circuit. When the IAT sensor is cold, the sensor Action Taken When the DTC Sets - Type A.
resistance is high. When the air temperature increases,
• The ECM uses an IAT substitution of default value.
the sensor resistance decreases. With high sensor
resistance, the ECM detects a high voltage on the • The ECM inhibits EGR control.
signal circuit. With lower sensor resistance, the ECM
detects a lower voltage on the signal circuit. If the ECM Condition for Clearing the DTC
detects an excessively low or high signal voltage, DTC • Refer to DTC Type Definitions for Condition for
P0112 or P0113 will set. Clearing the MIL/ DTC - Type A.
Condition for Running the DTC Diagnostic Aids

• DTCs P060B and P0651 are not set. • If an intermittent condition is suspected, refer to
• The battery voltage is between 18 to 32 volts. Intermittent Conditions in this section.
• The ignition switch is ON. • Use the Temperature vs. Resistance table to test
the IAT sensor at various temperature levels to
• The engine run time is longer than 3 minutes.
evaluate the possibility of a skewed sensor. A
(DTC P0113)
skewed sensor could result in poor driveability
concerns.



Observe the Intake Air Temperature Sensor
3 0.1 volts
Is the Intake Air Temperature Sensor parameter Go to Diagnostic
less than the specified value? Go to Step 4 Aids
2. Disconnect the mass air flow/ intake air
temperature (MAF/ IAT) sensor harness
4 connector. 4.5 volts
Is the Intake Air Temperature Sensor parameter

more than the specified value? Go to Step 6 Go to Step 5

72 of FB24) and the IAT sensor (pin 4 of J14
5 —

Replace the IAT sensor. Refer to MAF (Mass Air
3. Inspect connections at the harness connector
of the ECM (pins 60 and 72 of FB24) for
7 corrosion. —
4. Repair or clean the connection(s) as
necessary.


Records.

10 —



3 4.8 volts
more than the specified value? Go to Step 4 Aids
connector.
4 3. Connect a DMM between the signal circuit 5.5 volts
(pin 4 of J14 or FB128) and a known good
ground.
Is the DMM voltage more than the specified value? Go to Step 5 Go to Step 6
Important: The IAT sensor may be damaged if the
sensor signal circuit is shorted to a voltage source.
5 —

signal circuit and the low reference circuit (pins 4
6 and 5 of J14 or FB128). 0.1 volts
less than the specified value? Go to Step 10 Go to Step 7
signal circuit (pin 4 of J14 or FB128) and a known
7 good ground. 0.1 volts
or FB128) for an open circuit or high
8 resistance. —

Notice: The IAT sensor shares the low reference
circuit with other sensors. A fault condition in the
low reference circuit may set DTCs on sensors that
share this circuit.
9 ECM (pin 60 of FB24) and the IAT sensor (pin —
5 of J14 or FB128) for an open circuit or high
resistance.


72 of FB24) and the IAT sensor (pin 4 of J14,
FB128) for a short to any 5 volts reference
10 circuit. —

IAT sensor (pins 4 and 5 of J14 or FB128).
11 —


Replace the IAT sensor. Refer to MAF (Mass Air

Records.

16 —

Engine Coolant Temperature Sensor Circuit Condition for Setting the DTC
Range/ Performance • The ECM detects that the difference of maximum
and minimum engine coolant temperature is less
Circuit Description than 1 to 12°C (1.8 to 22°F).
The engine coolant temperature (ECT) sensor is
installed to the thermostat housing. The ECT sensor is Action Taken When the DTC Sets
a variable resistor and it measures the temperature of • The ECM illuminates the MIL on the second
the engine coolant. If the ECM detects that the consecutive driving cycle when the diagnostic runs
difference of engine coolant temperature is smaller and fails. Refer to DTC Type Definitions for Action
than the calculated range during the predetermined Taken When the DTC Sets - Type B.
conditions, this DTC will set. This DTC will only run
once per ignition cycle within the enabling condition. Condition for Clearing the DTC
• DTCs P0117, P0118, P0201 - P0206, P0500,
P0502, P0503, P060B, P0697, P1261, P1262, Diagnostic Aids
P2146, P2149 and P215A are not set. • After starting the engine, the ECT should rise
• The battery voltage is between 18 to 32 volts. steadily to about 80 to 85°C (176 to 185°F) then
• The ignition switch is ON. stabilize when the thermostat opens.
• The vehicle runtime is longer than 5 minutes with • Use the Temperature vs. Resistance table to test
the vehicle speed is more than 4 km/h. the ECT sensor at various temperature levels to
• The engine runtime is longer than 5 minutes with evaluate the possibility of a skewed sensor. A
the engine speed is more than 1300 RPM. skewed sensor could result in poor driveability
concerns.
• The accumulation fuel injection quantity since
engine start is more than a threshold. Connector End View Reference: Engine Controls

1. Test the engine cooling system for the
following conditions. Refer to Cooling System
in Section 1C Engine Cooling for testing.
• Engine coolant level
2 —
• Engine coolant leakage

2. Disconnect the engine coolant temperature
(ECT) sensor harness connector.
connector of the ECT sensor (pins 1 and 2 of
E55).
E26).


(pins 84 and 109 of E26) and the ECT sensor
(pins 1 and 2 of E55) for high resistance.
4 —

Replace the ECT sensor. Refer to Cylinder Head in
5 Section 1B Engine Mechanical. —
Records.

7 —

Engine Coolant Temperature Sensor Circuit • The ECM detects that the ECT sensor signal
Low or High voltage is more than 4.85 volts for 3 seconds.
(DTC P0118)
Circuit Description
installed to the thermostat housing. The ECT sensor is • The ECM illuminates the MIL when the diagnostic
a variable resistor and it measures the temperature of runs and fails. Refer to DTC Type Definitions for
the engine coolant. The sensor has a signal circuit and Action Taken When the DTC Sets - Type A.
a low reference circuit. The ECM supplies 5 volts to the • The ECM uses an ECT substitution of default
signal circuit and a ground for the low reference circuit. value.
When the ECT sensor is cold, the sensor resistance is • The ECM inhibits EGR control.
high. When the engine coolant temperature increases,
the sensor resistance decreases. With high sensor Condition for Clearing the DTC
resistance, the ECM detects a high voltage on the
detects a lower voltage on the signal circuit. If the ECM
detects an excessively low or high signal voltage, DTC
Diagnostic Aids
P0117 or P0118 will set.
Condition for Running the DTC Intermittent Conditions in this section.
• DTCs P060B and P0697 are not set. • Use the Temperature vs. Resistance table to test
the ECT sensor at various temperature levels to
• The ignition switch is ON. skewed sensor could result in poor driveability
• The engine run time is longer than 5 seconds. concerns.
(DTC P0118)
Condition for Setting the DTC Connector End Views or ECM Connector End Views
• The ECM detects that the ECT sensor signal
P0117)


Observe the Engine Coolant Temperature Sensor
3 0.1 volts
Is the Engine Coolant Temperature Sensor Go to Diagnostic
parameter less than the specified value? Go to Step 4 Aids
2. Disconnect the ECT sensor harness
connector.
4 4.5 volts
Is the Engine Coolant Temperature Sensor

parameter more than the specified value? Go to Step 6 Go to Step 5

84 of E26) and the ECT sensor (pin 1 of E55)
for the following conditions:
5 —

of the ECM (pins 84 and 109 of E26) for
7 corrosion. —
necessary.


Records.

10 —



3 4.8 volts
parameter more than the specified value? Go to Step 4 Aids
connector.
(pin 1 of E55) and a known good ground.
Important: The ECT sensor may be damaged if
source.
5 84 of E26) and the ECT sensor (pin 1 of E55) —
for a short to battery or ignition voltage.

6 and 2 of E55). 0.1 volts
parameter less than the specified value? Go to Step 10 Go to Step 7
signal circuit (pin 1 of E55) and a known good
7 ground. 0.1 volts
for an open circuit or high resistance.
8 —

Notice: The ECT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the ECT sensor —
(pin 2 of E55) for an open circuit or high
resistance.

for a short to any 5 volts reference circuit.
10 —


ECT sensor (pins 1 and 2 of E55).
11 —

ECM (pins 84 and 109 of E26).


Records.

16 —

Throttle Position Sensor Circuit Low or High Condition for Setting the DTC
• The ECM detects that the intake throttle position
Circuit Description sensor signal voltage is less than 0.1 volts for 3
The intake throttle position sensor is installed on the seconds. (DTC P0122)
intake throttle valve body together with the control • The ECM detects that the intake throttle position
motor. The intake throttle position sensor changes sensor signal voltage is more than 4.9 volts for 3
output voltage according to intake throttle valve seconds. (DTC P0123)
position. The sensor has the following circuits.
• 5 volts reference circuit Action Taken When the DTC Sets
• Low reference circuit • The ECM illuminates the MIL when the diagnostic
• Intake throttle position sensor signal circuit runs and fails. Refer to DTC Type Definitions for
The intake throttle position sensor provides a signal to Action Taken When the DTC Sets - Type A.
the ECM on the signal circuit, which is relative to the • The ECM inhibits EGR control.
position changes of the intake throttle valve. If the ECM
detects an excessively low or high signal voltage, DTC Condition for Clearing the DTC
P0122 or P0123 will set. • Refer to DTC Type Definitions for Condition for
• DTCs P060B and P0697 are not set. Diagnostic Aids
• The battery voltage is between 18 to 32 volts. • If an intermittent condition is suspected, refer to



Observe the Intake Throttle Position Sensor
3 0.1 volts
Is the Intake Throttle Position Sensor parameter Go to Diagnostic
connector.
3. Connect a DMM between the 5 volts reference
4 circuit (pin 5 of E46) and a known good 4.9 volts
ground.
Connect a 3-amp fused jumper wire between the 5
volts reference circuit and the signal circuit (pins 5
Is the Intake Throttle Position Sensor parameter

Notice: The intake throttle position sensor shares
the 5 volts reference circuit with other sensors. A
fault condition in the 5 volts reference circuit may
set DTCs on sensors that share this circuit.
6 ECM (pin 95 of E26) and the intake throttle —
valve (pin 5 of E46) for an open circuit or high
resistance.

85 of E26) and intake throttle valve (pin 6 of
E46) for the following conditions:
• An open circuit
7 —
• High resistance

intake throttle valve (pins 5 and 6 of E46).
8 —


Replace the intake throttle valve. Refer to Engine
10 Exterior Parts in Section 1B Engine Mechanical. —

Records.

13 —

2 4. Observe the Intake Throttle Position Sensor 4.9 volts

3 —
connector.
4 0.1 volts

less than the specified value? Go to DTC P0697 Go to Step 7
connector.
5 0.1 volts

Important: The intake throttle position sensor may
be damaged if the sensor signal circuit is shorted to
a voltage source.
85 of E26) and the intake throttle valve (pin 6
7 of E46) for the following conditions: —

the low reference circuit with other sensors. A fault
condition in the low reference circuit may set DTCs
on sensors that share this circuit.
resistance.


intake throttle valve (pin 4 of E46).
9 —



Records.

14 —

Fuel Temperature Sensor Circuit Low or High • The ECM detects that the FT sensor signal voltage
is more than 4.85 volts for 3 seconds. (DTC
The fuel temperature (FT) sensor is installed to the fuel
supply pump. The FT sensor is a variable resistor and it
measures the temperature of the fuel entering the fuel • The ECM illuminates the MIL when the diagnostic
supply pump. The sensor has a signal circuit and a low runs and fails. Refer to DTC Type Definitions for
reference circuit. The ECM supplies 5 volts to the Action Taken When the DTC Sets - Type A.
signal circuit and a ground for the low reference circuit. • The ECM uses a FT substitution of default value.
When the FT sensor is cold, the sensor resistance is
high. When the fuel temperature increases, the sensor Condition for Clearing the DTC
resistance decreases. With high sensor resistance, the • Refer to DTC Type Definitions for Condition for
ECM detects a high voltage on the signal circuit. With Clearing the MIL/ DTC - Type A.
lower sensor resistance, the ECM detects a lower
voltage on the signal circuit. If the ECM detects an Diagnostic Aids
excessively low or high signal voltage, DTC P0182 or
P0183 will set. • Before starting a cold engine, FT sensor and
engine coolant temperature (ECT) sensor
Condition for Running the DTC temperature should be relatively close to each
other.
• DTCs P060B and P0697 are not set.
• The engine run time is longer than 3 minutes. the FT sensor at various temperature levels to
(DTC P0183) evaluate the possibility of a skewed sensor. A
Condition for Setting the DTC concerns.
• The ECM detects that the FT sensor signal voltage
is less than 0.1 volts for 3 seconds. (DTC P0182) Connector End View Reference: Engine Controls


Observe the Fuel Temperature Sensor parameter
with a scan tool.
3 0.1 volts
Is the Fuel Temperature Sensor parameter less Go to Diagnostic
than the specified value? Go to Step 4 Aids
2. Disconnect the FT sensor harness connector.
Is the Fuel Temperature Sensor parameter more

than the specified value? Go to Step 6 Go to Step 5

83 of E26) and the FT sensor (pin 2 of E30) for
5 —

Replace the FT sensor. Refer to Fuel Temperature
6 Sensor in Section 1D Engine Fuel. —
7 corrosion. —
necessary.


Records.

10 —



with a scan tool.
3 4.8 volts
Is the Fuel Temperature Sensor parameter more Go to Diagnostic
3. Connect a DMM between the signal circuit
4 (pin 2 of E30) and a known good ground. 5.5 volts
Important: The FT sensor may be damaged if the
5 83 of E26) and the FT sensor (pin 2 of E30) for —
a short to battery or ignition voltage.

Is the Fuel Temperature Sensor parameter less
signal circuit of the sensor harness (pin 2 of E30)
7 and a known good ground. 0.1 volts
an open circuit or high resistance.
8 —

Notice: The FT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the FT sensor (pin —
1 of E30) for an open circuit or high
resistance.

a short to any 5 volts reference circuit.
10 —

FT sensor (pins 1 and 2 of E30).
11 —




Records.

16 —

Fuel Rail Pressure Sensor Circuit Low or High • The ECM detects that the FRP sensor signal
voltage is more than 4.75 volts. (DTC P0193)
Circuit Description
The fuel rail pressure (FRP) sensor is installed to the
fuel rail and it detects the fuel pressure in the fuel rail, • The ECM illuminates MIL when the diagnostic runs
converts the pressure into a voltage signal, and sends and fails. Refer to DTC Type Definitions for Action
the signal to the ECM. The sensor has the following Taken When the DTC Sets - Type A.
circuits. • The ECM uses a FRP substitution of default value.
• 5 volts reference circuit • The ECM limits fuel injection quantity.
• Low reference circuit • The ECM inhibits pre injection.
• FRP sensor signal circuit • The ECM inhibits EGR control.
The ECM monitors the FRP sensor signal voltage. • The ECM inhibits cruise control.
Higher fuel rail pressure provides higher signal voltage
while lower pressure provides lower signal voltage. The Condition for Clearing the DTC
ECM calculates actual fuel rail pressure (fuel pressure)
from the voltage signal and uses the result in fuel • Refer to DTC Type Definitions for Condition for
injection control and other control tasks. If the ECM Clearing the MIL/ DTC - Type A.
P0192 or P0193 will set. Diagnostic Aids
• DTCs P060B and P0651 are not set. • Electromagnetic interference may affect
• The battery voltage is between 18 to 32 volts. intermittent condition.
• The ignition switch is ON. Connector End View Reference: Engine Controls
Condition for Setting the DTC
• The ECM detects that the FRP sensor signal
voltage is less than 0.7 volts. (DTC P0192)


Observe the Fuel Rail Pressure Sensor parameter
with a scan tool.
3 0.7 volts
Is the Fuel Rail Pressure Sensor parameter less Go to Diagnostic
connector.
Is the Fuel Rail Pressure Sensor parameter more


Connect a DMM between the 5 volts reference
5 circuit (pin 3 of E49) and a known good ground. 4.5 volts
1. Test the signal circuits between the ECM (pins
82 and 90 of E26) and the FRP sensor (pin 2
of E49) for the following conditions:
6 —

Notice: The FRP sensor shares the 5 volts
reference circuit with other sensors. A fault
condition in the 5 volts reference circuit may set
DTCs on sensors that share this circuit.
7 ECM (pin 87 of E26) and the FRP sensor (pin —
resistance.

FRP sensor (pin 3 of E49).
8 —



Records.


13 —

Did you perform the Diagnostic System Check- Go to Diagnostic

with a scan tool.
3 4.5 volts
Is the Fuel Rail Pressure Sensor parameter more Go to Diagnostic
connector.
1. Connect a test lamp between the signal circuit
5 2. Connect a DMM between the probe of the test 4.5 volts
lamp and a known good ground.
signal circuit and the low reference circuit of the
6 sensor harness (pins 1 and 2 of E49). 0.1 volts
Is the Fuel Rail Pressure Sensor parameter less
Notice: The FRP sensor shares the low reference
share this circuit.
7 ECM (pin 101 of E26) and the FRP sensor —
resistance.

1. Test the signal circuit between the ECM (pins
of E49) for an open circuit or high resistance.
8 —


of E49) for a short to any 5 volts reference
9 circuit. —

Important: The FRP sensor may be damaged if
source.
10 82 and 90 of E26) and the FRP sensor (pin 2 —
of E49) for a short to battery or ignition
voltage.

FRP sensor (pins 1 and 2 of E49).
11 —

ECM (pins 82, 90 and 101 of E26).


Records.

16 —

DTC P0201, P0202, P0203, P0204, P0205 or P0206 (Flash Code 271, 272, 273, 274, 275 or
276)
Injector Circuit Open - Cylinder 1, 2, 3, 4, 5 or • The ECM detects an open circuit on the fuel
6 injector solenoid circuits.
• The ECM detects that the fuel injector solenoid
Circuit Description control circuit is shorted to voltage circuit or charge
voltage circuit.
The ECM calculates the optimum fuel injection ON time
using data sent from various engine sensors. The
common 1 and 2 fuel injector charge voltage circuits
are high-voltage supply, which drives fuel injectors for • The ECM illuminates the MIL when the diagnostic
each cylinder in conjunction with the ECM grounding runs and fails. Refer to DTC Type Definitions for
the fuel injector solenoid control circuit. The common 1 Action Taken When the DTC Sets - Type A.
covers fuel injectors in cylinders #1, #2 and #3, and the • The ECM limits fuel injection quantity.
common 2 covers fuel injectors in cylinders #4, #5 and • The ECM inhibits cruise control.
#6. If the fuel injector charge voltage circuit or solenoid
control circuit is open circuit, DTC P0201 - P0206 will Condition for Clearing the DTC
set depending upon which cylinder injector circuit
failed. If the fuel injector solenoid control circuit is • Refer to DTC Type Definitions for Condition for
shorted to voltage circuit or common charge voltage Clearing the MIL/ DTC - Type A.
circuit, this DTC will also set.
Diagnostic Aids
Condition for Running the DTC • If an intermittent condition is suspected, refer to
• DTCs P1261 and P2146 are not set. (DTC P0201, Intermittent Conditions in this section.
P0202 and P0203)
Notice: Each DTC agrees with engine cylinder order.
• DTCs P1262 and P2149 are not set. (DTC P0204,
P0205 and P0206) • P0201: Cylinder #1
• The battery voltage is between 18 to 32 volts. • P0202: Cylinder #2
• The ignition switch is ON. • P0203: Cylinder #3
• The engine is running. • P0204: Cylinder #4
• P0205: Cylinder #5
Condition for Setting the DTC • P0206: Cylinder #6
Either of following condition is met:

Go to Diagnostic
2. Disconnect the in-line harness connector
(H78) from the cylinder head cover case.
3 1.0 volt
4. Connect a DMM between the cylinder #1
charge voltage circuit (pin 3 of H78 female
side) and a known good ground.
Is the DMM voltage less than the specified value? Go to Step 4 Go to Step 8

Connect a DMM between the cylinder #1 solenoid
control circuit (pin 2 of H78 female side) and a
4 known good ground. 16.0 volts
Is the DMM voltage more than the specified value
5 12.0 volts
at Step 4? Go to Step 6 Go to Step 10
connections at the in-line harness connector
(pins 2 and 3 of H78).
6 —

1. Remove the cylinder head cover. Refer to
Cylinder Head in Section 1B Engine
Mechanical.
2. Inspect the fuel injector harness for loose
injector terminal nuts, objects touching injector
terminals.
7 —

119 of E26) and the in-line harness connector
(pin 2 of H78 female side) for a short to the
8 common 1 charge voltage circuit. —

(pin 2 of H78 female side) for a short to battery
9 or ignition voltage. —

(pin 2 of H78 female side) for an open circuit
10 or high resistance. —

1. Test the cylinder #1 fuel injector circuit
between the fuel injector terminals (pins 1, 2
and 3 of E71) and the in-line harness
connector (pins 2 and 3 of H80) for the
• An open circuit
11 —
• High resistance
2. Repair the circuit(s) or replace the fuel injector
harness as necessary.



programmed.
13 Replace the cylinder #1 fuel injector. Refer to —
Cylinder Head in Section 1B Engine Mechanical.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Engine Coolant Over Temperature Condition Action Taken When the DTC Sets
Circuit Description Refer to DTC Type Definitions for Action Taken
The engine coolant temperature (ECT) sensor is When the DTC Sets - Type D.
installed to the thermostat housing. The ECT sensor is
a variable resistor and it measures the temperature of Condition for Clearing the DTC
the engine coolant. If the ECM detects an excessive • Refer to DTC Type Definitions for Condition for
high coolant temperature, this DTC will set. Clearing the DTC - Type D.

• DTCs P0116, P0117, P0118, P060B and P0697 • After starting the engine, the ECT should rise
are not set. steadily to about 80 to 84°C (176 to 183°F) then
• The battery voltage is between 18 to 32 volts. stabilize when the thermostat opens.
• The engine is running. the ECT sensor at various temperature levels to
Condition for Setting the DTC skewed sensor could result in poor driveability
concerns.
• The Total Engine Coolant Overtemperature Events
• The ECM detects that the engine coolant parameter on the scan tool indicates number of
temperature is more than 110°C (230°F) for 5 overheat events.
seconds.
• The ECM detects that the engine coolant Notice: This DTC is caused by an engine overheat
temperature is more than 120°C (248°F) for 5 condition (e.g. low engine coolant level). Since this
seconds during the DPD filter regeneration. DTC does not illuminate any lamps, clear the DTC and
ensure there are no signs of engine damage.
Excessive engine overheat may damage internal
engine components.


following condition. Refer to Cooling System
• Cooling fan belt slippage
3 • Cooling fan clutch working —
• Thermostat working
• Water pump working
• Radiator clogging


Start the engine and wait until engine is fully warm
upped while observing the Coolant Temperature
4 parameter with a scan tool. 110°C (230°F)
Ask the driver if overheat is caused by low engine
coolant level, etc.
5 If engine overheat has experienced, the engine —
must be inspected and repaired as necessary.
Did you complete the action? Go to Step 7 —

1. Test the engine coolant temperature (ECT)
sensor at various temperature levels to
evaluate the possibility of a skewed sensor.
6 —
2. Replace the ECT sensor as necessary.
Go to Diagnostic
Did you find and correct the condition? Go to Step 7 Aids
7 4. Start the engine and wait until engine is fully 110°C (230°F)
warm upped while observing the Coolant
Temperature parameter with a scan tool.

8 —

Engine Overspeed Condition Condition for Clearing the DTC
Circuit Description Clearing the DTC - Type D.
The crankshaft position (CKP) sensor is located on the
flywheel housing. The ECM calculates the engine Diagnostic Aids
speed and exact position of the crankshaft based on • Make sure the CKP sensor is tight and the sensor
the signal pulse from the CKP sensor. If the ECM rotor teeth are not damaged.
detects an engine overrun condition, this DTC will set. • Electromagnetic interference in the CKP sensor
circuits may set this DTC.
• The Total Engine Overspeed Events parameter on
• The ECM detects that the engine speed is more the scan tool indicates number of overrun events.
than 3640 RPM.
Notice: This DTC is caused by an engine overspeed
Action Taken When the DTC Sets condition, which was most likely caused by driver error
• The ECM will not illuminate the MIL or SVS lamp. (i.e. downshifting a manual transmission on a steep
Refer to DTC Type Definitions for Action Taken grade). Since the DTC does not illuminate any lamps,
When the DTC Sets - Type D. clear the DTC and ensure there are no sign of engine
damage. Excessive engine overspeed may damage
internal engine components.

Important: If DTC P0335 or P0336 is set, diagnose
that DTC first.
2 3. Observe the Engine Speed parameter with a 3640 RPM
scan tool.
4. Accelerate the engine as necessary.
Does the Engine Speed parameter ever exceed the

Ask the driver if overrun is caused by gear slip-out,
shift error, down-slope driving, etc. If engine
3 overrun has experienced, the engine must be —
inspected and repaired as necessary.

1. Inspect the CKP sensor and sensor rotor for
4 and sensor rotor —
• Physical damage of sensor rotor
rotor


Replace the CKP sensor. Refer to Engine Exterior
5 Parts in Section 1B Engine Mechanical. —
6 5. Accelerate the engine between idle and 3640 RPM
W.O.T. (accelerator pedal full travel) many
times while observing the Engine Speed

7 —

Turbocharger Overboost Condition Condition for Clearing the DTC
Circuit Description Clearing the MIL/ DTC - Type A.
The boost pressure sensor is located in the air
induction tubing. The sensor is a transducer that varies Diagnostic Aids
voltage according to changes in the air pressure inside • An open circuit or high resistance in the boost
the air tubing. The ECM monitors the boost pressure pressure low reference circuit may set this DTC.
sensor signal for abnormal values. If the ECM detects • Check the turbocharger nozzle control solenoid for
that the sensor signal is excessively high, this DTC will a sticking.
set. This indicates excessive high boost pressure.
• Use a scan tool to verify the integrity of the boost
Condition for Running the DTC pressure sensor signal. Compare the sensor
values under all load conditions for an excessively
• DTCs P0045, P0237, P0238, P060B, P0697, high value.
U0073 and U0110 are not set.
• The fuel with which gasoline was mixed may set
• The ignition switch is ON. this DTC.
Condition for Setting the DTC Test Description

• The ECM detects an excessive boost pressure for The numbers below refer to the step number on the
longer than 5 seconds. Circuit/ System Testing.
3. A skewed boost pressure sensor value (shifted to a
Action Taken When the DTC Sets higher pressure) can set this DTC. The Boost Pressure
• The ECM illuminates the MIL when the diagnostic on the scan tool should read near Barometric Pressure
runs and fails. Refer to DTC Type Definitions for with the ignition switch ON and engine OFF.
Action Taken When the DTC Sets - Type A. 4. A skewed Barometric Pressure sensor value (shifted
• The ECM limits fuel injection quantity. to a lower pressure) may indicate a wrong boost
pressure. The Barometric Pressure on the scan tool
should read near surrounding barometric pressure.

2 —

P2228 or P2229 also set? DTC Go to Step 3
2. Observe the Boost Pressure and Barometric
Pressure with a scan tool. 10 kPa (1.5
3
psi)
Does the scan tool indicate that the difference
between the Boost Pressure and Barometric
Pressure is more than the specified value? Go to Step 4 Go to Step 5

Compare the Barometric Pressure value to the
range specified in the altitude vs. barometric
pressure table. Refer to Altitude vs. Barometric
4 Pressure. —
Is the Barometric Pressure parameter within the

range specified? Go to Step 6 Go to Step 7
1. Inspect the following for possible causes of
high boost pressure.
• Turbocharger nozzle control solenoid for
a stuck condition. Perform the
Turbocharger Solenoid Control with a
scan tool.
• Intake throttle valve sticking. Perform the
Intake Throttle Solenoid Control with a
5 scan tool. —
• Oil in the air induction tubing causing an
incorrect boost pressure sensor signal.
When there is adhesion of oil inside of
the tubing, intercooler or turbocharger it
needs to be wiped off.
Go to Diagnostic
Did you find and correction the condition? Go to Step 10 Aids
2. Disconnect the boost pressure sensor
harness connector.
boost pressure sensor (pin 2 of E54).
6 5. Inspect for an intermittent, for a poor —
connection and corrosion at the harness
connector of the ECM (pin 109 of E26).
6. Test for high resistance of the low reference
circuit.
necessary.

2. Disconnect the BARO sensor harness
connector.
BARO sensor (pins 2 and 3 of FL52).
FB24).
necessary.


Replace the boost pressure sensor. Refer to
Engine Exterior Parts in Section 1B Engine
8 Mechanical. —

Replace the BARO sensor.
9 —
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11 —

Turbo Charger Boost Sensor Circuit Low or Condition for Setting the DTC
High • The ECM detects that the boost pressure sensor
signal voltage is less than 0.1 volts for 3 seconds.
Circuit Description (DTC P0237)
The boost pressure sensor is located in the air • The ECM detects that the boost pressure sensor
induction tubing. The boost pressure sensor is a signal voltage is more than 4.9 volts for 3 seconds.
transducer that varies voltage according to changes in (DTC P0238)
the air pressure inside the air tubing. The sensor has
the following circuits. Action Taken When the DTC Sets
• 5 volts reference circuit • The ECM illuminates the MIL when the diagnostic
• Low reference circuit runs and fails. Refer to DTC Type Definitions for
• Boost pressure sensor signal circuit
The boost pressure sensor provides a signal to the • The ECM uses a boost pressure substitution of
ECM on the signal circuit, which is relative to the default value.
pressure changes in the air tubing. The ECM should • The ECM inhibits EGR control.
detect a low signal voltage at a low boost pressure,
such as low engine load. The ECM should detect high Condition for Clearing the DTC
signal voltage at a high boost pressure, such as high • Refer to DTC Type Definitions for Condition for
engine load. If the ECM detects an excessively low or Clearing the MIL/ DTC - Type A.
Diagnostic Aids
• DTCs P060B and P0697 are not set. Intermittent Conditions in this section.


Observe the Boost Pressure Sensor parameter
with a scan tool.
3 0.1 volts
Is the Boost Pressure Sensor parameter less than Go to Diagnostic
the specified value? Go to Step 4 Aids
harness connector.
ground.

Is the Boost Pressure Sensor parameter more than
the specified value? Go to Step 8 Go to Step 7
Notice: The boost pressure sensor shares the 5
volts reference circuit with other sensors. A fault
6 ECM (pin 95 of E26) and the boost pressure —
sensor (pin 3 of E54) for an open circuit or
high resistance.

91 of E26) and the boost pressure sensor (pin
1 of E54) for the following conditions:
• An open circuit
7 —
• High resistance

boost pressure sensor (pins 1 and 3 of E54).
8 —


10 Mechanical. —



Records.

13 —

2 4. Observe the Boost Pressure Sensor 4.9 volts
Is the Boost Pressure Sensor parameter more than Go to Diagnostic

3 —
harness connector.
4 0.1 volts
Is the Boost Pressure Sensor parameter less than

the specified value? Go to DTC P0697 Go to Step 7
harness connector.
5 0.1 volts


Important: The boost pressure sensor may be
damaged if the sensor signal circuit is shorted to a
voltage source.
7 1 of E54) for the following conditions: —

Notice: The boost pressure sensor shares the low
high resistance.

9 —


11 Mechanical. —


Records.


14 —

Turbocharger Underboost Condition for Clearing the DTC
Circuit Description Clearing the MIL/ DTC - Type B.
voltage according to changes in the air pressure inside • Induction air leakage can cause a low boost
the air tubing. The ECM monitors the boost pressure pressure condition. A whistling noise may be heard
sensor signal for abnormal values. If the ECM detects if a component is allowing air to enter the induction
that the sensor signal is excessively low, this DTC will system.
set. This indicates excessive low boost pressure. • Check for cracked air tubing that may only open
during certain engine movement conditions.
• Check the turbocharger nozzle control solenoid for
• DTCs P0045, P0079, P0080, P0087, P0088, a sticking.
P0089, P0091, P0092, P0093, P0102, P0103,
P0116, P0117, P0118, P0122, P0123, P0192,
pressure sensor signal. Compare the sensor
P0193, P0201 - P0206, P0237, P0238, P0401,
P0404, P0409, P0560, P060B, P0638, P0651,
low value.
P0697, P1093, P1261, P1262, P1404, P2146,
P2149, P2227, P2228, P2229, P2453, U0073 and • Fuel system problem (low fuel pressure condition)
U0110 are not set. may set this DTC.
Test Description
• The engine speed is between 1200 to 2400 RPM.
The numbers below refer to the step number on the
• The fuel injection quantity is higher than a Circuit/ System Testing.
predetermined range. 4. A skewed boost pressure sensor value (shifted to a
lower pressure) can set this DTC. The Boost Pressure
Condition for Setting the DTC on the scan tool should read near Barometric Pressure
• The ECM detects that the actual boost pressure is with the ignition switch ON and engine OFF.
more than specified value below the desired boost 5. A skewed Barometric Pressure sensor value (shifted
pressure under certain conditions for longer than 5 to a higher pressure) may indicate a wrong boost
seconds. pressure. The Barometric Pressure on the scan tool
• The ECM illuminates the MIL on the second Connector End View Reference: Engine Controls
consecutive driving cycle when the diagnostic runs Connector End Views or ECM Connector End Views

2 —
Is DTC P0045, P0237, P0238, P2227, P2228 or Go to Applicable

P2229 also set? DTC Go to Step 3

low boost pressure.
• Air leakage around the boost pressure
sensor or objects that block the sensor
hole.
• Air leaking around any of the air induction
tubing between the turbocharger and
intake manifold. Check for damaged
components and for loose clamps.
• Turbine shaft binding causing lower
turbocharger shaft spinning speeds.
Refer to Turbocharger Assembly in
Section 1J Induction.
• Turbocharger nozzle control solenoid for
a stuck condition. Perform the
3 Turbocharger Solenoid Control with a —
scan tool.
scan tool.
cleaner and the boost pressure sensor.

4
psi)
between the Boost Pressure and Barometric Go to Diagnostic
Pressure is more than the specified value? Go to Step 5 Aids
Compare the Barometric Pressure value to the
range specified in the altitude vs. barometric
5 Pressure. —

harness connector.
6 —
connector of the ECM (pins 91 and 95 of E26).
necessary.


connector.
BARO sensor (pin 1 of FL52).
connector of the ECM (pin 60 of FB24).
circuit.
necessary.

8 Mechanical. —

9 —
Records.

11 —

Crankshaft Position Sensor Circuit Condition for Setting the DTC
• The ECM detects that the CKP sensor signal
Circuit Description pulses are not generated during engine rotations.
The crankshaft position (CKP) sensor is located under
the fuel supply pump. There are 56 notches spaced 6° Action Taken When the DTC Sets
apart and a 30° section that is open span. This open • The ECM illuminates the MIL when the diagnostic
span portion allows for the detection of top dead center runs and fails. Refer to DTC Type Definitions for
(TDC). The CKP sensor is a magnetic resistance Action Taken When the DTC Sets - Type A.
element (MRE) type sensor, which generates a square
wave signal pulse. The sensor has the following Condition for Clearing the DTC
circuits.
• 5 volts reference circuit Clearing the MIL/ DTC - Type A.
• Low reference circuit
• CKP sensor signal circuit Diagnostic Aids
The ECM monitors both CKP sensor and camshaft • If an intermittent condition is suspected, refer to
position (CMP) sensor signal pulses to ensure they Intermittent Conditions in this section.
correlate with each other. If the ECM receives a certain • Electromagnetic interference in the CKP sensor
amount of CMP sensor signal pulses without a CKP circuits may set this DTC.
sensor signal pulse, this DTC will set.
• An intermittent CKP sensor signal pulse may set
Condition for Running the DTC this DTC.
• Ensure the sensor is tight and the sensor rotor
• DTCs P0016, P0336, P0340 and P0341 are not
teeth are not damaged.
set.
• The engine is running. Notice: If the CKP sensor signal pulse is lost while
• The CMP sensor signal pulse is detected. running, the engine will stop.


3. Start the engine (Note a slight start delay may
2 be noticed). —
Go to Diagnostic
Is DTC P0340, P0341 or P0697 also set? Go to Applicable
3 —
DTC Go to Step 4
2. Disconnect the crankshaft position (CKP)
ground.
Is the DMM voltage more than specified value? Go to Step 5 Go to Step 9


Connect a DMM between the signal circuit (pin 1 of
5 E50) and a known good ground. 5.5 volts
6 4.5 volts
8 circuit and low reference (pins 2 and 3 of E50). 4.5 volts
Notice: The CKP sensor shares the 5 volts
9 ECM (pin 95 of E26) and the CKP sensor (pin —
resistance.

Notice: The CKP sensor shares the low reference
share this circuit.
10 ECM (pin 109 of E26) and the CKP sensor —
resistance.

107 of E26) and the CKP sensor (pin 1 of E50)
• An open circuit
11 —
• High resistance

Important: The CKP sensor may be damaged if
source.
12 107 of E26) and the CKP sensor (pin 1 of E50) —


for a short to any 5 volts reference.
13 —

CKP sensor (pins 1, 2 and 3 of E50).
14 —

ECM (pins 95, 107, 108 and 109 of E26).

rotor


Records.

20 —

Crankshaft Position Sensor Circuit Range/ Action Taken When the DTC Sets
Performance • The ECM illuminates the MIL when the diagnostic
the fuel supply pump. There are 56 notches spaced 6° Condition for Clearing the DTC
apart and a 30° section that is open span. This open • Refer to DTC Type Definitions for Condition for
span portion allows for the detection of top dead center Clearing the MIL/ DTC - Type A.
(TDC). The ECM monitors both CKP sensor and
camshaft position (CMP) sensor signal pulses to Diagnostic Aids
ensure they correlate with each other. If the ECM • If an intermittent condition is suspected, refer to
receives extra or missing CKP sensor signal pulse, this Intermittent Conditions in this section.
DTC will set.
• Electromagnetic interference in the CKP sensor
this DTC.
set.
• The CKP sensor signal pulse is detected.
• The ECM detects extra or missing CKP sensor
signal pulses during engine rotations.

2 be noticed). —
Go to Applicable
1. Inspect all of the circuits going to the
crankshaft position (CKP) sensor for the
following:
• Routed too closely to fuel injection wiring
or components
• Routed too closely to after-market add-
3 on electrical equipment —
• Routed too closely to solenoids and
relays
2. If you find incorrect routing, correct the
harness routing.


109 of E26).
4. Disconnect the CKP sensor harness
4 connector. —
connector of the CKP sensor (pins 1, 2 and 3
of E50).

rotor

Records.

8 —

Camshaft Position Sensor Circuit Condition for Setting the DTC
• The ECM detects that the CMP sensor signal
The camshaft position (CMP) sensor is installed on the
cylinder head at the rear of the camshaft gear. The Action Taken When the DTC Sets
CMP sensor detects total of seven projections per one • The ECM illuminates the MIL when the diagnostic
engine cycle (six projections arranged equally every runs and fails. Refer to DTC Type Definitions for
60° and one reference projection on the camshaft gear Action Taken When the DTC Sets - Type A.
surface). The CMP sensor is a magnetic resistance
element (MRE) type sensor, which generates a square Condition for Clearing the DTC
wave signal pulse. The sensor has the following
circuits.
• 5 volts reference circuit
• Low reference circuit Diagnostic Aids
• CMP sensor signal circuit • If an intermittent condition is suspected, refer to
The ECM monitors both crankshaft position (CKP) Intermittent Conditions in this section.
sensor and CMP sensor signal pulses to ensure they • Electromagnetic interference in the CMP sensor
correlate with each other. If the ECM receives a certain circuits may set this DTC.
amount of CKP sensor signal pulses without a CMP
sensor signal pulse, this DTC will set. • An intermittent CMP sensor signal pulse may set
this DTC.
Condition for Running the DTC • Ensure the sensor is tight and the camshaft gear is
not damaged.
set.
Notice: If the CMP sensor signal pulse is lost while
• The CKP sensor signal pulse is detected. running, the engine will operate normally. If the CMP
• The engine speed is more than 500 RPM. sensor signal pulse is not present on start-up, the
engine will not start.


Go to Applicable
Is DTC P0601, P1261 or P1262 also set? DTC Go to Step 3
3 Is DTC P0651 also set? — Go to DTC P0651 Go to Step 4
2. Disconnect the camshaft position (CMP)
ground.


6 4.5 volts
circuit and low reference circuit (pins 2 and 3 of
8 E48). 4.5 volts
Notice: The CMP sensor shares the 5 volts
9 ECM (pin 87 of E26) and the CMP sensor (pin —
resistance.

Notice: The CMP sensor shares the low reference
share this circuit.
10 ECM (pin 101 of E26) and the CMP sensor —
resistance.

• An open circuit
11 —
• High resistance

Important: The CMP sensor may be damaged if
source.
12 98 of E26) and the CMP sensor (pin 1 of E48) —


98 of E26) and the CMP sensor (pin 1 of E48)
13 —

CMP sensor (pins 1, 2 and 3 of E48).
14 —

ECM (pins 87, 98, 100 and 101 of E26).

1. Inspect the CMP sensor and camshaft gear
16 and camshaft gear —
• Physical damage of camshaft gear
• Loose or improper installation of
camshaft gear

Replace the CMP sensor. Refer to Cylinder Head in

Records.

20 —

Camshaft Position Sensor Circuit Range/ Action Taken When the DTC Sets
cylinder head at the rear of the camshaft gear. The Condition for Clearing the DTC
CMP sensor detects total of seven projections per one • Refer to DTC Type Definitions for Condition for
engine cycle (six projections arranged equally every Clearing the MIL/ DTC - Type A.
surface). The ECM monitors both crankshaft position Diagnostic Aids
(CKP) sensor and CMP sensor signal pulses to ensure • If an intermittent condition is suspected, refer to
they correlate with each other. If the ECM receives Intermittent Conditions in this section.
extra or missing CMP sensor signal pulse, this DTC will
• Electromagnetic interference in the CMP sensor
set.
Condition for Running the DTC • An intermittent CMP sensor signal pulse may set
this DTC.
set. • Ensure the sensor is tight and the camshaft gear is
not damaged.
• The engine speed is more than 1900 RPM. Connector End View Reference: Engine Controls
• The ECM detects extra or missing CMP sensor

Go to Applicable
Is DTC P0340 or P0651 also set? DTC Go to Step 3
1. Inspect all of the circuits going to the camshaft
position (CMP) sensor for the following:
or components
relays
harness routing.


2. Disconnect the CMP sensor harness
connector.
connector of the CMP sensor (pins 1, 2 and 3
of E48).
101 of E26).

camshaft gear

Records.

8 —

Glow Plug Circuit Action Taken When the DTC Sets
• The ECM illuminates the SVS lamp when the
Circuit Description diagnostic runs and fails. Refer to DTC Type
The ECM controls the glow relay which supplies power Definitions for Action Taken When the DTC Sets -
to the glow plugs based on engine coolant Type C.
temperature. In the after glow phase, the glow plug
lamp is not illuminated but glow plugs remain active for Condition for Clearing the DTC
a certain period. If the ECM detects an open circuit or • Refer to DTC Type Definitions for Condition for
short circuit on the relay control circuit, this DTC will Clearing the SVS Lamp/ DTC - Type C.
set.
Diagnostic Aids
Test Description
Condition for Setting the DTC The numbers below refers to the step number on the
Either of following condition is met: Circuit/ System Testing.
• The ECM detects a low voltage condition on the 2. Listen for an audible click when the glow relay
glow relay control circuit for longer than 3 seconds operates. Command both the ON and OFF states.
when the relay is commanded OFF.
glow relay control circuit for longer than 3 seconds
when the relay is commanded ON.

2. Perform the Glow Relay Control with a scan
2 tool. —
3. Command the relay ON and OFF.
Go to Diagnostic
Does the glow relay click with each command? Aids Go to Step 3
2. Replace the glow relay with the starter relay or
3 replace with a known good relay. —
Does the glow relay click with each command? Go to Step 7 Go to Step 4
2. Remove the glow relay.
4 4. Connect a test lamp between the ignition —
voltage feed circuit of the relay coil side (pin 3
of X19) and a known good ground.


10 of FB24) and the relay (pin 5 of X19) for the
• An open circuit
5 —
• High resistance

the Engine Controller (10A) fuse and the glow relay
6 coil side (pin 3 of X19). Check the Engine —
Controller (10A) fuse first.

7 connection on each relay terminal. —


Replace the glow relay.
9 —

11 3. Perform the Glow Relay Control with a scan —
tool.
12 —

Glow Plug Indicator Circuit Condition for Setting the DTC
Circuit Description • The ECM detects a low voltage condition on the
The glow plug lamp is located on the instrument panel glow plug lamp control circuit for longer than 3
(IP) cluster. The glow control system is operated when seconds when the lamp is commanded OFF.
the engine coolant temperature is low, which allows • The ECM detects a high voltage condition on the
easier engine starting. If the ignition switch is turned glow plug lamp control circuit for longer than 3
ON when the engine coolant temperature is low, the seconds when the lamp is commanded ON.
ECM illuminates the glow plug lamp and turns ON the
glow plugs. After a fixed time passes, the ECM turns Action Taken When the DTC Sets
OFF the glow plug lamp and the glow plugs. The ECM
monitors the glow plug lamp control circuit for • The ECM illuminates the SVS lamp when the
conditions that are incorrect for the commanded state diagnostic runs and fails. Refer to DTC Type
of the glow plug lamp. For example, a failure condition Definitions for Action Taken When the DTC Sets -
exists if the ECM detects low voltage when the glow Type C.
plug lamp is commanded OFF, or high voltage when
the glow plug lamp is commanded ON. If the ECM Condition for Clearing the DTC
detects an improper voltage level on the control circuit, • Refer to DTC Type Definitions for Condition for
this DTC will set. Clearing the SVS Lamp/ DTC - Type C.



1. Verify whether the instrument panel (IP)
cluster is operational.
2 4. Turn ON the ignition for 10 seconds. —
Go to Diagnostic
2. Inspect the Meter (10A) fuse in the cabin fuse
3 block. —
Is the Meter (10A) fuse open? Go to Step 4 Go to Step 5

Replace the Meter (10A) fuse. If the fuse continues
to open, repair the short to ground on one of the
4 circuits that is fed by the Meter (10A) fuse or —
replace the shorted attached component.


Is the glow plug lamp OFF? Go to Step 6 Go to Step 12

1. Remove the Meter (10A) fuse that supplies
voltage to the glow plug lamp.
6 3. Measure the voltage from the glow plug lamp 1 volt
control circuit in the ECM harness connector
(pin 11 of FB24) to a known good ground.
Is the voltage less than the specified value? Go to Step 7 Go to Step 13

2. Reinstall the Meter (10A) fuse.
7 4. Connect a 3-amp fused jumper wire between —
the ECM harness connector (pin 11 of FB24)
and a known good ground.
Is the glow plug lamp illuminate? Go to Step 11 Go to Step 8

2. Remove the IP cluster.
voltage feed circuit of the IP cluster harness
8 connector (pin 40 of FU98) and a known good —
ground.

11 of FB24) and the IP cluster (pin 5 of FU98)
9 —

IP cluster (pins 5 and 40 of FU98).
10 —

11 —

Repair the short to ground between the ECM (pin
12 11 of FB24) and the IP cluster (pin 5 of FU98). —
Repair the short to battery or ignition voltage
between the ECM (pin 11 of FB24) and the IP
13 cluster (pin 5 of FU98). —


Repair the open circuit or high resistance on
ignition the voltage feed circuit between the Meter
14 (10A) fuse and the IP cluster (pin 40 of FU98). —

Repair or replace the IP cluster. Refer to Instrument
Panel (IP) Cluster in Section 9E Instrumentation/
15 Driver Info. —
Did you complete the repair or replacement? Go to Step 17 —


1. Reconnect all previously disconnected fuse or

18 —

EGR Flow Insufficient Detected Condition for Setting the DTC
• The ECM detects that the MAF amount is not
Circuit Description within the calculated range during the EGR flow
The ECM controls the EGR valve opening based on the test. This indicates insufficient amount of EGR
engine running condition and by controlling the EGR flow.
motor. The EGR valve position is detected by the
position sensor, and relayed to the ECM. When the Action Taken When the DTC Sets
proper enabling conditions are met, the ECM will open • The ECM blinks the MIL when the diagnostic runs
the EGR valve while monitoring the mass air flow and fails. Refer to DTC Type Definitions for Action
(MAF) signal. An expected MAF difference should be Taken When the DTC Sets - Type A.
detected between the closed and open positions. If the • The ECM limits fuel injection quantity.
ECM detects the MAF difference less than expected,
this DTC will set. This DTC will only run once per • The ECM inhibits cruise control.
ignition cycle within the enabling conditions.
Condition for Running the DTC • Refer to DTC Type Definitions for Condition for
• DTCs P0079, P0080, P0102, P0103, P0112, Clearing the MIL/ DTC - Type A.
P0113, P0116, P0117, P0118, P0122, P0123,
P0404, P0409, P0500, P0502, P0503, P0560, Notice: A history DTC remains 9,600 hours
P060B, P0638, P0651, P0697, P1404, P215A, (accumulated engine runtime) and will not clear with a
P2227, P2228 and P2229 are not set. scan tool.
• The engine is running. Intermittent Conditions in this section.
• A sticking or intermittently sticking the EGR valve
may set this DTC.

Go to Applicable
Warm up the engine (allow engine coolant
temperature to reach at least 75°C [167°F]) and let
3 idle for at least 3 minutes while observing the DTC —
Information with a scan tool.
Go to Diagnostic

• An EGR valve gasket that is missing or
damaged
• EGR gas leakage from any of the EGR
passages between the exhaust manifold
and intake manifold
• Restricted or collapsed EGR passage
between the exhaust manifold and the
EGR valve
system
4 • Any air induction leak —
system
• Skew or slow MAF sensor
Exhaust.
• A ventilation duct that is connected to the
exhaust tail pipe. Retest without the duct
if connected.

1. Perform the EGR Solenoid Control with a scan
tool several times.
2. Command the Desired EGR Position Increase
and Decrease while observing the EGR
5 Position 1. ± 5%
Does the EGR Position 1 parameter follow within

the specified value quick enough (compare with a Go to Diagnostic
similar unit if available)? Aids Go to Step 6
Replace the EGR valve.
6 —
Notice: A history DTC will not clear.

7 4. Start the engine and warm up (allow engine —
coolant temperature to reach at least 75°C
[167°F])
5. Let idle for at least 3 minutes while observing
the DTC Information with a scan tool.

8 —

EGR Control Circuit Range/ Performance Action Taken When the DTC Sets
• The ECM blinks the MIL when the diagnostic runs
Circuit Description and fails. Refer to DTC Type Definitions for Action
The ECM controls the EGR valve opening based on the Taken When the DTC Sets - Type A.
engine running condition and by controlling the EGR • The ECM limits fuel injection quantity.
motor. The EGR valve position is detected by the • The ECM inhibits EGR control.
position sensor, and relayed to the ECM. If the ECM
detects a variance between the actual EGR valve
position and desired EGR valve position for a
calibrated amount of time while the EGR valve is
commanded ON, this DTC will set. • Refer to DTC Type Definitions for Condition for
Notice: A history DTC remains 9,600 hours
• DTCs P0112, P0113, P0116, P0117, P0118,
(accumulated engine runtime) and will not clear with a
P0409, P060B, P0651, P0697, P2227, P2228 and
scan tool.
P2229 are not set.
• The EGR control is commanded ON. Intermittent Conditions in this section.
Condition for Setting the DTC may set this DTC.
• The ECM detects that the actual EGR valve
position is more than 15% below the desired valve Connector End View Reference: Engine Controls
position for longer than 5 seconds. Connector End Views or ECM Connector End Views


tool several times.
3 Position 1. ± 5%


1. Remove the EGR valve assembly from the
engine.
2. Inspect the EGR valve for the following
conditions:
• Restricted EGR valve by foreign
4 materials —
• Excessive deposits at valve
• Bent valve shaft or valve

2. Disconnect the EGR valve harness connector.
connector of the EGR valve (pins 1, 2, 3, 4, 5,
6, 7 and 8 of E45).
5 —
connector of the ECM (pins 87, 93, 94, 99,
101, 103, 110 and 111 of E26).
6. Test for an open circuit or high resistance on
each circuit.
necessary.

1. Test the motor circuits between the ECM (pins
103, 110 and 111 of E26) and the EGR valve
(pins 6, 7 and 8 of E45) for the following
conditions:
6 —
• A short to the EGR position sensor
circuit(s)

7 —

Records.




Records.

11 —

EGR Sensor Circuit Condition for Setting the DTC
• The ECM detects that all EGR valve position
Circuit Description sensor signals are stuck low or high for longer than
The exhaust gas recirculation (EGR) position sensor is 3 seconds.
installed on the EGR valve body together with the
control motor. The sensor is made up three individual Action Taken When the DTC Sets
sensors within one housing. The EGR position sensor • The ECM blinks the MIL when the diagnostic runs
1, EGR position sensor 2 and EGR position sensor 3 and fails. Refer to DTC Type Definitions for Action
are hall element type sensors, each with the following Taken When the DTC Sets - Type A.
circuits. • The ECM limits fuel injection quantity.
• 5 volts reference circuit • The ECM inhibits EGR control.
• Low reference circuit • The ECM inhibits cruise control.
• Signal circuit
The EGR position sensor provides a low or high signal Condition for Clearing the DTC
state to the ECM on the signal circuits, which is relative
to the position changes of the EGR valve. If the ECM
detects that each EGR position sensor signal state is
out of correlation such as all low signal state or high
signal state, this DTC will set.
scan tool.



3 —
4. Observe the EGR Position 1, 2 and 3
parameters with a scan tool.
Is there parameter which indicate High? Go to Step 7 Go to Step 4

5 E45). 4.5 volts

Observe the EGR Position 1, 2 and 3 parameter
with a scan tool while momentarily jumping a 3-
amp fused jumper wire across the EGR valve
harness connector between each signal circuit and
the 5 volts reference circuit.
6 • EGR position 1: pins 1 and 4 of E45 —
• EGR position 2: pins 1 and 3 of E45
Is there parameter which did not indicate High

when the circuit is jumpered? Go to Step 10 Go to Step 11
Important: The EGR position sensor may be
voltage source.
1. Test the signal circuits (which ever parameter
indicates High at Step 3) between the ECM
(pins 93, 94 and 99 of E26) and the EGR
7 valve (pins 2, 3 and 4 of E45) for the following —
conditions:

Notice: The EGR position sensor shares the 5
8 1. Test the 5 volts reference circuit between the —

ECM (pin 87 of E26) and the EGR valve (pin 1

Notice: The EGR position sensor shares the low
9 ECM (pin 101 of E26) and the EGR valve (pin —
resistance.

1. Test the position sensor circuits (which ever
parameter did not indicate High at Step 6)
between the ECM (pins 93, 94 and 99 of E26)
and the EGR valve (pins 2, 3 and 4 of E45) for
• An open circuit
10 —
• High resistance


EGR valve (pins 1, 2, 3, 4 and 5 of E45).
11 —

(pins 6, 7 and 8 of E45) for a short to the EGR
12 position sensor circuit(s). —

ECM (pins 87, 93, 94, 99 and 101 of E45).

14 —


Records.

17 —

Catalyst Temperature Sensor Circuit Range/ Action Taken When the DTC Sets
Performance Sensor 1 • The ECM illuminates the SVS lamp when the
diagnostic runs and fails. Refer to DTC Type
Circuit Description Definitions for Action Taken When the DTC Sets -
The exhaust temperature sensor 1 is installed to the Type C.
diesel particulate defuser (DPD) housing. The exhaust • The ECM limits fuel injection quantity.
temperature sensor 1 is a variable resistor and it • The ECM inhibits cruise control.
measures the temperature of the exhaust gas in front of
DPD filter. If the ECM detects an excessively high Condition for Clearing the DTC
exhaust temperature, this DTC will set.
Clearing the SVS Lamp/ DTC - Type C.
• DTCs P0427, P0428, P060B and P0697 are not Diagnostic Aids
set.
• Use the Temperature vs. Resistance table to test
• The ignition switch is ON. the exhaust temperature sensor at various
temperature levels to evaluate the possibility of a
Condition for Setting the DTC skewed sensor.
• The ECM detects that exhaust temperature 1 (in • Fuel system problem (e.g. fuel injector damage)
front of filter) is higher than 880°C (1616°F) for 5 may set this DTC.
seconds.
Notice: This DTC is caused by an excessively high
exhaust temperature condition, which was most likely
caused by uncontrolled burning while regeneration
event of DPD filter. Excessive high exhaust gas
temperature may damage DPD filter or oxidation
catalyst.

Go to Applicable
1. Test the exhaust temperature sensor 1 at
various temperature levels to evaluate the
possibility of a skewed sensor.
3 2. Replace the exhaust temperature sensor as —
necessary. Refer to Exhaust Pipe in Section
1G Engine Exhaust.


1. Remove the diesel particulate defuser (DPD)
assembly. Refer to Exhaust Pipe in Section
1G Engine Exhaust.
2. Inspect the DPD filter and the oxidation
catalyst for damage, cracks or melt.
4 Important: DPD status in the ECM must be —

reset when the DPD filter is replaced.
3. Replace the DPD filter or the oxidation
catalyst as necessary. Refer to Exhaust Pipe
in Section 1G Engine Exhaust.
Go to Diagnostic
5 —
observed from the Failure Records.

6 —

Catalyst Temperature Sensor Circuit Low or • The engine run time is longer than 3 to 10 minutes.
High Sensor 1 (DTC P0428)
Circuit Description Condition for Setting the DTC
The exhaust temperature sensor 1 is installed to the • The ECM detects that the exhaust temperature
diesel particulate defuser (DPD) housing. The exhaust sensor 1 signal voltage is less than 0.2 volts for 3
temperature sensor 1 is a variable resistor and it seconds. (DTC P0427)
measures the temperature of the exhaust gas in front of • The ECM detects that the exhaust temperature
DPD filter. The sensor has a signal circuit and a low sensor 1 signal voltage is more than 4.85 volts for
reference circuit. The ECM supplies 5 volts to the 5 seconds. (DTC P0428)
signal circuit and a ground for the low reference circuit.
When the exhaust temperature sensor 1 is cold, the Action Taken When the DTC Sets
sensor resistance is high. When the exhaust • The ECM illuminates MIL when the diagnostic runs
temperature increases, the sensor resistance and fails. Refer to DTC Type Definitions for Action
decreases. With high sensor resistance, the ECM Taken When the DTC Sets - Type A.
detects a high voltage on the signal circuit. With lower
• The ECM limits fuel injection quantity.
sensor resistance, the ECM detects a lower voltage on
the signal circuit. If the ECM detects an excessively low • The ECM inhibits pre injection.
or high signal voltage, DTC P0427 or P0428 will set. • The ECM inhibits cruise control.
Condition for Running the DTC Condition for Clearing the DTC
• DTCs P060B and P0697 are not set. (DTC P0427) • Refer to DTC Type Definitions for Condition for
P060B, P0651, P0697, P2227, P2228 and P2229
are not set. (DTC P0428) Diagnostic Aids
• The engine coolant temperature is more than 80°C
the exhaust temperature sensor 1 at various
(176°F). (DTC P0428)
• The engine speed is more than 1300 RPM. (DTC skewed sensor.
P0428)
• The desired fuel injection quantity is more than a Connector End View Reference: Engine Controls
predetermined value. (DTC P0428) Connector End Views or ECM Connector End Views
• The vehicle is running or the PTO control is
inactive.


Observe the Exhaust Temperature Sensor 1
3 0.2 volts
Is the Exhaust Temperature Sensor 1 parameter Go to Diagnostic

2. Disconnect the exhaust temperature sensor 1
harness connector.
4 4.5 volts
Is the Exhaust Temperature Sensor 1 parameter

73 of FB24) and the exhaust temperature
sensor 1 (pin 2 of FB67) for the following
conditions:

Replace the exhaust temperature sensor 1. Refer
6 to Exhaust Pipe in Section 1G Engine Exhaust. —
7 corrosion. —
necessary.


Records.

10 —



1. Start the engine and fully warm up (allow
engine coolant temperature to reach at least
80°C [176°F]).
3 times while observing the Exhaust 4.8 volts
Temperature Sensor 1 parameter with a scan
tool.

harness connector.
(pin 2 of FB67) and a known good ground.
Important: The exhaust temperature sensor 1 may
a voltage source.
5 73 of FB24) and the exhaust temperature —
sensor 2 (pin 2 of FB67) for a short to battery
or ignition voltage.

6 and 2 of FB67). 0.1 volts
signal circuit (pin 2 of FB67) and a known good
7 ground. 0.1 volts
sensor 1 (pin 2 of FB67) for an open circuit or


Notice: The exhaust temperature sensor 1 shares
9 ECM (pin 79 of FB24) and the exhaust —
temperature sensor 1 (pin 1 of FB67) for an
open circuit or high resistance.

sensor 1 (pin 2 of FB67) for a short to any 5
10 volts reference circuit. —

exhaust temperature sensor 1 (pins 1 and 2 of
11 FB67). —



80°C [176°F]).
15 4.8 volts
times while observing the Exhaust
tool.

16 —

DTC P042B (Flash Code 145)
oxidation catalyst. If the ECM detects an excessively Condition for Clearing the DTC
high exhaust temperature, this DTC will set.
• DTCs P042C, P042D, P060B and P0697 are not Diagnostic Aids
set.
front of oxidation catalyst) is higher than 870°C may set this DTC.
(1600°F) for 5 seconds.
temperature may damage DPD filter.
Circuit/ System Testing DTC P042B (Flash Code 145)

Go to Applicable
Is DTC P0093, P042C or P1093 also set? DTC Go to Step 3
necessary. Refer to Exhaust Pipe in Section
1G Engine Exhaust.


1G Engine Exhaust.

Go to Diagnostic
5 —

6 —

DTC P042C or P042D (Flash Code 49)
Catalyst Temperature Sensor Circuit Low or • The vehicle is running or the PTO control is
High Sensor 2 inactive.
• The engine run time is longer than 3 to 10 minutes.
Circuit Description (DTC P042D)
The exhaust temperature sensor 2 is installed to the
diesel particulate defuser (DPD) housing. The exhaust
temperature sensor 2 is a variable resistor and it • The ECM detects that the exhaust temperature
measures the temperature of the exhaust gas in front of sensor 2 signal voltage is less than 0.2 volts for 3
oxidation catalyst. The sensor has a signal circuit and a seconds. (DTC P042C)
low reference circuit. The ECM supplies 5 volts to the • The ECM detects that the exhaust temperature
signal circuit and a ground for the low reference circuit. sensor 2 signal voltage is more than 4.85 volts for
When the exhaust temperature sensor 2 is cold, the 5 seconds. (DTC P042D)
sensor resistance is high. When the exhaust
temperature increases, the sensor resistance Action Taken When the DTC Sets
decreases. With high sensor resistance, the ECM
Definitions for Action Taken When the DTC Sets -
the signal circuit. If the ECM detects an excessively low
Type C.
or high signal voltage, DTC P042C or P042D will set.
• DTCs P060B and P0697 are not set. (DTC P042C)
• DTCs P0112, P0113, P0116, P0117, P0118,
P060B, P0651, P0697, P2227, P2228 and P2229 Diagnostic Aids
are not set. (DTC P042D)
• The engine speed is more than 1300 RPM. (DTC the exhaust temperature sensor 2 at various
P042D) temperature levels to evaluate the possibility of a
• The engine coolant temperature is more than 80°C skewed sensor.
(176°F). (DTC P042D)
• The desired fuel injection quantity is more than a Connector End View Reference: Engine Controls
predetermined value. (DTC P042D) Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P042C (Flash Code 49)


3 0.2 volts

harness connector.
4 4.5 volts

conditions:

7 corrosion. —
necessary.


9 —

10 —
Circuit/ System Testing DTC P042D (Flash Code 49)



80°C [176°F]).
tool.

harness connector.
a voltage source.

7 ground. 0.1 volts




11 FB68). —



80°C [176°F]).
15 4.8 volts
tool.

16 —

Exhaust Pressure Control Valve Low or High Action Taken When the DTC Sets
Circuit Description runs and fails. Refer to DTC Type Definitions for
The ECM controls the exhaust brake, which supplies Action Taken When the DTC Sets - Type A.
air pressure to the exhaust brake valve based on the • The ECM blinks the exhaust brake indicator lamp
vehicle running condition. The exhaust brake solenoid when the diagnostic runs and fails.
valve energizes to apply air pressure to the exhaust • The ECM inhibits exhaust brake control.
brake valve. If the ECM detects an improper voltage
level on the exhaust brake solenoid valve control Condition for Clearing the DTC
circuit, DTC P0477 or P0478 will set.


• The ECM detects a low voltage condition on the The number below refers to the step number on the
exhaust brake solenoid control circuit for longer Circuit/ System Testing.
than 3 seconds when the solenoid is commanded DTC P0478
OFF. (DTC P0477) 3. If the exhaust brake solenoid control circuit between
• The ECM detects a high voltage condition on the the ECM and the solenoid valve is normal, voltage level
exhaust brake solenoid control circuit for longer low DTC P0477 will set.
than 3 seconds when the solenoid is commanded
ON. (DTC P0478) Connector End View Reference: Engine Controls

2. Perform the Exhaust Brake Control with a
2 scan tool. —
Go to Diagnostic
2. Disconnect the exhaust brake solenoid valve
harness connector.
3. Connect the test lamp between the ignition
3 voltage feed circuit (pin 1 of J8 or FB41) and a —
known good ground.

circuit (pin 2 of J8 or FB41) and battery
voltage.
4 scan tool. —


5 —
the ECM Main (15A) fuse and the exhaust brake
6 solenoid valve (pin 1 of J8 or FB41). Check the —
ECM Main (15A) fuse first.

15 of FB24) and the solenoid valve (pin 2 of J8
or FB41) for an open circuit or high resistance.
7 —

or FB41) for a short to ground.
8 —

solenoid valve (pins 1 and 2 of J8 or FB41).
9 —

10 connection at harness connector of the ECM —
(pin 15 of FB24).

Replace the exhaust brake solenoid valve.
11 —

13 3. Perform the Exhaust Brake Control with a —
scan tool.
14 —


2 scan tool. —
Go to Diagnostic
harness connector.
Is DTC P0477 set, but not P0478? Go to Step 5 Go to Step 4

or FB41) for a short to battery or ignition
4 voltage. —

5 —

scan tool.
8 —

Vehicle Speed Sensor Action Taken When the DTC Sets
The vehicle speed sensor (VSS) is used by the ECM Action Taken When the DTC Sets - Type A.
and other modules, which generates a speed signal • The ECM limits fuel injection quantity.
from the transmission output shaft rotational speed. • The ECM inhibits pre injection.
The sensor has the following circuits.
• Ignition voltage feed circuit
• Low reference circuit Condition for Clearing the DTC
• VSS signal circuit • Refer to DTC Type Definitions for Condition for
The VSS uses a hall effect element or magnetic Clearing the MIL/ DTC - Type A.
resistance element (MRE). It interacts with the
magnetic field created by the rotating magnet and Diagnostic Aids
outputs square wave pulse signal. The ECM calculates
the vehicle speed by the VSS. If the ECM detects VSS
signals are not generated, this DTC will set.
• Electromagnetic interference in the vehicle speed
Condition for Running the DTC signal circuit may set this DTC.
• The battery voltage is between 18 to 32 volts. • An aftermarket signal pulse pickup device may
affect intermittent condition.
• The commanded fuel injection quantity is OFF Notice: If this DTC set, the Vehicle Speed parameter
(accelerator pedal is not depressed). on the scan tool will display 10 km/h.
• The engine speed is more than 2000 RPM.
• The ECM detects that the vehicle speed signal
pulses are not generated for longer than 7
seconds.

Go to Applicable
Drive the vehicle while observing the Vehicle
3 Speed parameter with a scan tool. — Go to Diagnostic
Does the scan tool indicate correct vehicle speed? Aids Go to Step 4

1. Inspect the VSS, drive gear, driven gear or
output shaft for the following conditions:
• Physical damage of sensor, drive gear or
driven gear
• Loose or improper installation of sensor,
drive gear or driven gear
4 • Transmission output shaft teeth damage —
• Excessive transmission output shaft play
2. Disconnect the aftermarket signal pulse
pickup device and retest if installed.

Notice: If no ZF transmission is installed, skip to
Step 6.
1. Inspect the impulse sensor and speed signal
5 distributor. —
Refer to Manual Transmission (ZF) section.

1. Remove the VSS.
2. Connect a 3-amp jumper wire between the
vehicle speed sensor and the battery voltage.
Refer to IP Cluster and Warning in Section 9D
Wiring System.
vehicle speed sensor and a known good 0.5 to 1.5 volts
6 ground. Refer to IP Cluster and Warning in or 12 to 15
Section 9D Wiring System. volts
4. Connect a DMM between the vehicle speed
sensor and a known good ground. Refer to IP
Cluster and Warning in Section 9D Wiring
System.
5. Rotate the shaft of the VSS slowly.
Is the DMM voltage within the specified value? Go to Step 9 Go to Step 7

vehicle speed sensor. Refer to IP Cluster and
7 Warning in Section 9D Wiring System. —

Replace the VSS. Refer to Vehicle Speed Sensor in
8 Section 9E Instrumentation/ Driver Info. —
Replace the speed sensor control unit. Refer to
Speed Sensor Control Unit in Section 9E
9 Instrumentation/ Driver Info. —


4. Drive the vehicle while observing the Vehicle
Speed parameter with a scan tool.
Does the scan tool indicate correct vehicle speed? Go to Step 11 Go to Step 2
11 —

Vehicle Speed Sensor Circuit Low or High • The ECM detects that the vehicle speed signal
Input voltage is more than 20 volts. (DTC P0503)
Circuit Description Action Taken When the DTC Sets
The vehicle speed sensor (VSS) is used by the ECM • The ECM illuminates the MIL when the diagnostic
and other module, which generates a speed signal runs and fails. Refer to DTC Type Definitions for
from the transmission output shaft rotational speed. Action Taken When the DTC Sets - Type A.
The sensor has the following circuits. • The ECM limits fuel injection quantity.
• Ignition voltage circuit • The ECM inhibits pre injection.
• VSS signal circuit
The VSS uses a hall effect element or magnetic Condition for Clearing the DTC
resistance element (MRE). It interacts with the • Refer to DTC Type Definitions for Condition for
magnetic field created by the rotating magnet and Clearing the MIL/ DTC - Type A.
the vehicle speed by the VSS. If the ECM detects an Diagnostic Aids
excessively low or high signal voltage, DTC P0502 or • If an intermittent condition is suspected, refer to
• An aftermarket signal pulse pickup device may
• DTC P060B is not set.
• The battery voltage is between 21 to 32 volts. Notice: If this DTC set, the Vehicle Speed parameter
• The ignition switch is ON. on the scan tool will display 10 km/h.
Condition for Setting the DTC Connector End View Reference: Engine Controls

Go to Diagnostic
Step 4.
1. Inspect the impulse sensor and circuit.
3 Refer to Manual Transmission (ZF) section. —

1. Drive the vehicle.
2. Observer the Vehicle Speed parameter with
4 the scan tool. —
Does the Vehicle Speed parameter indicate correct Go to Diagnostic
vehicle speed? Aids Go to Step 5

Observer the speedometer in the instrument panel
(IP) cluster.
5 —
Does the speedometer indicate correct vehicle
speed? Go to Step 6 Go to Step 7
1. Test the vehicle speed signal input circuit
between the engine control module (ECM)
(pin 19 of FB24) and the speed sensor control
unit (pin 3 of FU173) for the following
conditions:
• An open circuit
6 —
• High resistance

7 2. Inspect the Meter (10A) fuse. —
circuits that fed by the Meter (10A) fuse or replace
8 the shorted attached component fed by the Meter —
(10A) fuse.

1. Remove the vehicle speed sensor. Refer to
Vehicle Speed Sensor in Section 9E
Instrumentation/ Driver Info.
2. Visually inspect the vehicle speed sensor for
the following conditions.
• Physical damage
9 • Being loose —
• Loose or improper installation
• For speedometer driven gear teeth
damage

2. Disconnect the vehicle speed sensor harness
connector.
voltage feed circuit of the vehicle speed
10 sensor and a known good ground. Refer to IP —
System.


1. Test the vehicle speed sensor power supply
circuit between the speed sensor control unit
and the vehicle speed sensor for open circuits
or high resistance. Refer to IP Cluster and
11 —
Warning in Section 9D Wiring System.

1. Keep the ignition switch ON.
2. Connect a test lamp between the low
reference circuit of the vehicle speed sensor
12 and battery voltage. Refer to IP Cluster and —

2. Intermittently jump the signal circuit of the
vehicle speed sensor with a test lamp that is
connected to 12 volts (apply form a battery)
13 while monitoring the Vehicle Speed parameter —
with the scan tool. Refer to IP Cluster and
Does the scan tool indicate any vehicle speed

when the circuit is intermittently pulled to 12 volts? Go to Step 23 Go to Step 14
2. Disconnect the speed sensor control unit
harness connector.
14 voltage feed circuit of the speed sensor —
control unit harness (pin 1 of FU173) and a
known good ground.

reference circuit of the speed sensor control
15 unit harness (pin 5 of FU173) and battery —
voltage.

speed sensor control unit (pin 3 of FU173)
with a test lamp that is connected to 12 volts
16 (apply form a battery) while monitoring the —
Vehicle Speed parameter with the scan tool.

Repair any open circuits or high resistance in the
vehicle speed sensor ground circuit between the
vehicle speed sensor and the chassis ground
17 (FU51). Refer to IP Cluster and Warning in Section —
9D Wiring System.


speed sensor control unit power supply circuit
18 between the Meter (10A) fuse and the speed —
sensor control unit (pin 1 of FU173).

speed sensor control unit ground circuit between
19 the speed sensor control unit (pin 5 of FU173) and —
the chassis ground (FU51).

between the speed sensor control unit and the
vehicle speed sensor for the following
conditions:
• An open circuit
20 • A short to battery or ignition voltage —
• High resistance
Wiring System.

between the ECM (pin 19 of FB24) and the
speed sensor control unit (pin 3 of FU173) for
• An open circuit
• High resistance

speed sensor control unit (pins 3 and 7 of
22 FU173). —

connector.


connection on the vehicle speed sensor signal
24 circuit at the harness connector of the ECM —
(pin 19 of FB24).


Replace the vehicle speed sensor. Refer to Vehicle
Speed Sensor in Section 9E Instrumentation/
26 Driver Info. —


28 —
5. Select the data display function of ECM.
6. Observe the Vehicle Speed parameter with
the scan tool.
Does the Vehicle Speed parameter indicate correct

vehicle speed? Go to Step 29 Go to Step 3
29 —

System Voltage • The ECM detects that the 12 volts reference circuit
voltage more than 19 volts.
Circuit Description
The ECM provides 12 volts reference voltage to the
mass air flow (MAF) sensor. Battery voltage is supplied • The ECM illuminates the MIL when the diagnostic
in ECM through the dropping resistor, and it is runs and fails. Refer to DTC Type Definitions for
converted into 12 volt. The ECM monitors the voltage Action Taken When the DTC Sets - Type A.
on the 12 volts reference circuit. If the ECM detects the • The ECM limits fuel injection quantity.
voltage is excessively low or high, this DTC will set. • The ECM inhibits cruise control.
• DTC P060B is not set. • Refer to DTC Type Definitions for Condition for
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type A.
Diagnostic Aids
Condition for Setting the DTC • If an intermittent condition is suspected, refer to
Either of following condition is met: Intermittent Conditions in this section.
• The ECM detects that the 12 volts reference circuit
voltage is less than 7 volts. Connector End View Reference: Engine Controls

Go to Diagnostic
3 connector. —
Does the DTC fail this ignition? Go to Step 4 Go to Step 13

2. Leave the MAF sensor harness connector
disconnected.
4 3. Disconnect the dropping resistor harness —
connector.

Measure the resistance across the dropping
5 resistor. 45 to 55 Ω
Is the resistance within the specified value? Go to Step 6 Go to Step 15
1. Connect a DMM between the ignition voltage
feed circuit (pin 1 of FB53) and a known good
ground.
6 18.0 volts

Connect a DMM between the voltage supply circuit
7 (pin 2 of FB53) and a known good ground. 13.0 volts
Repair the open circuit or high resistance on the
ignition voltage feed circuit between the ECM Main
8 (15A) fuse and the dropping resistor (pin 1 of —
FB53). Check the ECM Main (15A) fuse first.

1. Test the voltage supply circuit between the
ECM (pin 35 of FB24) and the dropping
resistor (pin 2 of FB53) for an open circuit or

resistor (pin 2 of FB53) for the following
conditions:

(pin 1 of J14 or FB128) for the following
conditions:
11 —
• A short to the low reference

dropping resistor (pins 1 and 2 of FB53).
12 —
Go to Diagnostic
1. Inspect for corrosion at the harness connector
of the MAF sensor (pin 1 of J14 or FB128).
13 2. Repair the connection(s) as necessary. —


Replace the dropping resistor.
15 —


Records.

19 —

System Voltage High Action Taken When the DTC Sets
The ECM monitors the ignition voltage on the ignition Definitions for Action Taken When the DTC Sets -
feed terminal to make sure that the voltage stays within Type C.
the proper range. If the ECM detects an excessively
high ignition voltage, this DTC will set. Condition for Clearing the DTC
Condition for Running the DTC Clearing the SVS Lamp/ DTC - Type C.
• A charging system problem may set this DTC.
• The ECM detects that the ignition voltage feed
circuit is more than 32 volts for 30 minutes.

Was the vehicle recently a battery charger placed
2 —
on the battery? Go to Step 7 Go to Step 3
3. Observe the Ignition Voltage parameter with
3 32.0 volts
the scan tool.
Does the scan tool indicate less than the specified Go to Diagnostic
value? Aids Go to Step 4
Test the charging system. Refer to Charging
4 System in Section 1E Engine Electrical. — Go to Diagnostic
Did you find a charging system problem? Go to Step 5 Aids
Repair the charging system. Refer to Charging
5 System in Section 1E Engine Electrical. —
2. Clear the DTCs with the scan tool.
6 4. Start the engine and let idle. 32.0 volts
5. Observe the ignition Voltage parameter with a
scan tool.
Does the scan tool parameter less than the

7 —

Brake Switch Circuit Action Taken When the DTC Sets
The brake switches are installed to the brake pedal Definitions for Action Taken When the DTC Sets -
bracket. Two brake switches are installed and both are Type C.
turned to ON when the brake pedal is depressed. The
power supply voltage is supplied to the brake switches Condition for Clearing the DTC
via the stoplight relay, stoplight relay diode and brake • Refer to DTC Type Definitions for Condition for
switch diode. When the brake switch turns to ON, each Clearing the SVS Lamp/ DTC - Type C.
ground circuit is completed and the signal is input to the
engine control module (ECM). The ECM sets the DTC Diagnostic Aids
when the number of signal inputs of brake switches 1
and 2 do not match to each other.
• The battery voltage is more than 20 volts. Connector End Views or ECM Connector End Views

The ECM detects the brake switch 1 signal and brake
switch 2 signal correlation error for 32 times.

3. Observe the Brake Switch 1 parameter with a
scan tool while fully depressing and releasing
2 —
the brake pedal.
Does the scan tool indicate Applied when the brake

pedal is applied and Released when the brake
pedal is released? Go to Step 10 Go to Step 3
1. Check for play or looseness in the installation
condition of the brake switch 1 connector,
ECM and coupling connector.
3 —

2. Disconnect the brake switch 1 harness
connector.
3. Connect a 3-amp fused jumper wire across
the switch harness connector (pins 1 and 2 of
4 FU159). —
4. Turn ON the ignition.
scan tool.
Does the scan tool indicate Applied? Go to Step 5 Go to Step 7


2. Disconnect the 3-amp fused jumper wire from
the brake switch 1 harness connector.
5 3. Turn ON the ignition. —
scan tool.
Does the scan tool indicate Released? Go to Step 6 Go to Step 9

Replace the brake switch 1.
6 —
1. Test the signal circuit between the Junction
Block 2 (pin 13 of FU134) and the brake
switch 1 (pin 1 of FU159) for an open circuit or

1. Test the ground circuit between the brake
switch 1 (pin 2 of FU159) and the ground
terminal (FU54) for an open circuit or high
8 resistance. —

Block 2 (pin 4 of FL67) and the ECM (pin 54 of
9 —

10 —
the brake pedal.

11 —

connector.
12 FB5). —
scan tool.


scan tool.

14 —
1. Test the signal circuit between the J/C-30P2
(pin 5 of FB35) and the brake switch 2 (pin 1
of FB5) for an open circuit or high resistance.
15 —

switch 2 (pin 2 of FB5) and the ground
terminal (FB21) for an open circuit or high
16 resistance. —

(pin 6 of FB35) and the ECM (pin 55 of FB24)
17 —


19 5. Observe the Brake Switch 1 and Brake Switch —
2 parameter with a scan tool while fully
depressing and releasing the brake pedal.

pedal is released on each parameter? Go to Step 2 Go to Step 20
20 —

Internal Control Module Memory Check Sum Action Taken When the DTC Sets
Error • The ECM illuminates the MIL when the diagnostic
This diagnostic applies to internal microprocessor • The ECM stops engine running. The engine will
integrity conditions within the ECM. run after the key is cycled when the ignition has
been turned OFF for longer than 10 seconds.
• The ECM detects that the calculated checksum
does not agree with the read only memory (ROM) • Refer to DTC Type Definitions for Condition for
internal registered checksum. Clearing the MIL/ DTC - Type A.



4 Running the DTC. You may also operate the —
Records.

5 —

Control Module Programming Error • The ECM detects an error in the programmed fuel
injector ID code.
Circuit Description
The electrically erasable & programmable read only
memory (EEPROM) memorizes fuel injector ID code • The ECM illuminates the SVS lamp when the
information. If the ECM detects fuel injector ID codes diagnostic runs and fails. Refer to DTC Type
are not programmed into the ECM or an error in the Definitions for Action Taken When the DTC Sets -
programmed fuel injector ID codes, this DTC will set. Type C.
• The ignition switch is ON. • Refer to DTC Type Definitions for Condition for
Notice: Clear the DTC with a scan tool after
programming the fuel injector ID code.
• The ECM detects that the fuel injector ID code is
not programmed.

1. Ensure that all tool connections are secure.
2. Ensure that programming equipment is
operating correctly.

1. Verify the correct fuel injector ID codes are
entered into the ECM with a scan tool. Refer
to ECM Replacement. If the fuel injector ID
codes are correctly entered, clear the DTC
3 with a scan tool. —


Records.


6 —

DTC P0604, P0606 or P060B (Flash Code 153, 51 or 36)
Internal Control Module RAM Error • The ECM detects a malfunction in its internal A/D
converter. (DTC P060B)
ECM Processor
Internal Control Module A/D Processing Action Taken When the DTC Sets
This diagnostic applies to internal microprocessor • The ECM limits fuel injection quantity.
integrity conditions within the ECM.
• The ECM inhibits pre injection.
Condition for Running the DTC • The ECM inhibits cruise control.
• The battery voltage is more than 16 volts. (DTC • The ECM stops engine running. The engine will
P0604 and P0606) run after the key is cycled when the ignition has
• The ignition switch is ON. (DTC P0604 and P0606) (DTC P0604)
Condition for Setting the DTC Condition for Clearing the DTC
• The ECM detects a malfunction in its internal • Refer to DTC Type Definitions for Condition for
random access memory (RAM). (DTC P0604) Clearing the MIL/ DTC - Type A.
• The ECM detects a malfunction in its internal main
central processing unit (CPU) or sub integrated
circuit (IC). (DTC P0606)
Circuit/ System Testing DTC P0604, P0606 or P060B (Flash Code 153, 51 or 36)



Records.

5 —

Immobilizer not programmed Action Taken When the DTC Sets
The electronically erasable & programmable read only When the DTC Sets - Type D.
memory (EEPROM) memorizes immobilizer security
information for communication with the immobilizer Condition for Clearing the DTC
control unit (ICU) and enabling the engine to start. If the • Refer to DTC Type Definitions for Condition for
ECM detects immobilizer security information are not Clearing the DTC - Type D.
programmed into the ECM, this DTC will set.
Diagnostic Aids
• Non-programmed ECM sets this DTC.
• The ECM detects that the immobilizer security
information is not programmed.

Go to Diagnostic
Program immobilizer security information into the
ECM. Refer to Immobilizer Control Unit &
3 Programming in Section 9I Security and Lock. —
Did you complete the programming? Go to Step 4 —

Records.

5 —

Throttle Actuator Control Range/ Performance Action Taken When the DTC Sets
The ECM controls the intake throttle valve opening Action Taken When the DTC Sets - Type A.
based on the engine running condition and by • The ECM inhibits EGR valve control.
controlling the intake throttle motor. The intake throttle
valve position is detected by the position sensor, and Condition for Clearing the DTC
relayed to the ECM. If the ECM detects a variance • Refer to DTC Type Definitions for Condition for
between the actual intake throttle valve position and Clearing the MIL/ DTC - Type A.
desired intake throttle valve position while the intake
throttle motor is commanded ON, this DTC will set. Diagnostic Aids
• DTCs P0122, P0123, P060B and P0697 are not
set. • A sticking or intermittently sticking intake throttle
valve may set this DTC.
• A sticking intake throttle valve at full closed
• The ignition switch is ON. position will cause engine starting problem.
• The desired intake throttle valve position is stable.
• The intake throttle motor is commanded ON. Connector End View Reference: Engine Controls
• The ECM detects that the difference between the
actual and the desired intake throttle position is
more than 40% for longer than 5 seconds.

Go to Applicable
1. Perform the Intake Throttle Solenoid Control
with a scan tool several times.
2. Command the Desired Intake Throttle Position
Increase and Decrease while observing the
3 Intake Throttle Position. ± 5%
Does the Intake Throttle Position parameter follow

within the specified value quick enough (compare Go to Diagnostic
with a similar unit if available)? Aids Go to Step 4

1. Remove the intake duct that is connected to
the intake throttle valve.
2. Inspect the intake throttle valve for the
• Restricted intake throttle valve by foreign
materials
4 • Excessive deposits at throttle bore —
• Bent butterfly valve
Notice: Replace the intake throttle valve if

there is any sticking.

connector.
connector of the intake throttle valve (pins 1,
2, 4, 5 and 6 of E46).
5 connections and corrosion on each intake —
throttle valve circuit at the harness connector
of the ECM (pins 85, 95, 104, 109 and 112 of
E26).
each circuit.
necessary.

104 and 112 of E26) and the intake throttle
valve (pins 1 and 2 of E46) for the following
conditions:
6 —
• A short to the intake throttle position
sensor circuit(s)


Records.


Records.

11 —

Sensor Reference Voltage 1 Circuit • The ECM detects that the 5 volts reference circuit
1 voltage is less than 4.5 volts.
Circuit Description • The ECM detects that the 5 volts reference circuit
The ECM provides 5 volts reference voltage through 1 voltage is more than 5.5 volts.
the reference circuit 1 to the following sensors:
• Accelerator pedal position (APP) sensor 1
• PTO throttle sensor • The ECM illuminates the MIL when the diagnostic
• Idle up sensor Action Taken When the DTC Sets - Type A.
The ECM also provides 5 volts reference voltage
through the reference circuit 1 to the cruise control • The ECM blinks the exhaust brake indicator lamp
switch on the combination switch. The 5 volts reference when the diagnostic runs and fails.
circuits are bussed together outside the ECM. • The ECM limits fuel injection quantity.
Therefore, a short circuit condition on one sensor 5 • The ECM inhibits exhaust brake control.
volts reference circuit may affect the entire 5 volts • The ECM inhibits cruise control.
reference circuit 1. The ECM monitors the voltage on
the 5 volts reference circuit 1. If the ECM detects the Condition for Clearing the DTC
voltage is excessively low or high, this DTC will set.
• DTC P060B is not set. Diagnostic Aids

Either of following condition is met: Connector End Views or ECM Connector End Views

Go to Diagnostic
2. Disconnect the idle up sensor harness
connector.
3 circuit (pin 3 of FL33) and a known good 5.5 volts
ground.
4 4.5 volts

1. Leave the DMM connected to the idle up
3. Disconnect the accelerator pedal position
5 (APP) sensor harness connector. 4.5 volts
Does the DMM voltage change to more than the

Notice: If no PTO throttle sensor is installed, skip
to Step 7.
6 3. Disconnect the PTO throttle sensor harness 4.5 volts
connector.

ECM (pin 42 of FB24) and the following
components for a short to ground or short to
the low reference circuit:
• APP sensor 1 (pin 4 of FL1)
7 —
• PTO throttle sensor (pin 3 of FB129)
• Idle up sensor (pin 3 of FL33)

components for a short to battery or ignition
voltage.
8 • Idle up sensor (pin 3 of FL33) —
ECM (pin 65 of FB24) and the combination
switch (pin 5 of FL19) for a short to battery or
ignition voltage.

Replace the idle up sensor.
9 —
Replace the APP sensor. Refer to Accelerator
Control Assembly in Section 1I Engine Speed
10 Control System. —

Replace the PTO throttle sensor.
11 —


Records.

14 —

Malfunction Indicator Lamp (MIL) Control • The ECM detects a low voltage condition on the
Circuit MIL control circuit when the lamp is commanded
OFF.
Circuit Description • The ECM detects a high voltage condition on the
MIL control circuit when the lamp is commanded
The malfunction indicator lamp (MIL) is located on the
ON.
instrument panel (IP) cluster. The MIL informs the
driver that an emission system fault has occurred and
that the engine control system requires service.
The ECM monitors the MIL control circuit for conditions • The ECM illuminates the MIL when the diagnostic
that are incorrect for the commanded state of the MIL. runs and fails. Refer to DTC Type Definitions for
For example, a failure condition exists if the ECM Action Taken When the DTC Sets - Type A.
detects low voltage when the MIL is commanded OFF,
or high voltage when the MIL is commanded ON. If the Condition for Clearing the DTC
ECM detects an improper voltage level on the control • Refer to DTC Type Definitions for Condition for
circuit, this DTC will set. Clearing the MIL/ DTC - Type A.


Go to Diagnostic
3 block. —


Is the MIL OFF? Go to Step 6 Go to Step 12


voltage to the MIL.
6 3. Measure the voltage from the MIL control 1 volt
circuit in the ECM harness connector (pin 6 of
FB24) to a known good ground.

Is the MIL illuminate? Go to Step 11 Go to Step 8

ground.

9 —

IP cluster (pin 40 of FU98 and pin 31 of
10 FU97). —

11 —

Repair the short to ground between the ECM (pin 6
12 of FB24) and the IP cluster (pin 31 of FU97). —
between the ECM (pin 6 of FB24) and the IP cluster
13 (pin 31 of FU97). —



15 Driver Info. —



18 —

2 or 5 voltage is less than 4.5 volts.
The ECM provides 5 volts reference voltage through 2 or 5 voltage is more than 5.5 volts.
• Barometric pressure (BARO) sensor • The ECM illuminates MIL when the diagnostic runs
• Intake air temperature (IAT) sensor Taken When the DTC Sets - Type A.
through the reference circuit 5 to the following sensors: • The ECM blinks the exhaust brake indicator lamp
when the diagnostic runs and fails.
• Camshaft position (CMP) sensor
• EGR position sensor
The 5 volts reference circuits 2 and 5 are independent • The ECM inhibits EGR control.
of each other outside of the ECM, but are bussed • The ECM inhibits exhaust brake control.
together inside the ECM. Therefore, a short circuit • The ECM inhibits cruise control.
condition on one sensor 5 volts reference circuit may
affect the entire 5 volts reference circuit 2 and 5. The Condition for Clearing the DTC
ECM monitors the voltage on the 5 volts reference • Refer to DTC Type Definitions for Condition for
circuit 2 and 5. If the ECM detects the voltage is Clearing the MIL/ DTC - Type A.
excessively low or high, this DTC will set.
Diagnostic Aids
• DTC P060B is not set. Intermittent Conditions in this section.
• The ignition switch is ON. Notice: If this DTC is set, the engine cranks but does
not start.
Either of following condition is met: Connector End View Reference: Engine Controls

Go to Diagnostic
3. Connect a DMM between the CMP sensor 5
3 volts reference circuit (pin 3 of E48) and a 5.5 volts
known good ground.
4 4.5 volts

1. Leave the DMM connected to the CMP sensor
harness connector.
3. Disconnect the fuel rail pressure (FRP) sensor
5 harness connector. 4.5 volts

harness connector.
6 3. Disconnect the EGR valve harness connector. 4.5 volts

harness connector.
3. Disconnect the barometric pressure (BARO)
7 sensor harness connector. 4.5 volts

harness connector.

1. Test the 5 volts reference circuit 2 between the
• BARO sensor (pin 3 of FL52)
ECM (pin 87 of E26) and the following
9 —
• FRP sensor (pin 3 of E49)
• CMP sensor (pin 3 of E48)
• EGR valve position sensor (pin 1 of E45)


voltage.
10 —
voltage.

13 —
14 —


Records.

18 —

ECM Power Relay Control Circuit Open or Condition for Setting the DTC
High • The ECM detects a low voltage condition on the
ECM main relay voltage feed circuit for 3 seconds
Circuit Description when the relay is commanded ON. (DTC P0685)
The ECM main relay is energized to feed the battery • The ECM detects that the ECM has been ON
voltage to the ECM through the relay switch side when when the ECM main relay is commanded OFF.
the ECM receives an ignition voltage switch ON signal. (DTC P0687)
When the ignition switch is OFF, the ECM main relay is
de-energized after a certain length of time passed. Action Taken When the DTC Sets
If the ECM detects a low voltage condition on the ECM • The ECM illuminates the SVS lamp when the
main relay voltage feed circuit when the relay is diagnostic runs and fails. Refer to DTC Type
commanded ON, DTC P0685 will set. Definitions for Action Taken When the DTC Sets -
If the ECM detects the ECM has been ON when the Type C.
relay is commanded OFF, DTC P0687 will set.
• DTC P060B is not set. (DTC P0685) Clearing the SVS Lamp/ DTC - Type C.
• DTC P0606 is not set. (DTC P0687)
(DTC P0685) • If an intermittent condition is suspected, refer to
• The ignition switch is ON. (DTC P0685) Intermittent Conditions in this section.
• The ignition switch is OFF. (DTC P0687)

Go to Diagnostic

1. Inspect for an intermittent, for poor tightening
and corrosion at the chassis ground terminal
(FB20).
2. Repair the tightening or clean the corrosion as
necessary.
3. Inspect the ECM (40A) slow blow fuse for an
4 open. —
4. Replace the ECM (40A) slow blow fuse if
open. If it continues to open, repair the short to
ground on one of the circuits that is fed by the
ECM (40A) slow blow fuse.


connector of the ECM (pins 2, 5, 21 and 40 of
FB24).
each relay circuit.
• Between pins 2 and 5 of FB24 and pin 2
5 of X18 —
• Between pins 21 and 40 of FB24 and pin
3 of X18
• Between ECM (40A) slow blow fuse and
pin 1 of X18
• Between pin 5 of X18 and chassis
ground (FB20)
necessary.

6 —


9 —

4. Monitor DTC Information with a scan tool.
Go to Diagnostic



Repair the short to battery on the battery voltage
feed circuits between the ECM (pins 2 and 5 of
5 FB24) and the ECM main relay (pin 2 of X18). —

supply circuits between the ECM (pins 21 and 40 of

7 —

9 —

Sensor Reference Voltage 3 Circuit • The ignition switch is ON.

The ECM provides 5 volts reference voltage through Either of following condition is met:
the reference circuit 3 to the following sensors: • The ECM detects that the 5 volts reference circuit
• Exhaust differential pressure sensor 3 or 4 voltage is less than 4.5 volts.
• Exhaust temperature sensor 1 • The ECM detects that the 5 volts reference circuit
• Exhaust temperature sensor 2 3 or 4 voltage is more than 5.5 volts.
through the reference circuit 4 to the following sensors: Action Taken When the DTC Sets
• Crankshaft position (CKP) sensor • The ECM illuminates the MIL when the diagnostic
• Boost pressure sensor
• Intake throttle position sensor
• Engine coolant temperature (ECT) sensor
• Fuel temperature (FT) sensor
The 5 volts reference circuits 3 and 4 are independent
of each other outside of the ECM, but are bussed • The ECM inhibits cruise control.
together inside the ECM. Therefore, a short circuit
condition on one sensor 5 volts reference circuit may Condition for Clearing the DTC
affect the entire 5 volts reference circuit 3 and 4. The • Refer to DTC Type Definitions for Condition for
ECM monitors the voltage on the 5 volts reference Clearing the MIL/ DTC - Type A.
circuit 3 and 4. If the ECM detects the voltage is
excessively low or high, this DTC will set. Diagnostic Aids
• The battery voltage is between 16 to 32 volts. Connector End View Reference: Engine Controls

Go to Diagnostic
harness connector.
ground.
4 4.5 volts

1. Leave the DMM connected to the boost
pressure sensor harness connector.


3. Disconnect the exhaust differential pressure

ECM (pin 80 of FB24) and the exhaust
differential pressure sensor (pin 3 of FB66) for
a short to ground or short to the low reference
circuit.
8 the low reference circuit: —
• CKP sensor (pin 3 of E50)
• Boost pressure sensor (pin 3 of E54)
• Intake throttle position sensor (pin 5 of
E46)

9 voltage. —
E46)


10 Mechanical. —

Important: Replacement exhaust differential
pressure sensor must be learned.
Replace the exhaust differential pressure sensor.
13 Refer to Exhaust Differential Pressure Sensor in —
Section 1G Engine Exhaust.


Records.

16 —

Transmission Control System Emissions • The ECM blinks the exhaust brake indicator lamp
Related Malfunction when the diagnostic runs and fails.
• The ECM inhibits exhaust brake control.
Circuit Description
The transmission control module (TCM) requests to
illuminate the malfunction indicator lamp (MIL) to the • Refer to DTC Type Definitions for Condition for
ECM via the controller area network (CAN) Clearing the MIL/ DTC - Type A.
communication bus when the TCM sets a MIL request
DTC(s). If the ECM detects the MIL illumination request Diagnostic Aids
signal, this DTC will set. • Under normal conditions if the TCM sets a DTC
that requests the MIL to be illuminated, P0700 will
Condition for Running the DTC set.
• DTC U0073 is not set.
• The ignition switch is ON. Test Description
The number below refers to the step number on the
Condition for Setting the DTC Circuit/ System Testing.
• The ECM detects that the MIL illumination is 2. If the TCM has DTCs set that are requesting MIL
requested by the TCM. illumination, diagnose that DTC first.
3, 5. If the TCM has DTCs set, clear the DTCs in the
Action Taken When the DTC Sets TCM first.

2 3. Start the engine. — Go to Applicable
4. Monitor the DTC Information with a scan tool. DTC in Section 5A
Transmission
Are there any TCM DTCs set? Control System Go to Step 3
Records.



Records.

6 —

Fuel Rail Pressure Too Low • The ECM inhibits EGR control.
Description
The common rail fuel system is comprised of two fuel Condition for Clearing the DTC
pressure sections: a suction side between the fuel tank • Refer to DTC Type Definitions for Condition for
and the fuel supply pump and a high-pressure side Clearing the DTC - Type B.
Fuel is drawn from the fuel tank via a feed pump and Diagnostic Aids
then pumped into the fuel rail by three plungers, all of • An intermittently sticking FRP regulator may have
which are internal to the fuel supply pump. This high allowed the fuel pressure to become low enough to
pressure is regulated by the ECM using the fuel rail set this DTC.
pressure (FRP) regulator dependant upon values from
the FRP sensor attached to the fuel rail. If the ECM • Actual Fuel Rail Pressure and Desired Fuel Rail
detects that the fuel rail pressure is certain pressure Pressure parameter between idle and W.O.T.
lower than the desired pressure, this DTC will set. (accelerator pedal full travel) in Park or Neutral
should follow within ± 5 MPa (± 725 psi) quick
Condition for Running the DTC enough.
• A skewed FRP sensor value can set this DTC. The
• DTCs P0087, P0091, P0092, P0192, P0193,
P0201 - P0206, P060B, P0651, P1261, P1262,
P2146 and P2149 are not set.
• The battery voltage is between 18 to 32 volts. minimum of 2 minutes.
• The engine is running. Notice: This DTC most likely indicates a loss of fuel
• The FRP regulator commanded fuel flow is more pressure by a fuel leak from the high pressure side.
than a threshold. Inspect the high pressure side fuel leakage between
the fuel supply pump and fuel injector first.
• The ECM detects that the actual fuel rail pressure might be allowed to go into the fuel system. With air in
is more than 50 MPa (7,200 psi) below the desired the fuel system, smooth flow of fuel into the supply
pressure for longer than 5 seconds. pump is interrupted and this DTC may set. Perform
• The ECM illuminates the MIL on the second Routing Reference: Fuel System Routing Diagram
consecutive driving cycle when the diagnostic runs Connector End View Reference: Engine Controls
and fails. Refer to DTC Type Definitions for Action Connector End Views or ECM Connector End Views

2 —


3 0.9 to 1.0 volt


may occur.
rail.



nut(s).
6 —

kinked.
condition.



2. Unclamp or unplug the fuel line from the
previous step and reconnect the fuel line (if
disconnected).
3. Start the engine and allow it to run for at least
1 minute.
9 —
tool.

connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
11 —
101 of E26).
necessary.

12 Engine Fuel. —


programmed.
Mechanical.

to the ECM.

15 —
Fuel.

Notice: There is a possibility that the pressure
limiter valve stuck open or operating pressure has
fallen.
16 Replace the pressure limiter valve. Refer to —

Pressure Limiter (Common Rail) in Section 1D
Engine Fuel.

Records.

18 —

Injector Positive Voltage Control Circuit Group • The ECM detects its internal common 2 fuel
1 or 2 injector charge up circuit is open circuit. (DTC
P1262)
Circuit Description
The charge up circuit in the ECM steps up the voltage
for fuel injectors and is divided into two banks, common • The ECM illuminates the MIL when the diagnostic
1 and 2. The common 1 covers fuel injectors in runs and fails. Refer to DTC Type Definitions for
cylinders #1, #2 and #3, and the common 2 covers fuel Action Taken When the DTC Sets - Type A.
injectors in cylinders #4, #5 and #6. If the common 1 or • The ECM limits fuel injection quantity.
common 2 fuel injector charge up circuit in the ECM is • The ECM inhibits EGR control.
an open circuit, DTC P1261 or P1262 will set. • The ECM inhibits cruise control.
• The battery voltage is between 18 to 32 volts. • Refer to DTC Type Definitions for Condition for
• The ignition switch is ON. Clearing the MIL/ DTC - Type A.
Condition for Setting the DTC Diagnostic Aids

• The ECM detects its internal common 1 fuel • If an intermittent condition is suspected, refer to
injector charge up circuit is open circuit. (DTC Intermittent Conditions in this section.
P1261)



Records.

5 —

EGR Position Fault Learned Position Error DTC
• The ECM detects that the EGR learned minimum
Circuit Description position is not within a predetermined range when
The ECM controls the EGR valve opening based on the the ignition switch is OFF.
engine running condition and by controlling the EGR
motor. The EGR valve position is detected by the Action Taken When the DTC Sets
position sensor, and relayed to the ECM. • The ECM blinks the MIL when the diagnostic runs
If the ECM detects that the actual EGR position is and fails. Refer to DTC Type Definitions for Action
higher than certain amount, this DTC will set. (Closed Taken When the DTC Sets - Type A.
Position Error DTC) • The ECM limits fuel injection quantity.
If the ECM detects a variance between the learned
closed position and actual closed position, this DTC will
also set. (Learned Position Error DTC) • The ECM inhibits cruise control.
Condition for Running the DTC Condition for Clearing the MIL/DTC
Closed Position Error DTC • Refer to DTC Type Definitions for Condition for
• DTCs P0112, P0113, P0116, P0117, P0118,
P0409, P060B, P0651, P0697, P2227, P2228 and
P2229 are not set.
• The battery voltage is between 16 to 32 volts. scan tool.
• The desired EGR valve position is stable.
Learned Position Error DTC Diagnostic Aids
• DTCs P0404, P0409, P0500, P0502, P0503, • If an intermittent condition is suspected, refer to
P060B, P0651 and P215A are not set. Intermittent Conditions in this section.
Closed Position Error DTC
• The ECM detects that the difference between the Connector End View Reference: Engine Controls
actual and the desired EGR valve position is more Connector End Views or ECM Connector End Views
than 40% for longer than 5 seconds.

Go to Applicable
engine.
conditions:
3 materials —


6, 7 and 8 of E45).
101, 103, 110 and 111 of E26).
each circuit.
necessary.

conditions:
5 —
circuit(s)

6 —
Notice: Ignition switch must be cycled before

clear the DTC.
4. Turn ON the ignition and clear the DTCs with
a scan tool.
7 —
Records.

8 —

PM Over Accumulation Action Taken When the DTC Sets
The ECM detects the condition of PM accumulations Action Taken When the DTC Sets - Type A.
from the exhaust differential pressure sensor attached • The ECM limits fuel injection quantity.
to the chassis frame near the diesel particulate defuser • The ECM inhibits cruise control.
(DPD) assembly. When it is reached to a certain
amount of PM accumulations or a certain length of Condition for Clearing the DTC
mileage, the automatic regeneration starts. If the
automatic regeneration cannot be completed by some • Refer to DTC Type Definitions for Condition for
reason, the manual regeneration is requested to the Clearing the MIL/ DTC - Type A.
driver by blinking the DPD amber lamp or "PUSH DPD
SWITCH" indicator on the instrument panel cluster. If Diagnostic Aids
the DPD filter regeneration interval is more than a • If manual regeneration is frequently requested,
predetermined mileage, this DTC will set. refer to DPD System Manual Regeneration
Frequently Chart in symptom diagnostic table.
• DTCs P0500, P0502, P0503 and P215A are not Notice: This DTC is caused by incomplete automatic
set. regeneration has occurred and manual regeneration
urged by the DPD lamp on the IP cluster was
• The ignition switch is ON. disregarded or forgot, which was most likely caused by
driver error. Primarily ask the driver about DPD amber
Condition for Setting the DTC lamp or "PUSH DPD SWITCH" indicator blinking in the
• The DPD filter regeneration interval is more than past.
520 km.

Ask the driver about DPD amber lamp or "PUSH
DPD SWITCH" indicator blinking in the past.
Explain DPD filter regeneration and lamp action to
the driver as necessary.
2 Notice: If manual regeneration is frequently —
requested, refer to DPD System Manual
Regeneration Frequently Chart in symptom
diagnostic table.


1. Turn ON the ignition for 30 seconds. DO NOT
start the engine. Make sure the DPD lamps or
“AUTO REGEN.”, “MANUAL REGEN.”
indicators on the instrument panel cluster is
turned OFF. (This is to relearn exhaust
differential pressure sensor.)
2. Clear the DTC and reset the DPD Status with
a scan tool.
5. Observe the Exhaust Temperature 1
3 parameter with a scan tool. Make sure the 7.9 kPa
temperature is less than 120°C (248°F). If
more than 120°C (248°F), let increase 1000
RPM without load. (Turn the idle up control
knob clockwise.)
6. Accelerate the engine to W.O.T. (accelerator
to 140°C (284°F).
Is the Exhaust Differential Pressure parameter less

2. Clear the DTC with a scan tool if set.
4 Important: Engine oil must be replaced after —

DPD slow regeneration is completed.
4. Perform the DPD Slow Regeneration with a
scan tool.

2. Replace the DPD filter. Refer to Exhaust Pipe
5 in Section 1G Engine Exhaust. —

parameter with a scan tool. Make sure the
knob clockwise.)
6 2. Accelerate the engine to W.O.T. (accelerator 3.3 kPa
Differential Pressure parameter when the Ash cleaning must
Exhaust Temperature 1 parameter is reached be performed. Refer
to 150°C (302°F). to appropriate
procedure in
Is the Exhaust Differential Pressure parameter less Section 1G Engine
than the specified value? Go to Step 7 Exhaust
7 —

DPD Insufficient Regeneration • The intake throttle position is more than 22%.
• The DPD filter regeneration is finished.
Description
The ECM detects the condition of PM accumulations Condition for Setting the DTC
from the exhaust differential pressure sensor attached • The DPD filter regeneration has been incomplete
to the chassis frame near the diesel particulate defuser purification status continuously.
amount of PM accumulations or a certain length of Action Taken When the DTC Sets
mileage, the automatic regeneration starts. If the • The ECM illuminates the MIL when the diagnostic
automatic regeneration cannot be completed by some runs and fails. Refer to DTC Type Definitions for
reason, the manual regeneration is requested to the Action Taken When the DTC Sets - Type A.
SWITCH" indicator on the instrument panel cluster. • The ECM limits fuel injection quantity.
After the regeneration event is finished, an exhaust • The ECM inhibits cruise control.
differential pressure monitors a purification of the filter.
If the filter regeneration has been incomplete Condition for Clearing the DTC
purification status continuously, this DTC will set. • Refer to DTC Type Definitions for Condition for
• DTCs P0079, P0080, P0116, P0117, P0118, Diagnostic Aids
P0122, P0123, P0201 - P0206, P0335, P0336, • If manual regeneration is frequently requested,
P0404, P0409, P0426, P042B, P042C, P042D, refer to DPD System Manual Regeneration
P0427, P0428, P0500, P0502, P0503, P060B, Frequently Chart in symptom diagnostic table.
P0638, P0641, P0651, P1261, P1262, P1404,
• An excessive ash accumulation in the DPD filter
P2146, P2149, P215A, P2227, P2228, P2229,
will cause this DTC to set.
P2453 - P2456 are not set.
• The mass air flow (MAF) sensor problem will
cause this DTC to set. Refer to DTC P0101 for
• The exhaust gas temperature 1 (in front of filter) is MAF sensor diagnosis and Use the Scan Tool Data
more than 100°C (212°F). List or a known good vehicle to determine nominal
• The engine speed is more than 1000 RPM. values.
• The EGR position is less than 95%.


• Misrouted or disconnected exhaust
differential pressure hoses or pipes
Important: There is installation

directionality in the exhaust differential
pressure hoses. Refer to Exhaust
Differential Pressure Sensor in Section
1G Engine Exhaust.
• Plugged, crushed or kinked exhaust
• Physical damage of the exhaust
differential pressure sensor
the exhaust differential pressure sensor
port
• Skewed or slow exhaust differential
pressure sensor
• An exhaust system gasket that is missing
or damaged
• Exhaust gas leakage from the exhaust
2 pipe, gasket, DPD assembly, exhaust —
temperature sensor(s) or exhaust
• Modified exhaust system
• Skewed or slow exhaust temperature
sensors
• Modified air induction system
the mass air flow (MAF) sensor inlet

harness connector(s) or components.

3 —
4. Observe the DPD Accumulation Status and
DPD Distance Status with a scan tool and plot
both readings on the DPD status table. Refer
to DPD Control System Check.
Is the intersected range located in C or D? Go to Step 4 Go to Step 5


2. Clear the DTC and the DPD status with a scan
tool.

scan tool.

tool.
4. Perform the DPD Normal Regeneration with a
scan tool.

knob clockwise.)
procedure in
7 —

Immobilizer wrong response Action Taken When the DTC Sets
The ECM communicates with the immobilizer control When the DTC Sets - Type D.
unit (ICU) to execute immobilizer function. The ECM
transmits a specific request signal to the ICU and the Condition for Clearing the DTC
ICU sends back a response signal to the ECM. Both • Refer to DTC Type Definitions for Condition for
communication signals are carried out via a controller Clearing the DTC - Type D.
area network (CAN) communication bus. If the ECM
receives a wrong response signal from the ICU, this Diagnostic Aids
DTC will set.
• Electromagnetic interference may affect
• The ECM receives a wrong immobilizer response intermittent condition.
signal from the ICU.

Go to Applicable
Is DTC P0633 or U0167 also set? DTC Go to Step 3
Monitor the immobilizer DTC Information with a
scan tool. Go to Applicable
3 — DTC for Immobilizer
Does the immobilizer DTCs fail this ignition? Section Go to Step 4


Records.

7 —

Control Module Long Term Memory Condition for Setting the DTC
Performance • The ECM detects that the calculated checksum
does not agree with the electrically erasable &
Circuit Description programmable read only memory (EEPROM)
This diagnostic applies to internal microprocessor internal registered checksum.
Condition for Running the DTC • The ECM illuminates MIL when the diagnostic runs
• The ignition switch is ON. and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type A.




Records.

5 —

Service Vehicle Soon Lamp Control Circuit • The ECM detects a low voltage condition on the
SVS lamp control circuit when the lamp is
Circuit Description commanded OFF.
The service vehicle soon (SVS) lamp is located on the • The ECM detects a high voltage condition on the
instrument panel (IP) cluster. The SVS lamp informs SVS lamp control circuit when the lamp is
the driver that a non-emission related fault has commanded ON.
occurred and vehicle service required.
The ECM monitors the SVS lamp control circuit for Action Taken When the DTC Sets
conditions that are incorrect for the commanded state • The ECM will illuminate the SVS lamp. Refer to
of the SVS lamp. For example, a failure condition exists DTC Type Definitions for Action Taken when the
if the ECM detects low voltage when the SVS lamp is DTC Sets - Type C.
commanded OFF, or high voltage when the SVS lamp
is commanded ON. If the ECM detects an improper Condition for Clearing the DTC
voltage level on the control circuit, this DTC will set. • Refer to DTC Type Definitions for Condition for

Go to Diagnostic
3 block. —


5 —
Is the SVS lamp OFF? Go to Step 6 Go to Step 12


voltage to the SVS lamp.
6 3. Measure the voltage from the SVS lamp 1 volt

Is the SVS lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 —

11 —


ignition voltage feed circuit between the Meter


15 Driver Info. —



18 —

DPD Lamp Control Circuit Condition for Setting the DTC
The diesel particulate defuser (DPD) amber lamp is DPD amber lamp control circuit when the lamp is
located on the instrument panel (IP) cluster. The DPD commanded OFF.
amber lamp informs the driver that an incomplete • The ECM detects a high voltage condition on the
automatic regeneration has occurred and manual DPD amber lamp control circuit when the lamp is
regeneration is required. commanded ON.
The ECM monitors the DPD amber lamp control circuit
for conditions that are incorrect for the commanded Action Taken When the DTC Sets
state of the DPD amber lamp. For example, a failure
condition exists if the ECM detects low voltage when • The ECM will illuminate the SVS lamp. Refer to
the DPD amber lamp is commanded OFF, or high DTC Type Definitions for Action Taken When the
voltage when the DPD amber lamp is commanded ON. DTC Sets - Type C.
If the ECM detects an improper voltage level on the
control circuit, this DTC will set. Condition for Clearing the DTC
If the IP cluster has a multi-information display (MID), • Refer to DTC Type Definitions for Condition for
the DPD amber lamp is not installed. However, a wire Clearing the SVS Lamp/ DTC - Type C.
harness is remaining between the ECM and the IP
cluster, and the ECM will set the DTC if an improper Diagnostic Aids
voltage level on the circuit. • If an intermittent condition is suspected, refer to
• The ignition switch is ON. Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P1669 (Flash Code 75) (without Multi-information Display)

2 —
4. Turn ON the ignition for 40 seconds while
observing the DTC Information with a scan
tool.
Go to Diagnostic
3 block. —


Is the DPD lamp OFF? Go to Step 6 Go to Step 12


voltage to the DPD lamp.
6 3. Measure the voltage from the DPD lamp 1 volt

Is the DPD lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 FU97). —

11 —

13 (pin 35 of FU97). —



15 Driver Info. —


17 —
tool.

18 —
Circuit/ System Testing DTC P1669 (Flash Code 75) (with Multi-information Display)

2 —
tool.
Go to Diagnostic
3 block. —


5 4. Measure the voltage from the DPD lamp 20 volts
Is the voltage more than the specified value? Go to Step 6 Go to Step 7


1. Disconnect the DMM.
2. Connect a test lamp between the ECM
6 harness connector (pin 9 of FB24) to a known —
good ground.

ground.


• An open circuit
• High resistance

10 —

11 —

12 —

13 Driver Info. —



15 —
tool.

16 —

Particulate Trap Efficiency Below Threshold • The barometric pressure is more than 80 kPa.
• The turbocharger control is under normal
Description condition.
The exhaust differential pressure sensor is attached to • The intake air temperature is between 2 to 50°C
the chassis frame near the diesel particulate defuser (36 to 122°F).
(DPD) assembly. The exhaust differential pressure • The DPD regeneration trip is less than 4,000 km.
sensor is a transducer that varies voltage according to
changes of the exhaust gas differential pressure Condition for Setting the DTC
between in front and in rear of DPD filter. If the ECM
• The ECM detects that the exhaust differential
detects that the exhaust differential pressure is certain
pressure is less than a predetermined range of the
pressure low as compared with the calculated exhaust
calculated pressure value for longer than 7
gas flow amount, this DTC will set.
seconds.
• DTCs P0079, P0080, P0102, P0103, P0116,
P0117, P0118, P0122, P0123, P0409, P0427,
P0428, P0477, P0478, P0500, P0502, P0503,
P0560, P060B, P0641, P0651, P0697, P2002,
P215A, P2227, P2228, P2229, P2454, P2455 and • The ECM limits fuel injection quantity.
P2456 are not set.
• The exhaust brake valve is commanded OFF.
• The exhaust throttle valve is inactive. Diagnostic Aids
• The intake throttle valve is inactive. • If an intermittent condition is suspected, refer to
• The mass air flow is more than 100 g/s. Intermittent Conditions in this section.
• The exhaust gas temperature 1 (in front of filter) is • Misrouted, disconnected or plugged exhaust
more than 200°C (392°F). differential pressure hoses or pipes will set this
• The fuel injection quantity is more than 75 mm3/st. DTC.
• The engine coolant temperature is between 50 to Connector End Views or ECM Connector End Views
150°C (122 to 302°F).

3. Disconnect a ventilation duct from the exhaust
tail pipe if connected.
2 —
tool.
Is DTC P2454 set? Go to DTC P2454 Go to Step 3


low exhaust differential pressure.

1G Engine Exhaust.
• Dislocated or inclined exhaust differential
pressure sensor. Refer to Exhaust
System in Section 1G Engine Exhaust.
3 port —
pressure sensor
or damaged
pipe, gasket, DPD assembly, exhaust
Exhaust.


1. Remove the DPD filter from the DPD
1G Engine Exhaust.
2. Inspect the DPD filter for damage, cracks or
melt.
3. Inspect the oxygen catalyst for damage or
excessive deposits.
4 —
Important: DPD status in the ECM must be
4. Replace the DPD filter or the oxygen catalyst
as necessary. Refer to Exhaust Pipe in


connector of the exhaust differential pressure
sensor (pins 1, 2 and 3 of FB66).
5 —
FB24).
6. Test each sensor circuit between the ECM and
the exhaust differential pressure sensor for
high resistance.
necessary.


start the engine. (This is to relearn exhaust
7 a scan tool. —
scan tool. If the DPD filter was replaced at
Step 4, skip to Step 9.

knob clockwise.)
to 200°C (392°F).
Is the Exhaust Differential Pressure parameter

9 —

Pedal Position Sensor 1 Circuit Low or High Condition for Setting the DTC
Input • The ECM detects that the APP sensor 1 signal
Circuit Description • The ECM detects that the APP sensor 1 signal
The accelerator pedal position (APP) sensor is voltage is more than 4.9 volts. (DTC P2123)
mounted on the accelerator pedal bracket. The sensor
is made up of two individual sensors within one Action Taken When the DTC Sets
housing. The ECM uses the APP sensors to determine • The ECM illuminates the MIL when the diagnostic
the amount of acceleration or deceleration that is runs and fails. Refer to DTC Type Definitions for
desired. The APP sensor 1 has the following circuits. Action Taken When the DTC Sets - Type A.
• 5 volts reference circuit • The ECM blinks the exhaust brake indicator lamp
• Low reference circuit when the diagnostic runs and fails.
• APP sensor 1 signal circuit • The ECM inhibits exhaust brake control.
The APP sensor 1 provides a signal to the ECM on the • The ECM inhibits cruise control.
signal circuit, which is relative to the position changes
of the accelerator pedal angle. If the ECM detects an Condition for Clearing the DTC
P2123 will set.
Diagnostic Aids


Fully depress and release the accelerator pedal
while observing the APP Sensor 1 (Accelerator
3 Pedal Position) parameter with a scan tool. 0.2 volts
value during depressing or releasing the pedal? Go to Step 4 Aids
2. Disconnect the APP sensor harness
connector.
ground.

5 and 5 of FL1). 4.5 volts
Is the APP Sensor 1 parameter more than the
Notice: The APP sensor 1 shares the 5 volts
6 ECM (pin 42 of FB24) and the APP sensor —
(pin 4 of FL1) for an open circuit or high
resistance.

63 of FB24) and the APP sensor (pin 5 of FL1)
• An open circuit
7 —
• High resistance

APP sensor (pins 4 and 5 of FL1).
8 —





12 0.2 volts
5. Fully depress and release the accelerator
pedal while observing the APP Sensor 1
Does the scan tool indicate less than the specified

value during depressing or releasing the pedal? Go to Step 3 Go to Step 13
13 —

2 pedal while observing the APP Sensor 1 4.9 volts
(Accelerator Pedal Position) parameter with a
scan tool.
Does the scan tool indicate more than the specified Go to Diagnostic
3 —
connector.
Is the APP Sensor 1 parameter less than the

connector.

6 circuit (pin 6 of FL1) and battery voltage. —

Important: The APP sensor 1 may be damaged if
source.
7 for the following conditions: —

Notice: The APP sensor 1 shares the low
resistance.

APP sensor (pin 6 of FL1).
9 —




13 4.9 volts

14 —

P2128 will set.
Diagnostic Aids


connector.
ground.

resistance.

• An open circuit
7 —
• High resistance

8 —





12 0.2 volts

13 —

scan tool.
3 —
connector.

connector.


source.

resistance.

9 —




13 4.9 volts

14 —

Pedal Position Sensor 1-2 Voltage Correlation • The APP sensor 1 signal voltage is between 0.2 to
4.9 volts.
Circuit Description • The APP sensor 2 signal voltage is between 0.2 to
The accelerator pedal position (APP) sensor is 4.9 volts.
is made up of two individual sensors within one Condition for Setting the DTC
housing. The APP sensor 1 and APP sensor 2 are hall • The ECM detects that the APP sensor 1 and 2 are
element type sensors, each with the following circuits. more than 45% out of range of each other.
• Low reference circuit Action Taken When the DTC Sets
• Signal circuit • The ECM illuminates the MIL when the diagnostic
The ECM supplies 5 volts to the APP sensor on the 5 runs and fails. Refer to DTC Type Definitions for
volts reference circuit. The ECM also provides a ground Action Taken When the DTC Sets - Type A.
on the low reference circuit. The APP sensor provides • The ECM blinks the exhaust brake indicator lamp
a signal to the ECM on the signal circuits, which is when the diagnostic runs and fails.
relative to the position changes of the accelerator pedal • The ECM inhibits exhaust brake control.
angle. The APP sensor 1 signal voltage is low at rest
and increases as the pedal is depressed. The APP Condition for Clearing the DTC
sensor 2 signal voltage is high at rest and decreases as
the pedal is depressed. If the ECM detects that the
APP sensor 1 signal voltage and the APP sensor 2
signal voltage are out of the correlation, this DTC will
Diagnostic Aids
set.
• DTCs P060B, P0641 and P0651 are not set.
• The battery voltage is between 18 to 32 volts. Connector End Views or ECM Connector End Views

2 —

while observing the DTC Information with a scan
3 tool. —
Go to Diagnostic

(APP) sensor harness connector.
connector of the APP sensor (pins 1, 2, 3, 4, 5
and 6 of FL1).
connector of the ECM (pins 41, 42, 60, 61, 63
and 64 of FB24).
6. Test for high resistance on each sensor circuit.
necessary.

63 and 64 of FB24) and the APP sensor (pins
2 and 5 of FL1) for a short circuit each other.
5 —


pedal while observing the DTC Information
with a scan tool.


with a scan tool.

10 —

DTC P2146 or P2149 (Flash Code 158 or 159)
Fuel Injector Group 1 or 2 Supply Voltage Condition for Setting the DTC
Circuit • The ECM detects that the common 1 fuel injector
charge voltage circuit is open circuit, shorted to
Circuit Description ground or shorted to voltage circuit, or cylinder #1,
The ECM calculates the optimum fuel injection ON time #2 or #3 fuel injector solenoid coil control circuit is
using data sent from various engine sensors. The shorted to ground. (DTC P2146)
common 1 and 2 fuel injector charge voltage circuits • The ECM detects that the common 2 fuel injector
are high-voltage supply, which drives fuel injectors for charge voltage circuit is open circuit, shorted to
each cylinder in conjunction with the ECM grounding ground or shorted to voltage circuit, or cylinder #4,
the fuel injector solenoid control circuit. The common 1 #5 or #6 fuel injector solenoid coil control circuit is
covers fuel injectors in cylinders #1, #2 and #3, and the shorted to ground. (DTC P2149)
common 2 covers fuel injectors in cylinders #4, #5 and
#6. If the common 1 or 2 fuel injector charge voltage Action Taken When the DTC Sets
circuit is open circuit, shorted to ground or shorted to • The ECM illuminates the MIL when the diagnostic
voltage circuit, DTC P2146 or P2149 will set depending runs and fails. Refer to DTC Type Definitions for
upon which bank injector common circuit failed. If the Action Taken When the DTC Sets - Type A.
fuel injector solenoid control circuit is shorted to
ground, this DTC will also set.
• DTCs P0201, P0202 and P0203 are not set. (DTC
P2146) Condition for Clearing the DTC
• DTCs P0204, P0205 and P0206 are not set. (DTC • Refer to DTC Type Definitions for Condition for
P2149) Clearing the MIL/ DTC - Type A.
Diagnostic Aids


Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #1, #2
or #3 solenoid control circuit (pins 2, 6 or 7 of
H78 female side) and a known good ground.

Connect a test lamp between the charge voltage
circuit (pin 3 of H78 female side) and a known good
4 ground. —

circuit (pin 3 of H78 female side) and battery
5 voltage. —

1. Test the control circuits between the ECM and
the in-line harness connector for a short to
ground.
• Cylinder #1: Between pin 119 of E26 and
2 of H78
6 • Cylinder #2: Between pin 114 of E26 and —

7 of H78
6 of H78

1. Test the charge voltage circuits between the
ECM (pin 121 of E26) and the in-line harness
connector (pin 3 of H78) for a short to battery

connector (pin 3 of H78) for a short to ground.
8 —

connection at the in-line harness connector
(pin 3 of H78).
9 4. Inspect for an open circuit or high resistance —
on the charge voltage circuit between the
connector (pin 3 of H78).
necessary.


Mechanical.
terminals.
10 —
(pin 3 of H80).

Measure insulation resistance of the cylinder #1, #2
and #3 fuel injector between each fuel injector
11 terminal and a known good ground. 1 MΩ
Is the resistance more than the specified value? Go to Step 12 Go to Step 13

Repair or replace the fuel injector harness.
12 —
Did you complete the repair or replace? Go to Step 15 —
Important: Replacement injector must be
programmed.
Replace the appropriate fuel injector that was less
13 insulation resistance found at Step 11. Refer to —


Records.

16 —


Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #4, #5
or #6 solenoid control circuit (pins 2, 6 or 7 of
H79 female side) and a known good ground.
4 ground. —

5 voltage. —

ground.
2 of H79
6 • Cylinder #5: Between pin 120 of E26 and —
7 of H79
6 of H79


8 —


(pin 3 of H79).
necessary.

Mechanical.
terminals.
10 —
(pin 3 of H81).

Measure insulation resistance of the cylinder #4, #5

12 —
programmed.


Records.


16 —

DTC P215A (Flash Code 25)
Vehicle Speed - Wheel Speed Correlation Condition for Setting the DTC
Circuit Description pulses are not generated for longer than 5
The vehicle speed sensor (VSS) is used by the ECM seconds.
and other modules, which generates a speed signal
from the transmission output shaft rotational speed. Action Taken When the DTC Sets
The sensor has the following circuits. • The ECM illuminates the MIL when the diagnostic
• Ignition voltage feed circuit runs and fails. Refer to DTC Type Definitions for
• Low reference circuit Action Taken When the DTC Sets - Type A.
• VSS signal circuit • The ECM limits fuel injection quantity.
The VSS uses a hall effect element or magnetic • The ECM inhibits pre injection.
resistance element (MRE). It interacts with the • The ECM inhibits cruise control.
magnetic field created by the rotating magnet and
outputs square wave pulse signal. The ECM calculates Condition for Clearing the DTC
the vehicle speed by the VSS.
The ECM receives the wheel speed information from
the electronic hydraulic control unit (EHCU) [ABS
module] or the ABS control unit via a controller area
Diagnostic Aids
network (CAN) communication bus. If the ECM detects
that the wheel speed from the EHCU or the ABS • If an intermittent condition is suspected, refer to
control unit is more than 20 km/h but the vehicle speed Intermittent Conditions in this section.
signal pulses are not generated, this DTC will set. • EHCU [ABS module] may output that wheel speed
signal is more than 20 km/h. Refer to Section 4C1
Condition for Running the DTC ABS/ ASR Air Over Hydraulic Type or Section 4C
• DTCs P0502, P0503 and P060B are not set. ABS Full Air Type.
Notice: If this DTC set, the Vehicle Speed
• The ignition switch is ON. parameter on the scan tool will display 10 km/h.
• The wheel speed is more than 20 km/h.
• The vehicle speed of the EHCU or the ABS control Connector End View Reference: Engine Controls
unit is effective. Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P215A (Flash Code 25)

Go to Applicable
2. Observe the speed meter in the instrument
3 panel (IP) cluster. —
Does the speed meter indicate correct vehicle
1. Drive the vehicle. Go to Diagnostic
2. Monitor the DTC Information with a scan tool. System Check -
ABS Controls in
4 —
Does the DTC fail this ignition? Section 4C1 ABS/
ASR or Section 4C Go to Diagnostic
ABS Full Air Type Aids

Step 6.
1. Inspect the impulse sensor and speed signal
5 distributor. —
Refer to Manual Transmission (ZF) section.

1. Test the vehicle speed sensor signal circuit
vehicle speed sensor for an open circuit. Refer
to IP Cluster and Warning in Section 9D
6 —
Wiring System.

• Physical damage
damage

connector.

9 Driver Info. —

Records.

11 —

Barometric Pressure Sensor Circuit Range/ • The accelerator pedal is not depressed.
Performance • The vehicle is not running.

The barometric pressure (BARO) sensor is located • The ECM detects that the BARO is more than 10
behind of the lower cover. The BARO sensor is a kPa (1.5 psi) over the boost pressure for longer
transducer that varies voltage according to changes the than 7 seconds.
barometric pressure. Within the ECM, the diagnostic • The ECM detects that the BARO is more than 11
compares the BARO sensor input to the boost pressure kPa (1.6 psi) below the boost pressure for longer
sensor input. If the ECM detects that the inputs are not than 7 seconds.
within a specified amount of each other, this DTC will
set. Action Taken When the DTC Sets
• DTCs P0102, P0103, P0116, P0117, P0118, Action Taken When the DTC Sets - Type B.
P0122, P0123, P0237, P0238, P0500, P0502,
P0503, P0560, P060B, P0638, P0651, P0697, Condition for Clearing the DTC
P215A, P2228 and P2229 are not set.
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type B.
AND following conditions are met longer than 3 Diagnostic Aids
seconds • If an intermittent condition is suspected, refer to
• The engine speed between 475 to 575 RPM. Intermittent Conditions in this section.
• The fuel injection quantity is less than a
predetermined value. Connector End View Reference: Engine Controls

Go to Applicable
2. Compare the Boost Pressure parameter to the
Barometric Pressure parameter with a scan 10 kPa (1.5
3 tool. psi)
Are both parameter within the range specified of Go to Diagnostic
each other? Aids Go to Step 4
Determine the outside barometric pressure from
your location specified in the altitude vs. barometric
4 Pressure. —
Is the Barometric Pressure parameter on the scan

tool close to the outside barometric pressure? Go to Step 5 Go to Step 7

harness connector.
connector of the boost pressure sensor (pins
1, 2 and 3 of E54).
E26).

(pins 91, 95 and 109 of E26) and the boost
pressure sensor (pins 1, 2 and 3 of E54) for

connector.
connector of the BARO sensor (pins 1, 2 and
3 of FL52).
FB24).

1. Test each sensor circuits between the ECM
(pins 60, 61 and 71 of FB24) and the BARO
sensor (pins 1, 2 and 3 of FL52) for high
8 resistance. —

9 Mechanical. —

10 —

Records.

12 —

Barometric Pressure Sensor Circuit Low Condition for Setting the DTC
• The ECM detects that the BARO sensor signal
Circuit Description voltage is less than 0.5 volts for 5 seconds. (DTC
The barometric pressure (BARO) sensor is located P2228)
behind of the lower cover. The BARO sensor is a • The ECM detects that the BARO sensor signal
transducer that varies voltage according to changes the voltage is more than 4.0 volts for 5 seconds. (DTC
barometric pressure. The sensor has the following P2229)
circuits:
• BARO sensor signal circuit runs and fails. Refer to DTC Type Definitions for
The BARO sensor provides a signal to the ECM on the Action Taken When the DTC Sets - Type A.
signal circuit, which is relative to the pressure changes • The ECM uses a BARO substitution of default
of the barometric pressure. The ECM should detect a value.
low signal voltage at a low barometric pressure, such • The ECM inhibits EGR control.
as high altitude place. The ECM should detect high
signal voltage at a high barometric pressure. The ECM Condition for Clearing the DTC
uses this voltage signal to calibrate the fuel injection
quantity and injection timing for altitude compensation.
If the ECM detects an excessively low or high signal
voltage, DTC P2228 or P2229 will set.
Diagnostic Aids


Observe the Barometric Pressure Sensor
3 0.5 volts
Is the Barometric Pressure Sensor parameter less Go to Diagnostic
connector.
ground.

Is the Barometric Pressure Sensor parameter more
Notice: The BARO sensor shares the 5 volts
6 ECM (pin 61 of FB24) and the BARO sensor —
resistance.

71 of FB24) and the BARO sensor (pin 2 of
FL52) for the following conditions:
• An open circuit
7 —
• High resistance

8 —


10 —


Records.

13 —

2 4. Observe the Barometric Pressure Sensor 4.0 volts
Is the Barometric Pressure Sensor parameter more Go to Diagnostic

3 —
connector.
4 0.1 volts
Is the Barometric Pressure Sensor parameter less

than the specified value? Go to DTC P0651 Go to Step 7
connector.
5 0.1 volts


Important: The BARO sensor may be damaged if
source.
7 FL52) for the following conditions: —

Notice: The BARO sensor shares the low
resistance.

9 —


11 —

Records.

14 —

DTC P242F (Flash Code 131)
DPD Restriction Condition for Setting the DTC
• The exhaust differential pressure is more than a
Description predetermined range of the calculated differential
The ECM detects the condition of PM accumulations pressure value for longer than 30 seconds.
from the exhaust differential pressure sensor attached
to the chassis frame near the diesel particulate defuser Action Taken When the DTC Sets
(DPD) assembly. When it is reached to a certain • The ECM illuminates the MIL when the diagnostic
amount of PM accumulations or a certain length of runs and fails. Refer to DTC Type Definitions for
mileage, the automatic regeneration starts. If the Action Taken When the DTC Sets - Type A.
automatic regeneration cannot be completed by some • The ECM limits fuel injection quantity.
reason, the manual regeneration is requested to the
driver by blinking the DPD amber lamp or "PUSH DPD • The ECM inhibits cruise control.
SWITCH" indicator on the instrument panel cluster. If
the ECM detects that the exhaust differential pressure Condition for Clearing the DTC
is more than a predetermined range of the calculated • Refer to DTC Type Definitions for Condition for
value, this DTC will set. Clearing the MIL/ DTC - Type A.

• DTCs P0500, P0502, P0503 and P215A are not • Misrouted, disconnected or plugged exhaust
set. differential pressure hoses or pipes may set this
• The ignition switch is ON. DTC.
• The exhaust gas temperature 1 (in front of filter) is • If manual regeneration is frequently requested,
more than 100°C (212°F). refer to DPD System Manual Regeneration
Frequently Chart in symptom diagnostic table.
• The EGR position is less than 95%. Notice: This DTC is caused by incomplete automatic
• The intake throttle position is more than 22%. regeneration has occurred and manual regeneration
• The DPD filter regeneration is inactive. urged by the DPD lamp on the IP cluster was
disregarded or forgot, which was most likely caused by
lamp or "PUSH DPD SWITCH" indicator blinking in the
past.
Circuit/ System Testing DTC P242F (Flash Code 131)

Regeneration Frequently Chart in symptom
diagnostic table.


a scan tool.
knob clockwise.)
to 140°C (284°F).


scan tool.


knob clockwise.)
procedure in
7 —

DPD Differential Pressure Sensor Circuit Action Taken When the DTC Sets
Range/ Performance • The ECM illuminates the MIL when the diagnostic
Description Action Taken When the DTC Sets - Type A.
The exhaust differential pressure sensor is attached to • The ECM limits fuel injection quantity.
the chassis frame near the diesel particulate defuser • The ECM inhibits cruise control.
(DPD) assembly. The exhaust differential pressure
sensor is a transducer that varies voltage according to Condition for Clearing the DTC
changes of the exhaust gas differential pressure
detects that the exhaust differential pressure went
excessively high, this DTC will set.
Diagnostic Aids
• DTCs P060B, P0697, P2454, P2455 and P2456
are not set. • Misrouted, disconnected or plugged exhaust
differential pressure hoses or pipes will set this
DTC.
• The exhaust differential pressure is more than 60
kPa.

2 start the engine. —


high exhaust differential pressure.

1G Engine Exhaust.
3 • Any contamination or objects that block —
port
pressure sensor
• Restricted or collapsed exhaust system


4 —
FB24).
high resistance.
necessary.

Important: Clear the DTC and the DPD Status in
the ECM must be reset when the DPD filter is
replaced.
5 Replace the DPD filter. Refer to Exhaust Pipe in —


6 3. Clear the DTC and reset the DPD Status with —

a scan tool.
scan tool.

knob clockwise.)
procedure in
8 —

DPD Differential Pressure Sensor Circuit Low Condition for Setting the DTC
or High • The ECM detects that the exhaust differential
pressure sensor signal voltage is less than 0.2
Circuit Description volts. (DTC P2454)
The exhaust differential pressure sensor is attached to • The ECM detects that the exhaust differential
the chassis frame near the diesel particulate defuser pressure sensor signal voltage is more than 4.9
(DPD) assembly. The exhaust differential pressure volts. (DTC P2455)
changes of the exhaust gas differential pressure Action Taken When the DTC Sets
between in front and in rear of DPD filter. The sensor • The ECM illuminates the MIL when the diagnostic
has the following circuits: runs and fails. Refer to DTC Type Definitions for
• Low reference circuit • The ECM limits fuel injection quantity.
• Exhaust differential pressure sensor signal circuit • The ECM inhibits pre injection.
The exhaust differential pressure sensor provides a • The ECM inhibits cruise control.
signal to the ECM on the signal circuit, which is relative
to the differential pressure changes in front and in rear Condition for Clearing the DTC
of DPD filter. The ECM should detect a low signal
voltage at a low differential pressure, such as small PM
accumulation. The ECM should detect high signal
voltage at high differential pressure, such as large PM
Diagnostic Aids
accumulation. If the ECM detects an excessively low or
high signal voltage, DTC P2454 or P2455 will set. • If an intermittent condition is suspected, refer to


Observe the Exhaust Differential Pressure Sensor
3 0.2 volts
Is the Exhaust Differential Pressure Sensor Go to Diagnostic
4 circuit (pin 3 of FB66) and a known good 4.5 volts
ground.

Is the Exhaust Differential Pressure Sensor
6 an open circuit or high resistance. —

67 of FB24) and the exhaust differential
pressure sensor (pin 2 of FB66) for the
• An open circuit
• High resistance

exhaust differential pressure sensor (pins 2
8 and 3 of FB66). —





Records.

13 —

2 4. Observe the Exhaust Differential Pressure 4.9 volts
Sensor parameter with a scan tool.

3 —
4 0.1 volts

parameter less than the specified value? Go to DTC P0697 Go to Step 7
5 0.1 volts

6 circuit (pin 1 of FB66) and battery voltage. —

Important: The exhaust differential pressure
sensor may be damaged if the sensor signal circuit
is shorted to a voltage source.
7 following conditions: —


Notice: The exhaust differential pressure sensor
shares the low reference circuit with other sensors.
A fault condition in the low reference circuit may set

exhaust differential pressure sensor (pin 1 of
9 FB66). —





Records.

14 —

DPD Differential Pressure Sensor Learned Condition for Setting the DTC
Position • The ECM detects that the learned exhaust
differential pressure is not within -4.5 to 4.5 kPa.
Circuit Description
The exhaust differential pressure sensor is attached to Action Taken When the DTC Sets
the chassis frame near the diesel particulate defuser • The ECM illuminates the MIL when the diagnostic
(DPD) assembly. The exhaust differential pressure runs and fails. Refer to DTC Type Definitions for
sensor is a transducer that varies voltage according to Action Taken When the DTC Sets - Type A.
changes of the exhaust gas differential pressure • The ECM limits fuel injection quantity.
between in front and in rear of DPD filter.
The ECM learns a variance of the exhaust differential
pressure sensor signal at every ignition cycle after the • The ECM inhibits cruise control.
ignition switch has been ON with the engine OFF for 30
seconds. (The DPD lamps or “AUTO REGEN.”, Condition for Clearing the DTC
“MANUAL REGEN.” indicators on the instrument panel • Refer to DTC Type Definitions for Condition for
cluster indicates this transition by commanded to OFF.) Clearing the MIL/ DTC - Type A.
If the ECM detects that learned exhaust differential
pressure is not within a predetermined range, this DTC Diagnostic Aids
will set. • If an intermittent condition is suspected, refer to
• A skewed exhaust differential pressure sensor
• DTCs P060B, P0697, P2454 and P2455 are not value can set this DTC. The Exhaust Differential
set. Pressure Sensor on the scan tool should read 0.9
• The battery voltage is between 18 to 32 volts. to 1.0 volts with the ignition switch ON and engine
• The ignition switch is ON. OFF.
• The engine is stopped.

Go to Applicable
Is DTC P2454 or P2455 set? DTC Go to Step 3
3 3. Turn ON the ignition for 30 seconds while —
tool.
Go to Diagnostic

FB24).

(pins 67, 79 and 80 of FB24) and the exhaust
differential pressure sensor (pins 1, 2 and 3 of
5 FB66) for high resistance. —


7 —
tool.

8 —

DPD Regeneration Duration Condition for Setting the DTC
• The DPD filter regeneration event continuously
Description exceeds a predetermined time.
The ECM detects the condition of PM accumulations
from the exhaust differential pressure sensor attached Action Taken When the DTC Sets
to the chassis frame near the diesel particulate defuser • The ECM illuminates the MIL when the diagnostic
(DPD) assembly. When it is reached to a certain runs and fails. Refer to DTC Type Definitions for
amount of PM accumulations or a certain length of Action Taken When the DTC Sets - Type A.
mileage, the automatic regeneration starts. If the • The ECM limits fuel injection quantity.
automatic regeneration cannot be completed by some
reason, the manual regeneration is requested to the • The ECM inhibits cruise control.
driver by blinking the DPD amber lamp or “PUSH DPD
SWITCH” indicator on the instrument panel cluster. Condition for Clearing the DTC
Once the regeneration starts, it must be finished within • Refer to DTC Type Definitions for Condition for
a certain time. If the regeneration event is continuously Clearing the MIL/ DTC - Type A.
over a predetermined time, this DTC will set.
Diagnostic Aids
Condition for Running the DTC • Use the Temperature vs. Resistance table to test
• DTCs P0079, P0080, P0116, P0117, P0118, the exhaust temperature sensor at various
P0122, P0123, P0201 - P0206, P0335, P0336, temperature levels to evaluate the possibility or a
P0404, P0409, P0426, P042B, P042C, P042D, skewed sensor.
P0427, P0428, P0500, P0502, P0503, P060B, • Fuel system problem (e.g. fuel injector damage)
P0638, P0641, P0651, P1261, P1262, P1404, may set this DTC.
P2146, P2149, P215A, P2227, P2228, P2229,
• Deteriorated or damaged oxidation catalyst will set
this DTC.
• If regeneration time is longer than normal, refer to
• The vehicle is running or the PTO control is DPD System Regeneration Long Time chart in
inactive. symptom diagnostic table.
Notice: Under a driving condition that the exhaust
temperature will not be stable during the DPD filter
regeneration event (e.g. frequent stop and start), this
DTC will set.

2 —

P042B, P042C or P042D set? DTC Go to Step 3

Important: There is installation directionality

in the exhaust differential pressure hoses.
Refer to Exhaust Differential Pressure Sensor
port
pressure sensor
or damaged
3 temperature sensor(s) or exhaust —
Exhaust.
sensors
2. Test the engine cooling system for an
overheating condition. Refer to Cooling
System in Section 1C Engine Cooling for
testing.


to DPD Status Table in DPD Control System
Check.
Is the intersected of a range located in C or D? Go to Step 5 Go to Step 6


2. Clear the DTC and the DPD Status with a
scan tool.

scan tool.

tool.
scan tool.

knob clockwise.)
procedure in
8 —

PTO Sensor Circuit Condition for Setting the DTC
• The ECM detects that the PTO throttle sensor
Circuit Description signal voltage is more than 4.8 volts.
The power take off (PTO) throttle sensor (body builder
installed) detects the PTO control throttle angle. The Action Taken When the DTC Sets
ECM receives the PTO control throttle angle from the • The ECM illuminates the SVS lamp when the
throttle sensor and controls the fuel injection quantity diagnostic runs and fails. Refer to DTC Type
(engine speed) during PTO. The PTO throttle sensor Definitions for Action Taken When the DTC Sets -
has the following circuits. Type C.
• 5 volts reference circuit • The ECM disables PTO throttle sensor control.
• PTO throttle sensor signal circuit Condition for Clearing the DTC
The PTO throttle sensor provides a signal to the ECM • Refer to DTC Type Definitions for Condition for
on the signal circuit, which is relative to the position Clearing the SVS Lamp/ DTC - Type C.
changes of the PTO throttle angle. If the ECM detects
an excessively high signal voltage, this DTC will set. Diagnostic Aids
• DTCs P060B and P0641 are not set. • PTO throttle sensor may have an intermittent open
• The battery voltage is between 18 to 32 volts. somewhere in the operating range.

Notice: If no PTO throttle sensor is installed,

2 skip to Step 3. 4.8 volts
4. Observe the PTO Remote Throttle Sensor
parameter with a scan tool while operating the
PTO throttle sensor.
value during operating the throttle? Go to Step 3 Aids
3 —
Is the DTC P0641 also set? Go to Step 4 Go to Step 5
2. Disconnect the PTO throttle sensor harness
connector.
4 0.1 volts
Is the PTO Remote Throttle Sensor parameter less


connector.
5 0.1 volts

Important: The PTO throttle sensor may be
voltage source.
70 of FB24) and the PTO throttle sensor (pin 2
7 of FB129) for the following conditions: —

Notice: The PTO throttle sensor shares the low
8 ECM (pin 41 of FB24) and the PTO throttle —
sensor (pin 1 of FB129) for an open circuit or
high resistance.

PTO throttle sensor (pin 1 of FB129).
9 —


11 —


13 4.8 volts

value during operating the throttle? Go to Step 3 Go to Step 14
14 —

Engine Idle Speed Selector Sensor • The ECM detects that the idle up sensor signal
voltage is less than 0.1 volts for longer than 3
Circuit Description seconds.
The idle up sensor controls the idle speed during warm • The ECM detects that the idle up sensor signal
up and it is installed in the driver’s side instrument voltage is more than 4.9 volts for longer than 3
panel. This sensor is active only when the gear position seconds.
is in the neutral position. When the shift lever is moved
to another position, the signal is ignored. The ECM Action Taken When the DTC Sets
receives the idle up signal from the idle up sensor and • The ECM illuminates the SVS lamp when the
controls the fuel injection quantity. The idle up sensor diagnostic runs and fails. Refer to DTC Type
has following circuits: Definitions for Action Taken When the DTC Sets -
• 5 volts reference circuit Type C.
• Low reference circuit • The ECM disables idle up sensor control.
• Idle up sensor signal circuit
The idle up sensor provides a signal to the ECM on the Condition for Clearing the DTC
signal circuit, which is relative to the position changes • Refer to DTC Type Definitions for Condition for
of the idle up sensor angle. If the ECM detects an Clearing the SVS Lamp/ DTC - Type C.
excessively low or high signal voltage, this DTC will set.
Diagnostic Aids
• The battery voltage is between 18 to 32 volts. • Idle up sensor may have an intermittent open
• The ignition switch is ON. somewhere in the operating range.

4. Fully turn the idle up sensor between lowest
position (full counterclockwise direction) and
2 0.2 to 4.8 volts
highest position (full clockwise direction) while
observing the Idle Up Sensor parameter with a
scan tool.
Does the scan tool indicate within the specified Go to Diagnostic

value during turning the sensor? Aids Go to Step 3
3 —
Is the Idle Up Sensor parameter less than the
4 0.1 volts
specified value at Step 2? Go to DTC P0641 Go to Step 8
Turn the idle up sensor to lowest position (full
counterclockwise direction).
5 0.1 volts

connector.
ground.
Is the Idle Up Sensor parameter more than the
connector.
8 0.1 volts

connector.
9 0.1 volts

Notice: The idle up sensor shares the 5 volts
11 ECM (pin 42 of FB24) and the idle up sensor —
resistance.

66 of FB24) and the idle up sensor (pin 2 of
• An open circuit
12 —
• High resistance


Important: The idle up sensor may be damaged if
source.

Notice: The idle up sensor shares the low
resistance.

Idle up sensor (pins 1, 2 and 3 of FL33).
15 —

ECM (pins 41, 42 and 66 of FB24).

Replace the idle up sensor.
17 —

19 5. Fully turn the idle up sensor between lowest 0.2 to 4.8 volts
scan tool.

value during turning the sensor? Go to Step 20 Go to Step 3
20 —

DTC U0073 (Flash Code 84)
Control Module Communication Bus Off Action Taken When the DTC Sets
Circuit Description consecutive driving cycle when the diagnostic runs
The ECM, the rotary electric actuator (REA), the and fails. Refer to DTC Type Definitions for Action
electric hydraulic control unit (EHCU) or ABS control Taken When the DTC Sets - Type B.
unit, the transmission control module (TCM), the body • The ECM blinks the exhaust brake indicator lamp
control module (BCM) or the data recording module when the diagnostic runs and fails.
(DRM) and instrument panel (IP) cluster communicate • The ECM limits fuel injection quantity.
control and diagnostic information via a controller area
network (CAN) communication bus. The ECM monitors
CAN operational status by expecting a constant flow of • The ECM inhibits cruise control.
messages from each module. If the ECM sets CAN Bus
OFF status, this DTC will set. Condition for Clearing the DTC
• The battery voltage is more than 20 volts.
Diagnostic Aids
Condition for Setting the DTC Intermittent Conditions in this section.
• The ECM sets the CAN Bus OFF status. • Parallel resistance of the 120 Ω resistor in the
ECM and the IP cluster should be 60 Ω.

Circuit/ System Testing DTC U0073 (Flash Code 84)

Go to Diagnostic
2. Disconnect the REA E10 harness connector.
Is DTC U0110 set, but not DTC U0073? Go to Step 11 Go to Step 4

Notice: If no ABS is installed, skip to Step 5.
2. Reconnect the REA E10 harness connector if
disconnected.
3. Disconnect the electric hydraulic control unit
4 (EHCU) J7 or ABS control unit FU2 harness —
connector.
Is DTC U0073 set? Go to Step 5 Go to Step 12


Notice: If no Smoother transmission is installed,
skip to Step 6.
disconnected.
3. Reconnect the EHCU J7 or ABS control unit
5 FU2 harness connector if disconnected. —
4. Disconnect the TCM FU108 harness
connector.
Is DTC P0101 set, but not DTC U0073? Go to Step 15 Go to Step 6

Notice: If no multi-information display is installed,
skip to Step 7.
disconnected.
FU2 harness connector if disconnected.
6 4. Reconnect the TCM FU108 harness —
connector if disconnected.
5. Disconnect the body control module (BCM)
FL105 harness connector.

disconnected.
FU2 harness connector if disconnected.
4. Reconnect the TCM FU108 harness
7 connector if disconnected. —
5. Disconnect the data recording module (DRM)

2. Reconnect the BCM FL105 or DRM FL101
harness connector if disconnected.
3. Remove the bezel surrounding the instrument
panel (IP) cluster enough to remove the IP
cluster.
8 —
4. Disconnect the IP cluster FU97 harness
connector.


1. Test the CAN Low and High circuits among
each control module for the following
conditions:

Replace the IP cluster. Refer to Instrument Panel
(IP) Cluster in Section 9E Instrumentation/ Driver
10 Info. —

turbocharger.) Refer to Turbocharger in Section 1J
11 Induction. —

Replace the EHCU or ABS control unit. Refer to
EHCU in Section 4C1 ABS/ ASR or ABS Control
12 Unit in Section 4C ABS. —

Important: Replacement BCM must be
programmed.
13 Replace the BCM. Refer to Repair Instructions in —
Section 10B Vehicle Control.

Replace the DRM.
14 —
Important: Replacement TCM must be
15 Replace the TCM. Refer to Repair Instructions in —
Section 5A Transmission Control System.


components or harness connector(s).
Records.

18 —

Lost Communication with TCM Action Taken When the DTC Sets
The ECM and the transmission control module (TCM) Action Taken When the DTC Sets - Type A.
communicate control and diagnostic information via a • The ECM blinks the exhaust brake indicator lamp
controller area network (CAN) communication bus. The when the diagnostic runs and fails.
ECM monitors CAN operational status by expecting a • The ECM inhibits exhaust brake control.
constant flow of messages from each module. If the
ECM fails to receive an expected message from the Condition for Clearing the DTC
TCM, this DTC will set.
• DTC U0073 is not set. Diagnostic Aids

• The battery voltage is more than 20 volts. • If an intermittent condition is suspected, refer to
• The ECM detects that the CAN Bus messages Connector End Views or ECM Connector End Views
from the TCM are not being received.

Go to Applicable
Is DTC U0073 or U0110 also set? DTC Go to Step 3
Attempt to communicate with the transmission Go to Diagnostic
control module (TCM) via the transmission data System Check -
table. Transmission
3 —
Controls in Section
Does the scan tool communicate with the TCM? 5A Transmission
Go to Step 4 Control System
connector.
4. Connect a DMM between the CAN Low circuit
4 1.5 to 3.5 volts
(pin 13 of FU108) and a known good ground.
5. Connect a DMM between the CAN High circuit
Are both voltage readings within the specified

CAN Low and High circuits (which ever voltage
reading did not read within the specified value at
5 Step 4) between the TCM (pins 12 and 13 of —
FU108) and the CAN joint connectors.


connector of the TCM (pins 12 and 13 of
6 FU108). —


Records.

9 —

Lost Communication with VNT System Action Taken When the DTC Sets
The ECM and the rotary electric actuator (REA) Action Taken When the DTC Sets - Type A.
communicate control and diagnostic information via a • The ECM limits fuel injection quantity.
controller area network (CAN) communication bus. • The ECM inhibits cruise control.
REA is internal to turbocharger. The ECM monitors
CAN operational status by expecting a constant flow of Condition for Clearing the DTC
messages from the REA. If the ECM receive an
expected message from the REA, this DTC will set. • Refer to DTC Type Definitions for Condition for
Diagnostic Aids
• The battery voltage is more than 20 volts. Intermittent Conditions in this section.
• The ECM detects that the CAN Bus messages
from the REA are not being received.

Go to Applicable
Is DTC U0073 or P0045 also set? DTC Go to Step 3
3 and High circuits (pins 1 and 4 of E10). 50 to 70 Ω
IP cluster should be 60 Ω)? Go to Step 8 Go to Step 4
1. Leave the DMM connected to the REA
harness connector.
4 2. Disconnect the IP cluster harness connector. 110 to 130 Ω

Measure the resistance of the IP cluster (pins 13
5 and 14 of FU97). 110 to 130 Ω

2. Disconnect the electronic hydraulic control
unit (EHCU) or ABS control unit harness
connector if installed.
3. Disconnect the transmission control module
(TCM) harness connectors if installed.
or body control module (BCM) harness
connector.
6 (pin 4 of E10) and a known good ground. 1.5 to 3.5 volts

8. Test the CAN Low and High circuits (which
ever voltage reading did not read within the
specified value) between the ECM (pins 18
and 37 of FB24) and the REA (pins 1 and 4 of
E10) for an open circuit or high resistance.
9. Repair the circuit(s) or connection(s) as
necessary.

1. Test the CAN Low and High circuits between
the IP cluster (pins 13 and 14 of FU97) and
the joint connection for an open circuit or high
resistance.
connector of the IP cluster (pins 13 and 14 of
FU97).
3. Repair the circuit(s) or connection(s) as
necessary.

feed circuit to the REA (pin 3 of E10) and a
known good ground.
8 20.0 volts
Connect a DMM across the ignition voltage feed
9 circuit and ground circuit (pins 3 and 6 of E10). 20.0 volts
the ECM Main (15A) fuse and the REA (pin 3 of
10 E10). Check the ECM Main (15A) fuse first. —

the REA (pin 6 of E10) and the ground terminal
11 (E20). Clean or tighten ground as necessary. —


12 connector of the REA (pins 1, 3, 4 and 6 of —
E10).

13 connector of the ECM (pins 18 and 37 of —
FB24).

14 Info. —


turbocharger). Refer to Turbocharger in Section 1J
16 Induction. —

Records.

18 —

Lost Communication With Vehicle Immobilizer Action Taken When the DTC Sets
Control Module • The ECM will not illuminate the MIL or SVS lamp.
Refer to DTC Type Definitions for Action Taken
Circuit Description When the DTC Sets - Type D.
The ECM communicates with the immobilizer control
unit (ICU) to execute immobilizer function. The ECM Condition for Clearing the DTC
sends a request signal to the ICU. The ECM receives a • Refer to DTC Type Definitions for Condition for
response signal from the ICU. Both communication Clearing the DTC - Type D.
signals are carried out via a controller area network
(CAN) communication bus. If the ECM does not detect Diagnostic Aids
a response signal from the ICU, this DTC will set. • If an intermittent condition is suspected, refer to
• The ECM does not receive a signal from the ICU. intermittent condition.
• Any communication fault with the ICU may set this
DTC.

Attempt to communicate with the immobilizer Go to Diagnostic
control unit (ICU) via the Immobilizer Data table. System Check -
2 — Immobilizer
Does the scan tool communicate with the ICU? Controls in Section
Go to Step 3 9I Security and Lock

5 —

6 —

EGR Control System Check
Description EGR Control Operation
The EGR system recirculates a part of exhaust gas • The engine coolant temperature (ECT) is between
back into the intake manifold, which results in reducing 70 to 100°C (158 to 212°F).
NOx emissions. The EGR control system uses an • The intake air temperature (IAT) is more than 0°C
electronic control system to ensure both driveability (32°F).
and low emission. A control current from the ECM
• The barometric pressure (BARO) is more than 90
operates a motor to control the lift amount of EGR
kPa (13 psi).
valve. Also, an EGR position sensor is provided at the
rear of the motor to feed actual valve lift amount back to
the ECM for more precision control.
The EGR control starts when the conditions for engine
speed, engine coolant temperature, intake air
temperature and barometric pressure are satisfied.
Then, the valve opening is calculated according to the
engine speed, and target fuel injection quantity. Based
on this valve opening, the drive duty of the motor is
determined and the valve is driven accordingly.
Circuit/ System Testing EGR Control System Check

2 4. Monitor the DTC Information with a scan tool. —
Are any DTCs set in which the "Action Taken When

the DTC Sets" under that particular code states, Go to Applicable
"The ECM inhibits EGR control"? DTC Go to Step 3

damaged
• EGR gas leakage any of the EGR
passage between the exhaust manifold
and intake manifold
EGR valve
system
3 system —
• Skewed engine coolant temperature
(ECT) sensor. Refer to Temperature vs.
Resistance table to test the ECT sensor
at various temperature levels to evaluate
the possibility of a skewed sensor.
• Skewed barometric pressure (BARO)
sensor. Determine the outside barometric
pressure from you location specified in
the altitude vs. barometric pressure table.
Refer to Altitude vs. Barometric
Pressure.
2. Repair the condition as necessary.

parking brake.
2. Start the engine and warm up (arrow engine
[167°F]).
4 W.O.T (accelerator pedal full travel) many ± 5%
times while observing the Desired EGR
Position and EGR Position parameter with a
scan tool.
Does the EGR Position parameter follow within the

tool several times.
5 and Decrease while observing the EGR ± 5%
Position.

specified value quick enough? Go to Step 6 Go to Step 7

6 Increase and Decrease while observing the ± 5%
Intake Throttle Position.

within the specified value quick enough? System OK Go to Step 9
engine.
conditions:
7 materials —
• Bent valve shaft

6, 7 and 8 of E45).
101 103, 110 and 111 of E26).
necessary.

materials



connector.
2, 4, 5 and 6 of E46).
connector of the ECM (pins 85, 95, 104, 109
and 112 of E26).
necessary.

11 —
Reconnect all previously disconnected components
13 or harness connector(s). —

Glow Control System Check
Description Glow Control Operation
The glow control system consists of the ECM, the glow • The glow plug lamp illuminates between 1.5
relay, the glow plug lamp and glow plugs. The glow seconds to approximately 10 seconds depending
control system is operated when the engine coolant upon the engine coolant temperature. It illuminates
temperature is low, which allows easier engine starting. 1.5 seconds at -5°C (23°F) or more.
The ECM commands the glow relay ON for a certain • In pre glow phase, the glow relay energizes
length of time at ignition switch is ON with engine OFF. between 3 seconds to approximately 15 seconds
In after glow phase, the glow plugs remain energized depending upon the engine coolant temperature.
for a certain period with engine run.
• In after glow phase, the glow relay energizes
between 3 seconds to approximately 30 seconds
depending upon the engine coolant temperature.

Circuit/ System Testing Glow Control System Check

Go to Applicable
Is DTC P0117, P0118, P0380 or P0381 set? DTC Go to Step 3
2. Make sure the metal bus bar that connects
switched battery voltage supply terminal (E31)
and all glow plugs is secured tightly.
4. Connect a test lamp between the metal bus
bar (glow plug power supply E31 terminal) and
3 a known good ground. —
tool.
6. Command the relay ON while observing the
test lamp.
Does the test lamp turn ON only when commanded

ON? Go to Step 4 Go to Step 5
2. Remove the metal bus bar from the glow
plugs.
3. Measure resistance of each glow plug
between the glow plug terminals and a known
4 good ground. Make sure to record all 1Ω
measurements and take them quickly as to
not allow engine temperature changes
between measurements.
Are the resistances within the specified value each

other? System OK Go to Step 15

replace with a known good relay.
bar (glow plug power supply E31 connector)
5 and a known good ground. —
tool.
test lamp.

Inspect the Glow (60A) slow blow fuse in the
6 chassis side fuse & relay box. —
Is the Glow (60A) slow blow fuse open? Go to Step 7 Go to Step 8
Replace the Glow (60A) slow blow fuse. If the slow
blow fuse continues to open, repair the short to
7 ground on a circuit fed by the slow blow fuse or —
check for a shorted attached component.

3. Connect a test lamp between the battery
8 —
voltage feed circuit of the relay (pin 1 of X19)

1. Connect a test lamp between the voltage
supply circuit of glow plugs (pin 2 of X19) and
a known good ground.
9 —

the Glow (60A) slow blow fuse and the glow relay
10 (pin 1 of X19). —

the glow relay (pin 2 of X19) and the glow plugs
11 (E31 terminal). —

Important: The glow plugs may be burnt out if the
battery voltage supply circuit is shorted to a voltage
source.
12 Repair the short to battery or ignition voltage —
between the glow relay (pin 2 of X19) and the glow
plugs (E31 terminal).

13 connection on each glow relay terminal. —


14 —
Replace the appropriate glow plug.
15 —
components, relay, fuse or harness
connector(s).
tool.
test lamp.


Exhaust Brake Control System Check
Description Test Description
The exhaust brake control system consists of the ECM, The number below refers to the step number on the
the intake throttle valve, the exhaust brake valve, the Circuit/ System Table.
exhaust brake solenoid valve and the exhaust brake 4. Use the scan tool to observe the Accelerator Pedal
switch. The ECM commands the intake throttle Position. The Accelerator Pedal Position parameter
solenoid valve and the exhaust brake solenoid valve to should change linearly from 0 to 100% according to the
close each valve based on vehicle running conditions accelerator pedal operation.
and exhaust brake switch input signal. 8. If the Exhaust Brake Solenoid Command parameter
indicates OFF, use the scan tool to observe the Vehicle
Exhaust Brake Control Operation Speed, Accelerator Pedal Position and Clutch Pedal
• The exhaust brake switch is ON. Switch parameters which allows the exhaust brake
control. Refer to engine control wirings and Scan Tool
Data List for diagnosis.
• The accelerator pedal is not depressed.
• The clutch pedal is not depressed (manual Connector End View Reference: Engine Controls
transmission). Connector End Views or ECM Connector End Views
• The vehicle speed is higher than predetermined
range.
Circuit/ System Testing Exhaust Brake Control System Check (1 of 2)

2 —
3. Apply the exhaust brake switch ON and OFF.
Does the exhaust brake indicator lamp turn ON and

OFF with each switch transition? Go to Step 3 Go to 2 of 2 Step 1
1. Drive the vehicle in order to gain exhaust
brake ON time long enough.
2. Apply the exhaust brake switch ON.
3. Release the accelerator pedal.
3 —
Does exhaust brake apply enough (if the vehicle
speed is reduced by applying the exhaust brake but
engine valve noise is heard, intake throttle valve
may not be closed enough)? Go to Step 4 Go to Step 7
1. Reenter the exhaust brake control. Observe the
2. Apply the accelerator pedal while in exhaust Accelerator Pedal
brake control. Position parameter
4 —
for accelerator pedal
Does the exhaust brake control cancel? position sensor
Go to Step 5 diagnosis
Notice: If no Smoother is installed, skip to Step 6. Go to Diagnostic
1. Reenter the exhaust brake control. System Check -
5 2. Operate the selector lever while in exhaust — Transmission
brake control. Controls in Section
5A Transmission
Does the exhaust brake control cancel? System OK Control System
1. Reenter the exhaust brake control.
2. Apply the clutch pedal while in exhaust brake
6 control. —
Does the exhaust brake control cancel? System OK Go to Step 9


1. Park the vehicle.
7 —
Are any DTCs set in which the “Action Taken When

the DTC Sets” under that particular code states, Go to Applicable
“The ECM inhibits exhaust brake control”? DTC Go to Step 8
2. Trigger the Snapshot function in order to
capture and store engine parameters while in
exhaust brake control.
8 3. Review the Exhaust Brake Valve Command —
parameter. The ECM is not
allowing exhaust
Does the Exhaust Brake Valve Command brake control. Refer
parameter indicate ON when the exhaust brake to Exhaust Brake
may operate enough? Go to Step 18 Control Operation
3. Observe the Clutch Pedal Switch parameter
with a scan tool while fully depressing and
9 —
releasing the clutch pedal.
Does the scan tool indicate Applied when the clutch

pedal is applied and Released when the clutch
1. Check to ensure the clutch pedal switch is
adjusted correctly. The plunger should be all
the way in when the pedal is released, yet
should not impede with the clutch pedal full
10 —
upward travel.
2. Adjust the clutch pedal switch as necessary.

2. Disconnect the clutch pedal switch harness
connector.
11 —
voltage feed circuit (pin 1 of FU179) and a
known good ground.

Observe the Clutch Pedal Switch parameter with a
scan tool while momentarily jumping 3-amp fused
jumper wire across the switch harness connector
12 between pins 1 and 2 of the FU179. —
Does the scan tool indicate Released when the
circuit is jumpered and Applied when the circuit is
not jumpered? Go to Step 15 Go to Step 14
the Engine Controller (10A) fuse and the switch
13 (pin 1 of FU179). —


26 of FB24) and the switch (pin 2 of FU179)
• An open circuit
• High resistance

switch (pins 1 and 2 of FU179).
15 —


Replace clutch pedal switch. Refer to Clutch
17 Control in Section 5E Clutch. —
1. Perform the Exhaust Brake Control with a Problem is relating
scan tool. to solenoid valve,
2. Command the solenoid ON and OFF. solenoid valve
wiring or exhaust
Does the solenoid valve click with each command? brake valve stuck.
Or faulty air
18 —
pressure lines.
Refer to applicable
diagnostic chart in
Section 1G Engine
Exhaust or engine
control wirings. Go to Step 19
harness connector.
19 —
voltage feed circuit (pin 1 of J8 or FB41) and a
known good ground.

1. Connect a test lamp across the exhaust brake
solenoid valve harness connector (pins 1 and
2 of J8 or FB41).
20 scan tool. —
3. Command the solenoid ON and OFF.

Does the test lamp remain illuminate with each
21 —

the ECM Main (15A) fuse and the solenoid valve
22 (pin 1 of J8 or FB41). —

• An open circuit
• High resistance

or FB41) for a short to ground.
24 —

solenoid valve (pins 1 and 2 of J8 or FB41).
25 —


27 —

Reconnect all previously disconnected
29 components, fuse or harness connector(s). —

3. Apply the exhaust brake switch ON and OFF
1 while observing the Exhaust Brake Switch —
Does the scan tool indicate ON and OFF with each

switch transition? Go to Step 2 Go to Step 3

Does the exhaust brake indicator lamp always ON
2 —
with each switch transition? Go to Step 10 Go to Step 11
2. Disconnect the combination switch harness
connector (FL73).
3 circuit of combination switch harness (pin 13 —
of FL73) and a known good ground.

Observe the Exhaust Brake Switch parameter with
a scan tool while momentarily jumping 3-amp fused
4 between pins 13 and 15 of FL73. —
Does the scan tool indicate ON when the circuit is
jumpered and OFF when the circuit is not
jumpered? Go to Step 7 Go to Step 6
5 (pin 13 of FL73). Check the Engine Controller (10A) —
fuse first.

45 of FB24) and the switch (pin 15 of FL73) for
• An open circuit
• High resistance

switch (pins 13 and 15 of FL73).
7 —

8 —

Repair or replace the combination switch.
9 —
Is the exhaust brake indicator lamp OFF? Go to Step 19 Go to Step 16


voltage to the exhaust brake indicator lamp.
11 1 volt
5. Measure the voltage from the exhaust brake
indicator lamp control circuit in the ECM
harness connector (pin 7 of FB24) to a known
good ground.

Is the exhaust brake indicator lamp illuminate? Go to Step 15 Go to Step 13

13 —

connection at the harness connector of the IP
cluster (pin 13 of FU98).
14 —

15 —

17 (pin 13 of FU98). —

18 Driver Info. —


Did you complete the action? Go to 1 of 2 Step 2 —

Cruise Control System Check
Description • The cruise cancel switch is applied.
The cruise control system consists of the ECM, the • The brake pedal is depressed.
cruise control main switch, set/ coast switch, resume/ • The selector lever is operated.
accel. switch and cancel switch. The cruise control • The exhaust brake is applied.
keeps the vehicle speed at a driver's set speed. When
the cruise control main switch is pressed ON, signal is • The actual vehicle speed becomes less than
provided to the ECM and the cruise control main approximately 40 km/h.
indicator lamp on the instrument panel cluster will light • The actual vehicle speed is more than 40 km/h
up. When the cruise set/ coast switch is turned to SET below the set speed.
(-), the switch signal is provided to the ECM and the By applying the resume/ accel. switch, the vehicle
vehicle speed is set. The vehicle speed is increased or speed is returned to the vehicle speed memorized by
decreased if the set/ coast switch or the resume/ accel. the ECM (resume function) if within the condition for
switch is turned to RES (+) or SET (-). When the cruise running the cruise control are satisfied.
cancel switch is applied, the switch signal is provided to 9. Function of Complete Cancellation
the ECM and the cruise control system is inactive. The cruise control is canceled completely if any of the
following condition is met:
Condition for Running the Cruise Control • The cruise control main switch is OFF.
• The vehicle speed is between approximately 40 to • The ignition switch is OFF.
100 km/h. (Speed limiter setting 100 km/h) • The DTCs relating to the cruise control system
• The cruise control main switch is ON. inhibits are set.
1. Function of "SET"
If the set/ coast switch is turned to SET (-) and released Connector End View Reference: Engine Controls
while condition for running the cruise control are Connector End Views or ECM Connector End Views
satisfied, the ECM memorize and maintain the vehicle
speed at that time.
2. Function of "COAST"
If the set/ coast switch is turned to SET (-) while the
cruise control system is operating, the vehicle speed is
decreased. Then, when the set/ coast switch is
released, the vehicle will maintain the vehicle speed at
that time.
3. Function of "RESUME"
If the resume/ accel. switch is turned to RES (+) while
the cruise control system is operating and the ECM
memorizes the vehicle speed, the vehicle speed is
returned to the vehicle speed memorized by the ECM.
4. Function of "ACCEL"
If the resume/ accel. switch is turned to RES (+) while
the cruise control system is operating, the vehicle
speed is increased. Then, when the resume/ accel.
switch is released, the vehicle will maintain the vehicle
speed at that time.
5. Function of "TAP UP"
If the resume/ accel. switch is tapped (momentarily
turned) while the cruise control system is operating, the
vehicle speed is increased 1 km/h at a time.
6. Function of "TAP DOWN"
If the set/ coast switch is tapped (momentarily turned)
while the cruise control system is operating, the vehicle
speed is decreased 1 km/h.
7. Function of Temporary Acceleration
If the accelerator pedal is depressed while the cruise
control system is operating, the vehicle speed is
increased.
8. Function of Temporary Cancellation
The cruise control is canceled temporarily if any of the

Circuit/ System Testing Cruise Control System Check

1. Drive the vehicle at 50 km/h on a flat level
road.
2. Press and release the cruise control main
switch.
3. Turn and release the cruise set/ coast switch.
4. Verify the 50 km/h vehicle speed is
2 maintained. —
5. Tap (momentarily turn) the cruise set/ coast

switch 10 times.
Did the vehicle maintain the set speed of 50 km/h,

and then decreased by 1 km/h each time the switch
was tapped (momentarily turned to SET [-])? Go to Step 3 Go to Step 7
Tap (momentarily turn) the cruise resume/ accel.
switch 10 times.
3 Does the vehicle speed increase 1 km/h each time —
the switch was tapped (momentarily turned to RES
[+])? Go to Step 4 Go to Step 10
Are the cruise control main and set lamps in the IP Refer to Cab and
cluster illuminated while in cruise control? Chassis Electrical
4 — Section for IP
cluster circuits
Press and release the cruise cancel switch.
5 —
Does the cruise control cancel? Go to Step 6 Go to Step 11
1. Reenter the cruise control. ECM does not
2. Depress and release the brake pedal. support brake
switch parameters
Does the cruise control cancel? on the scan tool.
Use transmission
data display and
6 — refer to Cab and
Chassis Electrical
Section or
Transmission
Control Section for
brake switch circuits
System OK diagnosis
7 —
the DTC Sets” under that particular code states, Refer to Applicable
“The ECM inhibits cruise control”? DTC Go to Step 8
Observe the Cruise Main Switch parameter with a
scan tool.
8 —
Does the scan tool indicate ON then OFF each
time the switch is pressed? Go to Step 9 Go to Step 12

Observe the Cruise Set/ Coast Switch parameter
with a scan tool. Retest the cruise
control. Refer to
9 Does the scan tool indicate ON when the switch is — Condition for
turned to SET (-) and OFF when the switch is Running the Cruise
released? Control Go to Step 17
Observe the Cruise Resume/ Acceleration Switch
10 Does the scan tool indicate ON when the switch is —
turned to RES (+) and OFF when the switch is Go to Intermittent
released? Conditions Go to Step 17
Observe the Cruise Cancel Switch parameter with
a scan tool.
11 —
Does the scan tool indicate ON when the switch is Go to Intermittent
pressed and OFF when the switch is released? Conditions Go to Step 17
2. Disconnect the cruise control main switch
harness connector. (Remove the switch from
the IP bezel as necessary)
12 —
voltage feed circuit of the cruise control main
switch (pin 3 of FU208) and a known good
ground.

jumper wire across the cruise control main switch
13 harness connector between pins 3 and 4 of FU208. —

time the circuit is jumpered? Go to Step 16 Go to Step 15
the Engine Controller (10A) fuse and the cruise
14 control main switch (pin 3 of FU208). —

25 of FB24) and the cruise control main switch
(pin 4 of FU208) for an open circuit or high
15 resistance. —

cruise control main switch (pins 3 and 4 of
16 FU208). —


connector (FL19). (Remove the steering cowl
cover)
17 3. Connect a DMM between the cruise control 4.5 volts
switch signal circuit (pin 5 of FL19) and a
known good ground.
jumper wire across the combination switch harness
connector between the cruise control switch signal
18 circuit and low reference circuit (pins 4 and 5 of —
FL19).

1. Test the cruise control switch signal circuit
between the ECM (pin65 of FB24) and the
combination switch (pin 5 of FL19) for the
• An open circuit
• High resistance

Notice: The cruise control switch shares the low
20 ECM (pin 41 of FB24) and the combination —
switch (pin 4 of FL19) for an open circuit or
high resistance.

combination switch (pins 4 and 5 of FL19).
21 —


Repair or replace the cruise control main switch.
23 —

24 —


Diesel Particulate Defuser (DPD) Control System Check
Description Range A: Normal range
The ECM detects the condition of PM accumulations Range B: DPD amber lamp or “PUSH DPD SWITCH”
from the exhaust differential pressure sensor attached indicator blinks but manual regeneration is possible.
to the chassis frame near the diesel particulate defuser Range C: Exhaust differential pressure is excessive
(DPD) assembly or from mileage. The exhaust high range and manual regeneration is inhibited.
differential pressure sensor is a transducer that varies Range D: Distance status is abnormal range and
voltage according to changes of the exhaust gas manual regeneration is inhibited.
differential pressure between in front and in rear of
filter. When it is reached to a certain amount of PM Test Description
accumulations or a certain length of mileage, the The number below refers to the step number on the
automatic regeneration starts. If the automatic Circuit/ System Table.
regeneration cannot be completed by some reason, the 6. 8. 9. If the regeneration is not started, any DTCs may
manual regeneration is requested to the driver by be set which inhibits regeneration control. If no DTC is
blinking the DPD amber lamp or “PUSH DPD SWITCH” set, use the scan tool to observe the Vehicle Speed,
indicator on the instrument panel cluster. Once the Accelerator Pedal Position, Neutral Switch, Idle Up
regeneration starts, it must be finished within a certain Sensor and PTO Switch parameters which allows the
time. After regeneration is finished, a purification of the DPD regeneration control. Refer to engine control
filter is judged by monitoring an exhaust differential wirings and Scan Tool Data List for diagnosis.
pressure. If an excessive PM accumulation has been
detected, the regeneration will not start since Connector End View Reference: Engine Controls
uncontrolled burning might be happened during Connector End Views or ECM Connector End Views
regeneration event.
The DPD Status Table is used to determine type of the
DPD filter regeneration procedure by comparing the
DPD Accumulation Status parameter and the DPD
Distance Status parameter. To use this table, observe
both parameters with a scan tool, and plot both
readings on the DPD status table. The intersected
range indicates A, B, C or D. (e.g. DPD Accumulation
Status is 3 and DPD Distance Status is 1. The range is
located in B)
5 C
4
B
3
D
2
1 A
0 1 2 3 4
DPD Distance Status
LNW76ESH003501
Circuit/ System Testing Diesel Particulate Defuser (DPD) Control System Check


cluster is operational. Go to P1669 for
2. Turn ON the ignition for 30 seconds, with the Turn OFF the DPD amber lamp
engine OFF. DO NOT start the engine. ignition for 30 circuit diagnosis or
2 —
seconds to relearn GO to IP cluster
Does the DPD amber lamp or “AUTO REGEN.”, exhaust differential diagnosis in Section
“MANUAL REGEN.” indicators turn ON, and then pressure sensor. 9E Instrumentation/
turn OFF? Go to Step 3 Driver Info.
1. Inspect engine oil level. Make sure the oil
amount is within a range.
3 —
4. Observe the DPD Regeneration Switch



1G Engine Exhaust.
pressure sensor. Refer to Exhaust Pipe
port
pressure sensor
or damaged
4 —
Exhaust.
sensors
• Modified air induction


Start the engine and let idle for 30 seconds.
5 Does the DPD amber lamp or “PUSH DPD —
SWITCH” indicator blink? Go to Step 6 Go to Step 7
Perform the DPD manual regeneration by pressing ECM is not allowing
the DPD regeneration switch. the DPD
regeneration
6 Does the regeneration start? —
control. Refer to
Test Description and
Go to Step 10 DTC List

Observe the DPD Accumulation Status and DPD
Distance Status with a scan tool, and plot both
7 readings on the DPD status table. —
Is the intersected range located in A or B? Go to Step 8 Go to Step 9

Important: Reset the DPD Status before ECM is not allowing
regeneration with a scan tool. the DPD
Perform the DPD Normal Regeneration with a scan regeneration
8 —
tool. control. Refer to
Does the regeneration start? Go to Step 10 DTC List
Important: Reset the DPD Status before
regeneration with a scan tool.
Important: Engine Oil must be replaced after DPD ECM is not allowing
slow regeneration is completed. the DPD
9 — regeneration
Perform the DPD Slow Regeneration with a scan
10 Does the regeneration complete? — Go to Step 11 Go to Step 13
knob clockwise.)
procedure in
Is the Exhaust Differential Pressure parameter Refer to DTC P2002
more than the specified value? for excessive low
12 1.0 kPa
exhaust differential
System OK pressure diagnosis
Notice: If the scan tool displays a message
"Regeneration is impossible", go to applicable
DTC.
1G Engine Exhaust. Inspect the following
conditions:
• DPD filter for damage, cranks or melt
• Oxidation catalyst for damage, cranks
melt or excessive deposits
13 • Deteriorated oxidation catalyst —
testing.
3. Inspect the fuel system problem. Refer to Fuel
System Check chart and appropriate
procedure in Section 1D Engine Fuel.


2. Remove the bezel surrounding the IP cluster
enough to disconnect the DPD regeneration
switch.
3. Disconnect the DPD regeneration switch
15 harness connector. —
circuit of the DPD regeneration switch harness

Observe the DPD Regeneration Switch parameter
with a scan tool while momentarily jumping 3-amp
fused jumper wire across the switch harness
16 connector between pins 1 and 2 of FU142. —
17 (pin 1 of FU142). Check the Engine Controller —
(10A) fuse first.

• An open circuit
• High resistance

19 —

1. Inspect for an intermittent, for a poor
20 —

Repair or replace the DPD regeneration switch.
21 —


components, fuse or harness connector(s).
23 3. Observe the DPD Regeneration Switch —

Symptoms - Engine Controls

Symptoms - Engine Controls Reform or replace connector terminals in the problem
circuit in order to ensure proper contact tension.
Important Preliminary Inspections Before Starting
Remove the terminal from the connector body in order
Perform Diagnostic System Check - Engine Controls to inspect for poor terminal wire connection.
before using the symptom tables, and verify that all of Road test the vehicle with the DMM connected to the
the following are true: suspected circuit. An abnormal reading that occurs
• The ECM and malfunction indicator lamp (MIL)/ when the malfunction occurs is a good indication that
service vehicle soon (SVS) lamp are operating there is a malfunction in the circuit being monitored.
correctly. Use the scan tool in order to help detect intermittent
• The scan tool data is within the normal operating conditions. Useful features of the Tech 2 scan tool
range. Refer to Scan Tool Data List in this section. include the following:
• Verify the customer concern and locate the correct • Trigger the Snapshot feature in order to capture
symptom in the table of contents. Inspect the items and store engine parameters when the malfunction
indicated under that symptom. occurs. Review this stored information in order to
see the specific running conditions that caused the
Visual and Physical Inspection malfunction.
Several of the symptom procedures ask for careful • Freeze Frame/ Failure Record can also aid in
visual and physical inspection. This step is extremely locating an intermittent condition. Review and
important. The visual and physical inspection can lead capture the information in the Freeze Frame/
to correcting a problem without further inspections, and Failure Record associated with the intermittent
can save valuable time. Ensure that: DTC being diagnosed. Drive the vehicle within the
conditions that were present when the DTC
• The ECM grounds are clean, tight, and in their originally set.
proper location.
• Use the Plot Function on the scan tool in order to
• The air hoses are not split or kinked, and properly plot selected data parameters. Review this stored
connected. Inspect thoroughly for any type of leak information to aid in locating an intermittent
or restriction. problem. Refer to the scan tool Users Guide for
• The air intake ducts are not collapsed or damaged. more information.
• The exhaust pipes are not collapsed or damaged. Use the data recording module (DRM) or body control
• The engine harness wiring and terminals are module (BCM) data recording function in order to help
properly connected and are not pinched or cut. detect intermittent conditions. The DRM or the BCM
has ability to store engine log data when an event of
Intermittent DTC. Maximum three log data can be stored in the
DRM or the BCM memory. If more than maximum
Important: Inspect for improper installation of electrical number of storage is set, oldest log data is overwritten.
components if an intermittent condition exists. Inspect However, if same DTC is set within eight hours that
for aftermarket add-on electrical equipment devices, DTC is not stored in the DRM or the BCM memory.
lights, and cellular phones. Verify that no aftermarket The manual trigger function is to store the log data by
equipment is connected to the controller area network an arbitrary operation of the driver when an event of
(CAN) or other serial data circuit. wrong vehicle performance that is instead of an event
of DTC. If the driver presses and releases the manual
Important: The problem may or may not turn ON the trigger switch once, that time becomes a trigger and
MIL/ SVS lamp or store a DTC. Faulty electrical one log data before and behind the trigger is stored in
connections or wiring cause most intermittent the DRM or the BCM memory. When there is a space in
problems. Perform a careful visual and physical the DRM or the BCM memory, log data is stored in that
inspection of the suspect connectors for the following space. However, when more than maximum number of
conditions: storage is set, oldest log data is overwritten.
• Improperly mated connector halves
• Terminals that are not seated Important: If the intermittent condition exists as a start
• Terminals that are damaged or improperly formed and then stall, test for DTCs relating to the vehicle theft
deterrent system. Test for improper installation of
electrical options such as lights, cellular phones, etc.
Important: Any of the following may cause an

intermittent MIL/ SVS lamp with no stored DTC:
• The ECM grounds are loose or dirty. Refer to
engine control wirings.

• The MIL/ SVS lamp circuit intermittently shorted to
ground
• Electrical system interference caused by a
malfunctioning relay, ECM driven solenoid, or
switch. The electrical component can cause a
sharp electrical surge. Normally, the problem will
occur when the malfunctioning component is
operating.
• There are any open diodes.
Important: The following symptom tables contain

groups of possible causes for each symptom. The
order of these procedures is not important. If the scan
tool readings do not indicate the problems, then
proceed in a logical order, easiest to check or most
likely to cause first. In order to determine if a specific
vehicle is using a particular system or component, refer
to engine control wirings for an application.
Important: Use the following tables when diagnosing a

symptom complaint:
• Intermittent Conditions
• Hard Start
• Rough, Unstable, or Incorrect Idle and Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or Sponginess
• DPD System Manual Regeneration Frequently

Intermittent Conditions
Checks Action
Definition:
The problem is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom cannot currently be duplicated, if the problem is not DTC related.
Preliminary Checks • Refer to Symptoms - Engine Controls before starting.
Harness/ Connector Many intermittent open or shorted circuits are affected by harness/ connector
movement that is caused by vibration, engine torque, bumps/ rough pavement, etc.
Test for this type of condition by performing the applicable procedure from the following
list:
• Move related connectors and wiring while monitoring the appropriate scan tool data.
• Move related connectors and wiring with the component commanded ON, and OFF,
with the scan tool. Observe the component operation.
• With the engine running, move related connectors and wiring while monitoring
engine operation.
If harness or connector movement affects the data displayed, component/ system
operation, or engine operation, inspect and repair the harness/ connections as
necessary.
Electrical Connections or Wiring Poor electrical connections, terminal tension or wiring problems cause most
intermittent. To perform the following inspections:
• Poor mating of the connector halves, or terminals improperly seated in the
connector body.
• Improperly formed or damaged terminals. Test for poor terminal tension.
• Poor terminal to wire connections including terminals crimped over insulation. This
requires removing the terminal from the connector body.
• Corrosion/ water intrusion. Pierced or damaged insulation can allow moisture to
enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wires that are broken inside the insulation.
• Harness for pinched, cut or rubbed through wiring.
• Ensure that the wiring does not come in contact with hot exhaust components.
Control Module Power and Grounds Poor power or ground connections can cause widely varying symptoms.
Component Power and Grounds • Test all control module power supply circuits. Many vehicles have multiple circuits
supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/ component connectors, fuses, and any intermediate connections
between the power source and the module/ component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.
• Test all control module ground and system ground circuits. The control module may
have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and
in splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.
Checks Action
Temperature Sensitivity • An intermittent condition may occur when a component/ connection reaches normal
operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.
• Freeze Frame, Failure Records or Snapshot Data may help with this type of
intermittent conditions, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the
following:
- High ambient temperatures.
- Underhood/ engine generated heat.
- Circuit generated heat due to a poor connection, or high electrical load.
- Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a
connection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern
that is temperature related.
Electromagnetic Interference (EMI) Some electrical components/ circuits are sensitive to EMI or other types of electrical
and Electrical Noise noise. Inspect the following conditions:
• A misrouted harness that is too close to high voltage/ high current devices such as
injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the ECM driven
solenoid or switch. These conditions can cause a sharp electrical surge. Normally,
the problem will occur when the malfunctioning component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as
lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test for any open diodes. Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the
electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
- An ECM from another vehicle is installed.
- Revised software/ calibration files have been released for this vehicle.
Important: DO NOT reprogram the ECM with the SAME software/ calibration files that
are already present in the ECM. This is not an effective repair for any type of driveability
problem.
• Verify that the ECM contains the correct software/ calibration. If incorrect
programming is found, reprogram the ECM with the most current software/
calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/ or capture the
failure conditions.
• Freeze Frame/ Failure Records data, where applicable, contains the conditions that
were present when the DTC set.
- Review and record Freeze Frame/ Failure Records data.
- Operate the vehicle under the same conditions that were noted in Freeze
Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.
• An alternate method is to drive the vehicle with the DMM connected to a suspected
circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
Checks Action
Scan Tool Snapshot The scan tool can be set up to take a Snapshot of the parameters available via serial
data. The Snapshot function records live data over a period of time. The recorded data
can be played back and analyzed. The scan tool can also graph parameters singly or in
combinations of parameters for comparison. The Snapshot can be triggered manually
at the time the symptom is noticed, or set up in advance to trigger when a DTC sets.
An abnormal value captured in the recorded data may point to a system or component
that needs to be investigated further.
Refer to the scan tool Users Guide for more information.
DRM or BCM Memory Use data stored in the DRM or the BCM memory or use manual trigger function. The
DRM or the BCM has ability to store engine log data when an event of DTC. The
manual trigger function is to store the log data by an arbitrary operation of the driver
when an event of wrong vehicle performance that is instead of an event of DTC. If the
driver presses and releases the manual trigger switch once, that time becomes a
trigger and one log data before and behind the trigger is stored in the DRM or the BCM
memory.

Hard Start
Checks Action
Definition:
The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
Preliminary Checks • Diagnostic System Check - Engine Controls.
• Ensure the driver is using the correct starting procedure.
• Inspect the ECM grounds for being clean, tight, and in their proper locations.
• Inspect that the harness connectors are correctly connected.
• Inspect the fuel type and quality.
• Inspect the programmed fuel injector ID code for each cylinder.
• Inspect the Scan Tool Data List in this section.
• Inspect the Service Bulletin.
Sensor Checks Inspect the engine control sensors for the following conditions. Refer to Scan Tool Data
List in this section.
• Compare the Coolant Temperature with the Intake Air Temperature (IAT) and Fuel
Temperature (FT) parameters on a cold engine condition. If the difference among
temperature reading is more than 5°C (9°F) on a cold engine, check for high
resistance in each circuit or for a skewed sensor.
Notice: The mass air flow (MAF) sensor is heated and as a result the IAT may indicate
a higher than normal intake air temperature if the ignition switch is being ON.
• Observe the Fuel Rail Pressure Sensor parameter with the engine OFF. The FRP
Sensor should read 0.9 to 1.0 volt with the ignition switch ON and engine OFF after
the engine has stopped running for a minimum of 1 minute. If not, check for high
• Crankshaft position (CKP) sensor is tight and the sensor rotor is not damaged.
• Camshaft position (CMP) sensor is tight and the camshaft gear is not damaged.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to Fuel System Check chart
and appropriate procedure in Section 1D Engine Fuel.
• Air in the fuel system.
• Water contamination in the fuel.
• Fuel waxing or icing.
• Fuel filter clogging.
• External fuel leaks or high engine oil level.
• Fuel leak off from the fuel pressure limiter valve and fuel injectors.
• Fuel lines between the fuel tank and fuel supply pump for being crushed, kinked,
tightness, cracks and plugged.
• A plugged fuel tank vent hose.
• Inside the fuel tank for any foreign material that may be getting drawn into the fuel
line pickup causing a blocked condition.
• Fuel supply pump operation.
Notice: The fuel supply pump must be timed to the engine and adjustment value must
be learned to the ECM.
• Perform the Cylinder Balance Test with a scan tool.

• Perform the Injector Forced Drive with a scan tool.
• Observe the FRP Regulator Feedback current on the scan tool.
Air Intake System Checks Inspect the air intake system for the following conditions.
• Air cleaner, air intake ducts and charge air cooler for a restriction, holes, or leaks.
• A restriction in the turbocharger inlet duct.
• Intake throttle valve for a stuck condition.
• A restriction or leak in the intake manifold.
Checks Action
Exhaust System Checks Inspect the exhaust system for a possible restriction. Refer to Exhaust System in
Engine Mechanical Checks Inspect the engine mechanical for the following conditions. Refer to Section 1B Engine
Mechanical.
• Poor cylinder compression.
• Improper mechanical timing (timing gear).
• Improper valve gap.
• Broken or weak valve springs.
• Worn camshaft lobes.
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to Section 1E Engine
Electrical.
• Glow plug control system operation. Refer to Glow Control System Check in this
section.
• Slow cranking speed.
• Weakened batteries.

Rough, Unstable, or Incorrect Idle and Stalling
Checks Action
Definition:
Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition
may be severe enough to stall the engine.
• Remove the air cleaner and check for dirt, or for air ducts being plugged or
restricted. Replace as necessary.
• Observe the Fuel Rail Pressure parameter at idle in Neutral. The Fuel Rail Pressure
should always be more than 25 MPa (3,600 psi) after warm up.

• Observe the Fuel Compensation for each cylinder at idle on the scan tool.
Checks Action
Mechanical.
• Incorrect basic engine parts such as camshaft, cylinder head, pistons, etc.
Additional Checks • Electromagnetic interference (EMI) on the reference circuit can cause an engine
miss condition. The scan tool can usually detect EMI by monitoring the engine
speed. A sudden increase in speed with little change in actual engine speed change
indicates that EMI is present. If a problem exists, check routing of high voltage
components, such as fuel injector solenoid valve wiring, near the sensor circuits.
• Faulty engine mounts.
• Faulty crank pulley.
• Faulty generator & A/C compressor.
• Generator output voltage.
• EGR system operating correctly. Refer to EGR Control System Check in this
section.
• A/C operation.

High Idle Speed
Checks Action
Definition:
Engine idle speed is higher than normal in regardless of engine coolant temperature or DPD system regeneration.
• Use the scan tool to compare the engine speed and tachometer on the instrument
panel (IP) cluster.
• Inspect the A/C operation.
• Inspect the engine oil level.
should always be more than 25 MPa (3,600 psi) after warm up.
• Observe the Accelerator Pedal Position (APP). APP parameter should change
linearly from 0 to 100% according to the accelerator pedal operation.
• Observe the Idle Up Sensor. Idle Up Sensor parameter should read less than 0.6
volts at full counterclockwise. If not, check for high resistance in the low reference
circuit or skewed sensor.
• Observe the PTO Remote Throttle Sensor. PTO Remote Throttle Sensor parameter
should read less than 0.4 volts at lowest position. If not, check for high resistance in
the low reference circuit or skewed sensor.
Fuel System Checks Inspect the fuel system for the following conditions. Refer to Fuel System in Section 1D
Engine Fuel.
• Fuel injectors. Remove the injectors and visually inspect. (Injector tip(s) may be
damaged)

Cuts Out
Checks Action
Definition:
A constant jerking that follows the engine speed, usually more pronounced as the engine load increase. The exhaust has a
steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Check • Diagnostic System Check - Engine Controls.
• Observe the Mass Air Flow (MAF) parameter for a skewed or slow MAF sensor.
• Observe the Fuel Rail Pressure and Desired Fuel Rail Pressure parameter between
idle and W.O.T. (accelerator pedal full travel) in Neutral. Fuel Rail Pressure
parameter should follow within ± 5 MPa (± 725 psi) quick enough.

Surges
Checks Action
Definition:
The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down with no
change in the accelerator pedal.
• Ensure the driver understands the A/C compressor operation.
• Use the scan tool in order to make sure the Vehicle Speed parameter reading
matches the vehicle speedometer.

• Turbocharger nozzle control solenoid for a stuck condition. Refer to Turbocharger
Assembly in Section 1J Induction.
Checks Action
Additional Checks • Inspect the EGR system operating correctly. Refer to EGR Control System Check in
this section.
• Inspect deformed tire(s) that may cause surges at fixed vehicle speed range.

Lack of Power, Sluggishness or Sponginess
Checks Action
Definition:
The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator
pedal.
• Compare the vehicle with a similar unit. Ensure the vehicle has an actual problem.
• Have the tire sizes changed?
• Are excessively heavy loads being carried?
• Inspect for clutch slip.
• Inspect brake drag.
• Inspect for a proper transmission shift pattern and down shift operation.
• Inspect the fuel quality (cetane index).
• Inspect the engine oil level and quality.
• Observe the Boost Pressure and Barometric Pressure (BARO) with ignition ON and
engine OFF. Both parameters should be within the 7.0 kPa (1.0 psi) each other.
Checks Action

• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer to
Turbocharger Assembly in Section 1J Induction.
Mechanical.
this section.
• Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.

Hesitation, Sag or Stumble
Checks Action
Definition:
The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur at any vehicle
speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe enough, the condition
may cause the engine to stall.
• Observe the MAF parameter for a skewed or slow MAF sensor.

Checks Action

• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Refer
to Turbocharger Assembly in Section 1J Induction.
Mechanical.
this section.
Engine Cooling.

Abnormal Combustion Noise
Checks Action
Definition:
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with the throttle
opening.
• Ensure the vehicle has an actual problem.
• Inspect for smoke associated with the combustion noise.
Fuel System Checks • If excessive smoke is present, check for a stuck open fuel injector. Inspect for fuel
leakage into the combustion chamber.
• Inspect the fuel injectors. Remove the injectors and visually inspect.
Mechanical.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks • Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.

Poor Fuel Economy
Checks Action
Definition:
Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected. Also, the
economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Is the acceleration too much, too often?
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (Smoother
only).
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
• Inspect the odometer is correctly operated.
Engine Fuel.
• Fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to Cooling System in
Section 1C Engine Cooling.
• Engine coolant level.
• Engine thermostat for always being open or for the wrong heat range.
• Engine cooling fan for always being ON.
Checks Action
Mechanical.

Excessive Smoke (Black Smoke)
Checks Action
Definition:
Black smoke under load, idle or start up hot or cold.
Preliminary Check • Ensure the vehicle has an actual problem.

Engine Fuel.
• Fuel injectors. Remove the injectors and visually inspect.
• Perform the Pre Injection Control with a scan tool.
• A restriction or damaged at MAF sensor.
Checks Action
Mechanical.
• Inspect for poor cylinder compression.
• Any excessive oil entering combustion chamber.
Additional Checks • EGR system operating correctly. Refer to EGR Control System Check in this
section.
• Excessive blow-by gasses.

Excessive Smoke (White Smoke)
Checks Action
Definition:
White smoke under load, idle or start up hot or cold.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Oil leak
from turbocharger. Refer to Turbocharger Assembly in Section 1J Induction.
Exhaust System Checks If an excessive white smoke is present while DPD filter regeneration event, a
deteriorated or damaged oxidation catalyst is suspected.
Checks Action
Mechanical.
• Thermostat working (open stuck).
Electrical System Checks • Glow plug control (preheating) system operation. Refer to Glow Control System
Check in this section.

DPD System Manual Regeneration Frequently
Checks Action
Definition:
The manual regeneration is frequently requested to the driver by blinking the DPD amber lamp. Or, it is frequently requested as
compared with before. (The automatic regeneration cannot be completed frequently.)
Preliminary Checks • Inspect the fuel quality.
• If an excessive black smoke is present, refer to Excessive Smoke (Black Smoke)
chart in symptom diagnostic table.
• An excessive ash accumulation in the DPD filter.
Inspect the driving habits/conditions of the owner for the following conditions. Suggest
to the owner to use the selectable regeneration as necessary:
In normal operation;
• Is the idling time too long?
• Is the driving at slow vehicle speed too often?
• Is the driving at long downhill?
• Is a small cargo delivery truck or a garbage truck?
• Is the PTO operating time too long?
In regeneration;
• Is the PTO operating too often and/or for a long time?
• Is the engine runtime short?
• Is the vehicle runtime short?
• Is the accelerator pedal ON and OFF too often?
Sensor Checks Inspect the engine control sensors relating to the DPD system control for the following
conditions. Refer to Scan Tool Data List in this section.
• Misrouted or disconnected exhaust differential pressure hoses or pipes.
Notice: There is installation directionality in the exhaust differential pressure hoses.

Refer to Exhaust Differential Pressure Sensor in Section 1G Engine Exhaust.
• Plugged, crushed or kinked exhaust differential pressure hoses or pipes.

• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust Pipe in
• Physical damage of the exhaust differential pressure sensor.
• Any contamination or objects that block the exhaust differential pressure sensor
port.
• Observe the Exhausts Differential Pressure parameter for a skewed or slow exhaust
differential pressure sensor.
• Skewed or slow exhaust temperature sensors. Use the Temperature vs. Resistance
table to test the exhaust temperature sensor at various temperature levels to
evaluate the possibility or a skewed sensor.
Fuel System Checks Inspect the fuel system problem. Refer to Fuel System Check chart and appropriate
Checks Action
• Modified air induction system.
• A restriction or damaged or any contamination or objects that block at MAF sensor.
Exhaust System Checks Inspect the exhaust system for the following conditions. Refer to Exhaust System in
• An exhaust system gasket that is missing or damaged.
• Exhaust gas leakage from the exhaust pipe, gasket, DPD assembly, exhaust
temperature sensor(s) or exhaust differential pressure hoses or pipes.
• Modified exhaust system.
• Exhaust throttle valve or exhaust brake valve for stuck condition. Refer to Exhaust
• DPD filter for damage, cracks, melt or excessive deposits.
• Oxidation catalyst for damage, cracks, melt or excessive deposits.
• If an excessive white smoke is present while regeneration event, a deteriorated or
damaged oxidation catalyst is suspected.

DPD System Regeneration Long Time
Checks Action
Definition:
The regeneration time longer than an expected time. Or, it takes longer than before.
• Is the engine warm up control misunderstood as the DPD regeneration?
Inspect the driving habits/conditions of the owner for the following conditions:
In regeneration;
• Has the manual regeneration started from cold engine?
• Is the PTO operating too often and/or for a long time?
• Is the ambient temperature excessively high?


• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust Pipe in
port.
Cooling System Checks Inspect the cooling system for an overheating conditions. Refer to Cooling System in
• Engine coolant leakage.
• Cooling fan belt slippage.
• Cooling fan clutch working.
• Thermostat working.
• Water pump working.
• Radiator clogging.
• Modified cooling system which is less cooling capacity.
Checks Action
Additional Checks • Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.
Repair Instructions
Engine Control Module (ECM) Replace-
ment
Description
The following A to G steps provide an overview
procedure to replace and reprogram an ECM. Each A -
SAMPLE
G steps is explained further in this section.
1
6HK1
A. Upload the fuel injector ID codes from the old 2 64 05 4F 08 F5 F5 F5 DD 0A 00 00 14
ECM. 64 F0 00 12 0E 04 16 00 0A 0A 20 BA
3 64 00 31 06 0A 14 00 10 FA 00 25 82
B. Reset the immobilizer security information in 64 E5 00 00 10 12 0F 16 0C 11 23 A4
4 64 05 3A 0C F6 D9 FB DA 00 EE EC 5B
the old ECM. 64 32 61 1B 1C 0C 0D FA 1D 0F 0C D5
5
C. Replace the old ECM with the new ECM.
D. Program the immobilizer security information 6
into the new ECM. 7
E. Program the latest software and calibrations
into the new ECM using the Service
Programming System (SPS). MFW81ASH000601
F. Program the uploaded fuel injector ID codes Legend

and program the vehicle identification number 1. Cylinder #1 fuel injector ID code
(VIN) into the ECM using a scan tool 2. Cylinder #2 fuel injector ID code
programming function. 3. Cylinder #3 fuel injector ID code
G. Perform the fuel supply pump relearn 4. Cylinder #4 fuel injector ID code
procedure by allowing the engine to idle in Park 5. Cylinder #5 fuel injector ID code
or Neutral until normal operating temperature is 6. Cylinder #6 fuel injector ID code
achieved. 7. Injector ID code label
Recording from each fuel injector
A. Uploading Fuel Injector ID Code
1. Remove the cylinder head cover. Refer to Fuel
The current fuel injector ID code data can be uploaded Injector Replacement.
with a scan tool. If the old ECM cannot be 2. Record 24 figures of each fuel injector ID plate.
communicated with a scan tool, go to Retrieving the The correct order for the fuel injector ID codes of
Fuel Injector ID Code Data with a Non-communicating the following illustration is as follows:
ECM. 64 DA A5 05 2F 4C 0F 36 FA 17 25 8C
2. Turn ON the ignition, with the engine OFF. 2 1
Programming > Store ECU setting 64DA A505
4. After complete the uploading, turn OFF the scan 2F4C 0F36
tool. FA17 25 00
5. Turn OFF the ignition. 0000 8C
Retrieving the Fuel Injector ID Code Data with a
Non-communicating ECM 3
If a scan tool does not communicate, the fuel injector ID
codes must be recorded from the factory affixed label
on the cylinder head cover or each fuel injector ID
plate.
Recording from the label on cylinder head cover LNW76ESH002601
Legend
Notice: Only perform this procedure if the fuel injectors 1. Fuel injector ID plate
are not being replaced in the past. 2. Fuel injector ID code
1. Record all numbers of each cylinder on the label. 3. Fuel injector

B. Resetting Immobilizer Security Information 3. Select Diagnostics > appropriate vehicle
Reset immobilizer security information in the old ECM. identification > appropriate engine model >
Refer to Resetting and Programming Guidelines in the Programming > Program ECU.
immobilizer section. If the old ECM cannot be 4. In order to get programming approval, the on-
communicated with a scan tool, go to the next screen displays a message to user. Get
procedure. programming approval from the TIS 2000 using
the following procedure:
C. Removal and Installation a. Connect a scan tool to the terminal that
Removal Procedure installed TIS 2000 with the latest software and
the hardware key is plugged into port.
1. Disconnect the negative battery cable.
b. Turn ON the scan tool and keep at title screen.
2. Disconnect the ECM harness connectors.
c. Launch the TIS application.
3. Loosen the nuts (4) and remove the ECM with
bracket. d. Select the Security Access at the main screen.
4. Loosen the bolts (2) from the bracket (3) and e. Highlight the “Tech 2” on the Diagnostic Tool
remove the ECM (1). Selection screen and click “Next”.
f. Click “Close” on the Security Access Enabled
1 screen.
2
3
h. Disconnect the scan tool from the terminal.
4 Programming > Program ECU.
8. Verify the VIN on the screen and follow the on
screen messages. If not programmed or incorrect
VIN, input correct VIN.
9. Verify the fuel injector ID code on the screen and
follow the on screen messages. If not programmed
or incorrect ID cord, input ID code.
MFW71ASH002501
Installation Procedure
1. Install the ECM (1) to the bracket (3) and tighten
for no DTC's. Refer to Diagnostic System Check -
the ECM fixing bolts (2).
Engine Controls if needed.
2. Install the ECM with bracket (3) and tighten the
nuts (4). G. Supply Pump Relearn
3. Reconnect the ECM harness connectors. 1. Install a scan tool.
4. Reconnect the negative battery cable. 2. Start the engine and let idle until engine coolant
D. Programming Immobilizer Security Information observing the Fuel Supply Pump Status parameter
Program immobilizer security information into the ECM. with a scan tool. The scan tool parameter changes
Refer to Resetting and Programming Guidelines in the status Not Learned > Learned.
immobilizer section.
E. Programming Software and Calibrations

Program latest software/ calibrations if released. Refer
to Service Programming System (SPS) Description and
SPS (Remote Procedure) or SPS (Pass-Thru
Procedure) in this section.
F. Programming Fuel Injector ID Codes and VIN


Service Programming System (SPS) De- • The hardware key is plugged into the computer
scription port.
• Vehicle system voltage:
The service programming system (SPS) allows a
technician to program a control module through the - There are no charging system concerns. All
data link connector (DLC). The information transfer charging system concerns must be repaired
circuit that is used at the DLC is the same serial data before programming the ECM.
circuit used by the scan tool for retrieving DTCs, - The battery voltage is greater than 24 volts but
displaying data, clearing DTCs etc. This procedure less than 30 volts. The battery must be fully
offers the ability to install software/ calibrations charged before programming the ECM.
matched to a particular vehicle. - A battery charger is NOT connected to the
Most control modules have two types of memory. The vehicles battery. Incorrect system voltage or
software/ calibrations reside in the flash memory. The voltage fluctuations from a battery charger may
two types of memory are listed below: cause programming failure or ECM damage.
• Electrically Erasable Programmable Read Only - Turn OFF or disable any system that may put a
Memory (EEPROM) load on the vehicles battery. Turn OFF or
This type of memory allows selected portions of disable systems such as:
memory to be programmed while other portions
◊ Heating, ventilation, and air conditioning
remain unchanged.
(HVAC) systems
Certain learned values reside in the EEPROM,
such as: ◊ Headlights
- The vehicle identification number (VIN) ◊ Room lights
- The software/ calibrations identification ◊ Accessory equipment
numbers • The ignition switch is in the proper position. The
- The control module security information scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of
• Flash Read Only Memory-Flash Memory
the ignition switch during the programming
Flash memory has increased memory storage
procedure unless instructed to do so.
capacity. During programming, all information
within this type of memory is erased, and then • All tool connections are secure:
replaced with entirely new information. - The RS-232 cable
- The connection at the DLC
Service Programming Methods
- The voltage supply circuits
The two methods of programming a ECM are listed • DO NOT disturb the tool harnesses while
below: programming. If an interruption occurs during the
• Remote Programming programming procedure, programming failure or
• Pass Thru Programming ECM damage may occur.
For information on programming an ECM using one of • If you are performing the Pass-Thru programming
the methods listed above, refer to Service procedure using a notebook computer without the
Programming System (SPS) (Remote Procedure) or power cord, ensure that the internal battery is fully
Service Programming System (SPS) (Pass-Thru charged.
Procedure).
Before Programming a Control Module Service Programming System (SPS) (Re-

Important: DO NOT program an existing ECM with the mote Procedure)
identical software/ calibration file. This procedure is not Notice: Some module will not accept SPS remote
a short cut to correct the driveability concern. This is an procedure using 10MB PCMCIA card. In such case,
ineffective repair. An ECM should only be programmed use 32MB PCMCIA card or SPS pass-thru procedure.
when the following occurs: The Remote SPS method is a three-step process that
• When a service procedure instructs you to replace involves the following procedures:
the ECM. 1. Connecting the scan tool to the vehicle and
• An updated software/ calibrations is released. obtaining the information from the ECM.
Ensure that the following conditions are met before 2. Connecting the scan tool to the terminal and
programming an ECM: downloading a new calibration file from the
• The scan tool PCMCIA card is programmed with terminal into the scan tool memory.
the latest software. 3. Reconnecting the scan tool to the vehicle and
• The TIS 2000 is installed with the latest software. uploading the new calibration file into the ECM.

Performing the Remote Procedure f. Verify the VIN on the Validate Vehicle
1. Connect a scan tool to the vehicle and obtain the Identification Number (VIN) screen, then click
ECM information using the following procedure: "Next".
Notice: Ensure the ECM is installed in the vehicle Notice: If the ECM is replaced to new one, VIN
and the battery is fully charged before does not displayed. Input correct VIN reading
programming. from stamped VIN or affixed VIN plate on the
vehicle. If the ECM from another vehicle is
a. Install a scan tool.
installed, input correct VIN by same way.
b. Turn ON the ignition, with the engine OFF.
g. Highlight Engine on the Select System Type
c. Select Service Programming System (SPS) > screen, then click "Next", if on-screen
Request Info. instruction displayed.
d. If there is already stored in the scan tool, the h. Complete the following information based on
existing data is displayed on the screen. The the service ID plate on the Validate Vehicle
scan tool asks user to keep existing data "Keep Data screen until "Next" is highlighted, then
Data" or "Continue" to request new vehicle click "Next".
information from the ECM. If there is no data in
• Model
the scan tool, it will immediately start vehicle
identification. • Model year
e. Select the vehicle description by following the • Engine type
on-screen instructions based on stamped VIN • Model designator
or affixed VIN plate on the vehicle. • Destination code
f. During obtaining information, the scan tool is • Transmission type
receiving information from all modules at the i. Verify your selection on the Summary screen.
same time. But only ECM information is
displayed on the screen. Notice: Refer to Service Bulletin and
g. Turn OFF all accessories and press "Okay". Description column before service
h. Verify that the correct VIN is displayed on the programming is performed if the bulletins are
scan tool. If the VIN is incorrect or no VIN, listed along with the calibration files.
record the correct VIN. Notice: Select Cancel if you receive a message
2. Turn OFF the ignition. stating that the calibration selected is already
the current calibration in the ECM and
3. Turn OFF the scan tool and disconnect from the
reprogramming with the same download is not
vehicle.
allowed.
4. Transfer the data from the terminal to the scan tool
j. Click "Reprog".
using the following procedure:
k. The Transfer Data screen will appear until the
Notice: The TIS supports service programming progress bar reaches 100%.
with the Tech 2 scan tool only. 5. Close the application and return to the TIS
a. Connect the scan tool to the terminal. application selection screen after the download is
complete.
b. Launch the TIS application.
c. Select the Service Programming System at the
terminal.
main screen.
7. Transfer the data from the scan tool to the ECM
d. Highlight the following information on the Select
Diagnostic Tool and Programming Process
screen, then click "Next": a. Install a scan tool.
• Select Diagnostic Tool - Tech 2 b. Turn ON the ignition, with the engine OFF.
• Select Programming Process - Identify c. Select Service Programming System (SPS) >
whether an existing ECM is being Program ECU.
reprogrammed or an ECM is being replaced d. Turn OFF all accessories and press "Continue".
with a new one e. Programming in Process will appear until the
• Select ECU Location - Vehicle progress bar reaches 100%.
e. Verify the connections on the Preparing for
Communication screen, then click "Next". Notice: Some warning lamp may turn ON or
blink while programming the ECM since
communication between the ECM and other
modules are interrupted. Clear DTC in any
module after programming.

f. Press "Continue" and exit the program after the 9. Verify your selection on the Summary screen.
scan tool displays "Programming Was
Successful". Notice: Refer to Service Bulletin and Description
8. Turn OFF the ignition. column before service programming is performed if
the bulletins are listed along with the calibration
files.
vehicle.
Notice: Select Cancel if you receive a message
stating that the calibration selected is already the
Service Programming System (SPS) (Pass- current calibration in the ECM and reprogramming
Thru Procedure) with the same download is not allowed.
10. Click "Reprog".
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughout 11. The Transfer Data screen will appear until the
the programming process. The vehicle must be in close progress bar reaches 100%.
proximity to the terminal while using Pass-Thru. Some warning lamp may turn ON or blink while
programming the ECM since communication
1. Launch the TIS application.
between the ECM and other modules are
2. Select the Service Programming System at the interrupted. Clear DTC in any module after
main screen. programming.
3. Highlight the following information on the Select 12. Close the application and return to the TIS
Diagnostic Tool and Programming Process screen, application selection screen after the download is
then click "Next": complete.
• Select Diagnostic Tool-Select Pass - Thru 13. Turn OFF the ignition.
• Select Programming Process - Identify whether 14. Turn OFF the scan tool and disconnect from the
as existing ECM is being reprogrammed or an vehicle.
ECM is being replaced with a new one.
• Select ECU Location - Vehicle
4. Complete all vehicle data on the Preparing for
Communication/ Determine Vehicle screen until
"Next" is highlighted, then click "Next".
5. Follow the instruction on the Preparing for
Communication screen, then click "Next".
Notice: In order to reduce the potential for signal

loss, the RS-232 cable should not be more than 25
feet long.
6. Verify the VIN on the Validate Vehicle Identification
Number (VIN) screen, then click "Next".
Notice: If the ECM is replaced to new one, VIN

does not displayed. Input correct VIN reading from
stamped VIN or affixed VIN plate on the vehicle. If
the ECM from another vehicle is installed, input
correct VIN by same way.
7. Highlight Engine on the Select System Type
screen, then click "Next", if on-screen instruction
displayed.
8. Complete the following information based on the
service ID plate on the Validate Vehicle Data
screen until "Next" is highlighted, then click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
Description and Operation

Engine Control Module (ECM) Description • The exhaust gas recirculation (EGR) system
control
Engine Control Module (ECM) Service Precautions
• The turbocharger system control
• The diesel particulate defuser (DPD) system
control
• The preheating (glow) system control
• The exhaust brake system control
• The immobilizer system control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
CAUTION diagnostic function of the system. The ECM can
recognize operational problems, alert the driver
To avoid electric shock; through the malfunction indicator lamp (MIL), and store
Set the key switch to the "OFF" or "LOCK" diagnostic trouble codes (DTCs). DTCs identify the
position before checking or repairing the system faults to aid the technician in making repairs.
computer, wiring or/and connectors.
LNW76ESH000301
Important: The symbol “!” warns you of an electric

shock hazard. To avoid shock and possible serious
injury, DO NOT touch the terminals. When
disconnecting the harness connectors, always turn
OFF the ignition switch or disconnect the battery cable.
-------------------------------------------------------
-----------------------
------------------------------------------------------- -----------------------------------
-----------------------------------
----------------------------
---------------------------
---------------------------
CAUTION
---------------------------------
--------------------------------------------------------
------------------------------ -------------------- ------------------------------------------------------
-------------------------------------------------
MFW84CSH002201
The engine control module (ECM) is designed to

withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. When testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a DMM. The ECM should remain connected to the
ECM harness. The ECM mainly controls the following
items:
• The fuel system control
1A-354
MG6HKED-WE-1101AU.book
Sensor inputs Fuel injection controls

Intake air temperature (IAT) sensor Fuel rail pressure (FRP) regulator
Mass air flow (MAF) sensor Fuel injector 1
ECM Input & Output
Engine coolant temperature (ECT) sensor Fuel injector 2

Fuel temperature (FT) sensor Fuel injector 3
Barometric pressure (BARO) sensor Fuel injector 4
Boost pressure sensor Fuel injector 5
Accelerator pedal position (APP) sensor Fuel injector #6
EGR position sensor
Crankshaft position (CKP) sensor Actuator controls
Camshaft position (CMP) sensor Intake throttle motor
Fuel rail pressure (FRP) sensor EGR motor
Vehicle speed sensor (VSS) Exhaust brake solenoid
Engine Control System (6HK1)
Exhaust differential pressure sensor Exhaust throttle solenoid

Exhaust temperature sensor 1 Rotary electric actuator (REA)
Exhaust temperature sensor 2
Idle up sensor
ECM Relay controls
PTO throttle sensor
354 ページ２０１０年１１月２５日　木曜日　午前１０時４３分
Glow relay
Starter cut relay
ECM main relay
Switch inputs
Ignition switch (ON/ start position)
Lamp controls
Clutch switch
Malfunction indicator lamp (MIL)
Parking brake switch
Service vehicle soon (SVS) lamp
Neutral switch
Glow plug lamp
Exhaust brake lamp
Exhaust brake switch
DPD lamp
Oil level switch
Oil pressure lamp
Cruise control main lamp (through CAN)
Cruise control set/ coast switch
Cruise control set lamp (through CAN)\
Cruise resume/ accel switch
A/C switch
Communications
Diagnostic request switch
Controller area network (CAN)
MFWB1AXF000201

ECM Voltage Description • If the part has been handled while sliding across
The ECM supplies a buffered voltage to various the seat, while sitting down from a standing
switches and sensors. The ECM can do this because position, or while walking a distance, touch a
resistance in the ECM is so high in value that a test known good ground before installing the part.
lamp may not illuminate when connected to the circuit. • Charge by induction occurs when a person with
An ordinary shop voltmeter may not give an accurate well insulated shoes stands near a highly charged
reading because the voltmeter input impedance is too object and momentarily touches ground. Charges
low. Use a 10-megaohm input impedance DMM, to of the same polarity are drained off leaving the
ensure accurate voltage readings. The input and/ or person highly charged with opposite polarity.
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special Malfunction Indicator Lamp (MIL) Operation
drivers. The ECM controls most components with The MIL is located in the instrument panel cluster. The
electronic switches which complete a ground circuit MIL will display the engine symbol when commanded
when turned ON. ON:
Aftermarket Electrical and Vacuum Equipment

Aftermarket or add-on electrical and vacuum
equipment is defined as any equipment which connects
to the vehicle's electrical or vacuum systems that is
installed on a vehicle after the vehicle leaves the
factory. No allowances have been made in the vehicle
design for this type of equipment. No add-on vacuum
equipment should be added to this vehicle. Add-on
electrical equipment must only be connected to the
vehicle's electrical system at the battery power and
ground. Add-on electrical equipment, even when
installed to these guidelines, may still cause the power
train system to malfunction. This may also include
equipment not connected to the vehicle electrical
system such as portable telephones and audios.
Therefore, the first step in diagnosing any power train
fault is to eliminate all aftermarket electrical equipment MFW81ASH000301
from the vehicle. After this is done, if the fault still
exists, the fault may be diagnosed in the normal The MIL indicates that an emission related fault (Type
manner. A or B) has occurred and vehicle service is required.
The following is a list of the modes of operation for the
Electrostatic Discharge Damage MIL:
Electronic components used in the ECM are often • The MIL illuminates when the ignition switch is
designed to carry very low voltage. Electronic turned ON, with the engine OFF. This is a lamp test
components are susceptible to damage caused by to ensure the MIL is able to illuminate.
electrostatic discharge. By comparison, as much as
• The MIL turns OFF after the engine is started if a
4,000 volts may be needed for a person to feel even
diagnostic fault is not present.
the zap of a static discharge. There are several ways
for a person to become statically charged. The most • The MIL remains illuminated after the engine is
common methods of charging are by friction and started if the ECM detects a fault. A DTC is stored
induction. any time the ECM illuminates the MIL due to an
emission related fault.
• An example of charging by friction is a person
sliding across a vehicle seat.
Important: To prevent possible electrostatic discharge
damage, follow these guidelines:
• Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
• Do not open the replacement part package until
the part is ready to be installed.
• Before removing the part from the package,
ground the package to a known good ground on
the vehicle.

Service Vehicle Soon (SVS) Lamp Operation
The service vehicle soon (SVS) lamp is located in the
instrument panel cluster. The SVS lamp will display the
vehicle with wrench symbol when commanded ON:
Ignition switch ON 1 sec. 1 sec. 1 sec.
ON
OFF
15 sec.
1 sec. 1 sec. 1 sec.
LNW91ASH000201
Engine Control Component Description

MFW81ASH000501 Accelerator Pedal Position (APP) Sensor
The SVS lamp indicates that an non-emission related

fault (Type C DTC) has occurred and vehicle service
required. The following is a list of the modes of 1 2
operation for the SVS lamp:
• The SVS lamp illuminates when the ignition switch
is turned ON, with the engine OFF. This is a lamp
test to ensure the SVS lamp is able to illuminate.
• The SVS lamp illuminates for approximately 15
seconds and blinks 3 times when the ignition
switch is turned ON, with the engine OFF. This is a 3
lamp test to the SVS lamp is able to illuminate and
a speed limiter device installation check. (with
speed limiter device)
• The SVS lamp turns OFF after the engine is
started if a diagnostic fault is not present.
• The SVS lamp remains illuminated after the engine
is started if the ECM detects a fault. A DTC is LNW81ASH000801
stored any time the ECM illuminates the SVS lamp Legend
due to a non-emission related fault. 1. Accelerator pedal bracket
3. Accelerator pedal
The APP sensor is mounted on the accelerator pedal

bracket. The sensor is made up of two individual
sensors within one housing. The ECM uses the APP
sensors to determine the amount of acceleration or
deceleration that is desired. The APP sensors are hall
element type sensors. Each APP sensor provides a
different signal to the ECM on the each signal circuit,
which relative to the position changes of the
accelerator pedal angle. The APP sensor 1 signal
voltage is low at rest and increases as the pedal is
depressed. The APP sensor 2 signal voltage is high at
rest and decreases as the pedal is depressed.

Barometric Pressure (BARO) Sensor The boost pressure sensor is located in the air
induction tubing. The boost pressure sensor is a
transducer that varies voltage according to changes in
the air pressure inside the air tubing. The boost
pressure sensor provides a signal to the ECM on the
signal circuit, which is relative to the pressure changes
in the air tubing. The ECM should detect a low signal
voltage at a low boost pressure, such as low engine
load. The ECM should detect high signal voltage at a
high boost pressure, such as high engine load.
60
RTW76ESH002401
15
The BARO sensor is located behind of the lower cover.
The BARO sensor is a transducer that varies voltage
according to changes the barometric pressure. The 2
BARO sensor provides a signal to the ECM on the
of the barometric pressure. The ECM should detect a
low signal voltage at a low barometric pressure, such 3
signal voltage at a high barometric pressure. The ECM
uses this voltage signal to calibrate the fuel injection LNW76ESH002001
quantity and injection timing for altitude compensation. Legend
1. Camshaft gear
Boost Pressure Sensor 2. Rotating direction
3. Camshaft position (CMP) sensor
The CMP sensor is installed on the cylinder head at the

rear of the camshaft gear. The CMP sensor detects
total of seven projections per one engine cycle (six
projections arranged equally every 60° and one
reference projection on the camshaft gear surface).
The CMP sensor is a magnetic resistance element
(MRE) type sensor, which generates a square wave
signal pulse.
LNW76ESH002101

Crankshaft Position (CKP) Sensor The ECT sensor is installed to the thermostat housing.
The ECT sensor is a variable resistor and it measures
the temperature of the engine coolant. When the ECT
sensor is cold, the sensor resistance is high. When the
A
engine coolant temperature increases, the sensor
resistance decreases. With high sensor resistance, the
2
ECM detects a high voltage on the signal circuit. With
voltage on the signal circuit.
6
Fuel Temperature (FT) Sensor
30
1
2 1
Section A-A
MFW76ESH000801
Legend
1. Crankshaft position (CKP) sensor
2. Flywheel
The CKP sensor is located under the fuel supply pump.

There are 56 notches spaced 6° apart and a 30°
section that is open span. This open span portion
allows for the detection of top dead center (TDC). The
CKP sensor is a magnetic resistance element (MRE) MFW76ESH000701
type sensor, which generates a square wave signal
Legend
pulse. Detecting the open span portion from the CKP
1. Fuel temperature (FT) sensor
sensor and one reference projection from the camshaft
position (CMP) sensor, the ECM determines cylinder
#1 compression TDC to ensure they correlate with
each other. The FT sensor is installed to the fuel supply pump. The
FT sensor is a variable resistor and it measures the
Engine Coolant Temperature (ECT) Sensor temperature of the fuel entering the fuel supply pump.
high. When the fuel temperature increases, the sensor
LNW71ASH002101

Intake Air Temperature (IAT) Sensor The MAF sensor is an air flow meter that measures the
amount of air that enters the engine. It is fitted between
the air cleaner and turbocharger. A small quantity of air
that enters the engine indicates deceleration or idle
speed. A large quantity of air that enters the engine
indicates acceleration or a high load condition. The
MAF sensor assembly consists of a MAF sensor
element and an intake air temperature (IAT) sensor that
are both exposed to the air flow to be measured. The
MAF sensor element measures the partial air mass
through a measurement duct on the sensor housing.
AAW46ESH001401
The IAT sensor is fitted between the air cleaner and

turbocharger. It is internal to the mass air flow (MAF)
sensor. The IAT sensor is a variable resistor and it
measures the temperature of the air entering the
engine. When the IAT sensor is cold, the sensor
detects a lower voltage on the signal circuit.
Mass Air Flow (MAF) Sensor
AAW46ESH001401

Fuel System Description
Pressure
Pressure sensor Fuel rail limiter valve
Fuel filter
Supply pump
Injectors
Fuel tank ECM
Various sensors
(accelerator position sensor, coolant temperature,
Camshaft Crankshaft mass air flow, etc.)
position position
sensor sensor
MFW76EMF000201
The common rail system uses a type of accumulator

chamber called the common rail (fuel rail) to store
pressurized fuel, and injectors that contain
electronically controlled solenoid valves to spray the
pressurized fuel in the combustion chambers. The
injection system (injection pressure, injection rate, and
injection timing) is controlled by the ECM, and therefore
the common rail system can be controlled
independently, free from the influence of engine speed
and load. This ensures a stable injection pressure at all
time, particularly in the low engine speed range, so that
black smoke specific to diesel engines generated
during vehicle starting or acceleration can be reduced
dramatically. As a result, exhaust gas emissions are
clear and reduced, and higher output is achieved.
1. High Pressure Control
• Enables high pressure injection from low engine
speed range.
• Optimizes control to minimize particulate matter
and NOx emissions.
2. Injection Timing Control
• Enables finely tuned optimized control in
accordance with running conditions.
3. Injection Rate Control
• Pre injection control that performs a small amount
of injection before main injection.
The common rail system consists primarily of a fuel
supply pump, fuel rail, injectors, and ECM.

Fuel System Component Description
Injector
6
64
00 2
0000
3
5
LNW76EMH000101
Legend
1. Terminal stud
2. Fuel leak off port
3. O-ring
4. Fuel inlet port
5. Injector parts number marking
6. QR plate
Electronic control type injectors controlled by the ECM

are used. Compared with conventional injection
nozzles, a command piston, solenoid valve, etc. are
added.
ID codes displaying various injector characteristic are
laser marked in the plate, and ID codes showing these
in numeric form (30 alphanumeric figures are displayed
and only 24 are used). This system uses fuel injector
flow rate information (ID codes) to optimize injection
quantity control. When an injector is newly installed in a
vehicle, it is necessary to input the ID codes in the
ECM.
QR codes or fuel injector flow rate (ID codes) have
been adopted to enhance the injection quantity
precision of the injectors. The adoption of codes
enables injection quantity dispersion control throughout
all pressure ranges, contributing to improvement in
combustion efficiency and reduction in exhaust gas
emissions.
Return port
Solenoid
Driving current Driving current Driving current
TWV
Outlet orifice From fuel rail

Control chamber
Inlet orifice
Pressure in Pressure in Pressure in

Command piston control chamber control chamber control chamber
Nozzle
Injection rate Injection rate
No injection Injection Injection end
RTW76EMF000601
1) Non-injection state
The two way valve (TWV) closes the outlet orifice by
means of a spring force, when no current is supplied
from the ECM to the solenoid. At this time, the fuel
pressure applied to the nozzle leading end is equal to
the fuel pressure applied to the control chamber
through the inlet orifice. As for the force competition in
this state, the pressure on the command piston upper
surface + nozzle spring force defeat the pressure on
the nozzle leading end, and consequently the nozzle is
pushed downward to close the injection holes.
2) Injection start
The TWV is pulled up to open the outlet orifice, and
thus the fuel leaks toward the return port, when the
current is supplied from the ECM to the solenoid. As a
result, the nozzle is pushed up together with the
command piston by the fuel pressure applied to the
nozzle leading end, and then the nozzle injection holes
open to inject the fuel.
3) Injection end
The TWV lowers to close the outlet orifice, when the
ECM shuts off a current supply to the solenoid. As a
result, the fuel cannot leak from the control chamber,
and thus the fuel pressure in the control chamber rises
abruptly and then the nozzle is pushed down by the
command piston to close the nozzle injection holes,
resulting in the end of fuel injection.

Fuel Supply Pump
Injector Fuel rail

Suction pressure
Delivery valve Suction valve Feed pressure
High pressure
Plunger
Return pressure
Return
FRP regulator
Fuel overflow
Regulation valve
Feed pump
Driveshaft Fuel inlet
Suction
Fuel filter
Fuel tank
Priming pump
MFW81AMF002401
The fuel supply pump is the heart of the common rail Fuel Rail (Common Rail)
type electronic fuel injection system. The fuel supply
pump is installed at the same location as the
conventional injection type pump, which spins at a 1 to
1 ratio of fuel supply pump to crankshaft speed. A fuel
rail pressure (FRP) regulator and fuel temperature
sensor are part of the fuel supply pump assembly.
Fuel is drawn from the fuel tank via the fuel supply 1
pump by the use of an internal feed pump (trochoid
type). This feed pump pumps fuel into a 3-plunger
chamber also internal to the fuel supply pump. Fuel into
this chamber is regulated by the FRP regulator solely
controlled by current supplied from the ECM. No
current to the solenoid results in maximum fuel flow
whereas full current to the solenoid produces no fuel 2
flow. As the engine spins, these three plungers produce
high pressure in the fuel rail. Since the ECM controls
the flow of fuel into this 3-plunger chamber, it therefore
controls the quantity and pressure of the fuel supply to
the fuel rail. This optimizes performance, improves MFW76ESH000401
economy and reduces NOx emissions. Legend

2. Fuel rail pressure (FRP) sensor

Along with the employment of a common rail type The pressure limiter relieves pressure by opening the
electronic control fuel injection system, the fuel rail is valve if abnormally high pressure is generated. The
provided to store high pressure fuel between supply valve opens when pressure in rail reaches
pump and injectors. A pressure sensor and a pressure approximately 220 MPa (32,000 psi), and closes when
limiter are installed on the fuel rail. The pressure sensor pressure falls to approximately 50 MPa (7,250 psi).
detects the fuel pressure inside the fuel rail and sends Fuel leakage through the pressure limiter re-turns to
its signal to the ECM. Based on this signal, the ECM the fuel tank.
controls the fuel pressure inside the fuel rail via the fuel
rail pressure (FRP) regulator of the supply pump. The Fuel Rail Pressure (FRP) Regulator
pressure limiter opens the valve mechanically to relieve
the pressure when the fuel pressure inside the fuel rail
is excessive.
2 1
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is installed to the fuel rail and it
detects the fuel pressure in the fuel rail, converts the
pressure into a voltage signal, and sends the signal to
the ECM. The ECM monitors the FRP sensor signal
voltage. Higher fuel rail pressure provides higher signal
voltage while lower pressure provides lower signal
voltage. The ECM calculates actual fuel rail pressure
(fuel pressure) from the voltage signal and uses the
result in fuel injection control and other control tasks.
Pressure Limiter Valve
MFW76ESH000701
Legend
1 2 3 4 5
The fuel rail pressure (FRP) regulator [also known as
suction control valve (SCV)] is attached to the fuel
supply pump.
6 7
The ECM controls the duty ratio of the linear type fuel
rail pressure (FRP) regulator (the length of time that the
current is applied to the FRP regulator), in order to
control the quantity of fuel that is supplied to the high-
pressure plungers. Since only the quantity of fuel that is
required for achieving the target rail pressure is drawn
in, the drive load of the supply pump is decreased.
When current flows to the FRP regulator, variable
LNW41ASH001301
electromotive force is created in accordance with the
Legend duty ratio, moving the solenoid plunger and changing
1. Valve the opening of the fuel passage and thus regulating the
2. Valve body fuel quantity. With the FRP regulator OFF, the return
3. Valve guide spring stretches, completely opening the fuel passage
4. Spring and supplying fuel to the plungers (Full quantity intake
5. Housing and full quantity discharge). By turning the FRP
6. Fuel rail regulator ON/ OFF, fuel is supplied in an amount
7. Fuel return pipe corresponding to the actuation duty ratio, and fuel is
discharged by the plungers.

Fuel Injection System Description
Fuel Injection Quantity Control
This control determines the fuel injection quantity by
adding coolant temperature, fuel temperature, intake
air temperature, barometric pressure, mass air flow and
some switch inputs information corrections to the basic
injection quantity is calculated by the ECM based on
the engine operating conditions (engine speed,
accelerator pedal pressing amount and boost pressure
sensor). More fuel rate indicates if the engine load is
increased as the accelerator pedal is stepped on at
constant engine speed.
Combined with high pressure injection of atomized fuel,
this control improves exhaust gas and ensures proper
fuel consumption. Compared with conventional
mechanical governors, an electronic control system
provides higher degree of freedom of fuel injection
quantity control, thereby presenting high accelerator
response (acceleration feeling and pressing feeling).
Starting Injection Quantity Control

At the engine starting (after the key switch is turned to
the START position to start the engine, up to return of
key switch to the ON position), optimum fuel injection
quantity is controlled based on the information on the
engine speed and coolant temperature. At low
temperature, the fuel injection quantity increases.
When the engine started completely, this boosted
quantity mode at the starting is cancelled and normal
running mode is restored.
Idle Speed Control

A control is made so as to achieve stable idling speed
at all time regardless of engine secular changes or
engine condition variations. The ECM sets target idling
speed and controls the fuel injection quantity according
to the engine conditions (actual engine speed, coolant
temperature and engine load) to follow actual engine
speed to the target idling speed so as to ensure stable
idling speed.
Idle Vibration Control

A control is made so as to reduce the engine vibration
caused by torque variations between cylinders due to
variations in fuel injection quantity of each cylinder or
injector performance. The ECM corrects the injection
quantity between cylinders based on the revolution
signals from the crankshaft position (CKP) sensor.
Normal range of correction quantity between cylinders
is within ± 5 mm3.

Exhaust Gas Recirculation (EGR) System Description
1
2
MFW76EMF000801
Legend
1. EGR cooler 4. ECM
2. Oil cooler & EGR cooler 5. MAF sensor
3. EGR valve 6. Intake throttle valve
The EGR system recirculates a part of exhaust gas

back into the intake manifold, which results in reducing
nitrogen oxide (NOx) emissions. The EGR control
system uses an electronic control system to ensure
both driveability and low emission. A control current
from the ECM operates a motor to control the lift
amount of EGR valve. Also, EGR position sensors are
provided at the rear of the motor to feed actual valve lift
amount back to the ECM for more precision control of
the EGR amount.
provided and the valve is driven accordingly.

EGR Valve Intake Throttle Valve
RTW56ESH001101
The intake throttle valve is located on the intake

manifold inlet. The ECM controls the intake throttle
valve opening based on the engine running condition.
The ECM controls the intake throttle valve by
controlling the motor. The motor is controlled based on
pulse width modulation (PWM) signal sent from the
ECM. A duty ratio change 0% to appropriate
percentage is intake throttle valve opening angle
MFW76EMH000101
control. To close the valve, duty ratio is increased. To
open the valve, duty ratio becomes small.
The EGR valve is mounted on the intake manifold. The The intake throttle valve position is detected by the
ECM controls the EGR valve opening based on the position sensor, and relayed to the ECM. The position
engine running condition. The ECM controls the EGR sensor provides a signal to the ECM on the signal
valve by controlling the motor. The motor is controlled circuit, which is relative to the position changes of the
based on pulse width modulation (PWM) signal sent intake throttle valve. The ECM should detect a low
from the ECM. The EGR valve position is detected by signal voltage at a small opening amount or closed
the position sensor, and relayed to the ECM. The position. The ECM should detect high signal voltage at
position sensor is made up three individual sensors a large opening amount.
within one housing. The EGR position sensor 1, 2 and
3 are hall element type sensors. The position sensor
provides a low or high signal state to the ECM on the
signal circuits, which is relative to the position changes
of the EGR valve.

Turbocharger Description The turbocharger is used to increase the amount of air
that enters the engine cylinders. This allows a
proportional increase of fuel to be injected into the
cylinders, resulting in higher power output, more
3 4
2 complete combustion, and decreasing temperature of
cylinder heads, pistons, valves, and exhaust gas. This
5 cooling effect helps engine life longer.
Heat energy and pressures in the exhaust gas are
1
utilized to drive the turbine. Exhaust gas is directed to
the turbine housing, and rotate the turbine wheel. Since
the compressor wheel is attached directly to the turbine
shaft, the compressor wheel rotates same speed as the
6 turbine wheel. Clean air from the air cleaner is drawn
into the compressor housing and wheel. The air is
compressed and flow through the intercooler, intake
manifold, and go into the cylinders.
MFW76ESH001201
Legend
1. Exhaust gas
2. Turbine wheel
3. Nozzle
4. Compressor wheel
3
5. Air cleaner
6. Charge air cooler
2
1
4
5
MFW76ESH001501
Legend
1. Rotary electric actuator (REA)
2. Close direction of nozzles
3. Open direction of nozzles
4. Control rod
5. Nozzle
The position of the turbocharger nozzle is controlled by

the rotary electric actuator (REA) control module based
on the command from the ECM. When the engine is
low load condition, the turbocharger nozzles are moved
to the open direction and boost pressure becomes low.
When the engine is high load condition, the REA
control module commands the control solenoid to close
the turbocharger nozzles, and boost pressure becomes
high. The ECM will vary the target boost pressure
dependent upon the requirements of the engine power
output.
The intercooler also helps the performance of the
engine. Pressurized air from the turbocharger have
higher temperature than intake air, and intercooler
cools the pressurized air. Cooling the intake air
temperature make the engine efficiency higher and
engine power higher.

Diesel Particulate Defuser (DPD) System Description
2 1
15
17
14
8 16
6 7 12
5
4
11 13
9 10
LNW81AMF000801
Legend
1. Air cleaner 10. DPD filter
2. Mass air flow (MAF) sensor 11. Exhaust throttle valve
3. Engine assembly 12. Exhaust throttle solenoid valve
4. Exhaust brake valve 13. Exhaust silencer
5. Exhaust brake solenoid valve 14. ECM
6. Exhaust temperature sensor 2 15. Other inputs
7. Exhaust temperature sensor 1 16. DPD regeneration switch
8. Exhaust differential pressure sensor 17. DPD lamps (green and amber)
9. Oxidation catalyst
4
1
2
3
MFW76ESF000201
Legend
2. Exhaust temperature sensor 2 (in front of 5. Exhaust throttle valve
oxidation catalyst) 6. DPD assembly
The DPD is a system that uses an oxidation catalyst to Exhaust Differential Pressure Sensor
clean the exhaust gas, and a filter to collect PM
discharged from the engine. When PM accumulated in
the filter, regeneration is performed. The ECM detects
the condition of PM accumulations from the exhaust
differential pressure sensor or from mileage. When it is
reached to a certain amount of PM accumulations or a
certain length of mileage, the automatic regeneration
starts. If the automatic regeneration cannot be
completed by some reason, the manual regeneration is
requested to the driver by blinking the DPD amber lamp
or “PUSH DPD SWITCH” indicator on the instrument
panel cluster. During regeneration, the temperature
inside the filter is raised, and the accumulated PM is
burned off. In order to adjust to optimized temperature,
the ECM detects exhaust temperature using the
exhaust temperature sensors, and then raises the
temperature by controlling fuel injections, the exhaust
brake valve and exhaust throttle valve to burn off the
accumulated PM. Once the regeneration starts, it must MFW4ADSH002301
be finished within a certain time. After regeneration is

finished, a purification of the filter is judged by The exhaust differential pressure sensor is attached to
monitoring the exhaust differential pressure. the chassis frame near the DPD assembly. The
exhaust differential pressure sensor is a transducer
that varies voltage according to changes of the exhaust
gas differential pressure between in front and in rear of
DPD filter. The exhaust differential pressure sensor
provides a signal to the ECM on the signal circuit,
which is relative to the differential pressure changes in
front and in rear of DPD filter. The ECM should detect a
low signal voltage at a low differential pressure, such
as small PM accumulation. The ECM should detect
high signal voltage at high differential pressure, such as
large PM accumulation.

MFW4ADSH002401
The exhaust temperature sensor 1 and 2 are installed

to the DPD housing. Both exhaust temperature sensors
have thermistor (negative temperature coefficient
resistor type). The sensor 1 measures the temperature
of the exhaust gas in front of DPD filter and the sensor
2 measures the temperature of the exhaust gas in front
of oxidation catalyst. While the sensor detects that the
exhaust temperature is low, the sensor resistance is
high. When the exhaust temperature increases, the
sensor resistance decreases. With high sensor
Exhaust Throttle Valve & Exhaust Brake Valve

The exhaust throttle valve is installed in rear of the DPD
housing and it composes a part of the exhaust system.
The ECM controls the exhaust throttle solenoid valve,
which supplies power to the exhaust throttle solenoid
valve based on the DPD system regeneration status.
The exhaust throttle solenoid valve energizes to apply
air pressure to the exhaust throttle valve.
The exhaust brake valve is installed in front of the DPD
housing and it also composes a part of the exhaust
system. The ECM controls the exhaust brake solenoid
valve based on the DPD regeneration status or exhaust
brake command signal. The exhaust brake solenoid
valve energizes to apply air pressure to the exhaust
brake valve.
Special Tools and Equipment

5-8840-2835-0 (J-35616-C)
Connector Test Adapter Kit
Adapter Harness
(With Test Lamp)
5884028350 ADAPTER-H
5-8840-2691-0
Digital Multimeter
5884026910
Tech2 Kit
AAW0Z0SH015701
THA-10
Tech2 DC24 Volt Adapter 2
ADAPTER2
CAN-di Module
CANDI
C Breaker Box
BREAKER
67015_MG6HKED-WE-1101AU_奥付 10.10.22 4:48 PM ページ 1

First Edition
WORKSHOP MANUAL
(6HK1 model)
0-XXXKI
67015_MG6HKED-WE-1101AU_奥付 10.10.22 4:48 PM ページ 2
2011MY
2011MY

WORKSHOP MANUAL

(6HK1 model)
2011MY
2011MY

WORKSHOP MANUAL

(4HK1 model)
Section Sub Section
1C Engine Cooling
1D Engine Fuel
1F Emission Control
1G Engine Exhaust
1J Induction
2B Front Suspension
2C Rear Suspension
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4D Parking Brake
5E Clutch
9C Entertainment
9D Wiring System
9F Body Structure
9G Cab
9H Seats
9L Cab Mounting
MG4HKED-WE-1101AU.book 1 ページ２０１０年１１月２５日　木曜日　午後１時５８分
ENGINE
(4HK1)
TABLE OF CONTENTS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-3 DTC P0336 (Flash Code 15). . . . . . . . . . . . . 1A-140
Temperature vs. Resistance . . . . . . . . . . . . . . . 1A-3 DTC P0340 (Flash Code 14). . . . . . . . . . . . . 1A-142
Altitude vs. Barometric Pressure. . . . . . . . . . . . 1A-4 DTC P0341 (Flash Code 14). . . . . . . . . . . . . 1A-145
Diagnostic Trouble Code (DTC) Type DTC P0380 (Flash Code 66). . . . . . . . . . . . . 1A-147
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5 DTC P0381 (Flash Code 67). . . . . . . . . . . . . 1A-149
Diagnostic Trouble Code (DTC) List . . . . . . . . . 1A-6 DTC P0401 (Flash Code 93). . . . . . . . . . . . . 1A-152
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0404 (Flash Code 45). . . . . . . . . . . . . 1A-155
Overview Wirings . . . . . . . . . . . . . . . . . . . . . . . 1A-9 DTC P0409 (Flash Code 44). . . . . . . . . . . . . 1A-158
Routing Diagrams . . . . . . . . . . . . . . . . . . . . . . . 1A-11 DTC P0426 (Flash Code 143). . . . . . . . . . . . 1A-161
Fuel System Routing Diagram . . . . . . . . . . . . 1A-11 DTC P0427 or P0428 (Flash Code 48) . . . . . 1A-163
Component Locator . . . . . . . . . . . . . . . . . . . . . . 1A-12 DTC P042B (Flash Code 145) . . . . . . . . . . . 1A-168
Engine Controls Component Views . . . . . . . . 1A-12 DTC P042C or P042D (Flash Code 49) . . . . 1A-170
Engine Control Module (ECM) Connector DTC P0477 or P0478 (Flash Code 46) . . . . . 1A-175
End Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-18 DTC P0500 (Flash Code 25). . . . . . . . . . . . . 1A-178
Engine Control Connector End Views. . . . . . . 1A-20 DTC P0502 or P0503 (Flash Code 25) . . . . . 1A-180
Diagnostic Information and Procedures . . . . . . . 1A-31 DTC P0560 (Flash Code 155). . . . . . . . . . . . 1A-185
Engine Control System Check Sheet . . . . . . . 1A-31 DTC P0563 (Flash Code 35). . . . . . . . . . . . . 1A-188
Diagnostic Starting Point - Engine Controls . . 1A-32 DTC P0571 (Flash Code 26). . . . . . . . . . . . . 1A-189
Diagnostic System Check - Engine Controls . 1A-33 DTC P0601 (Flash Code 53). . . . . . . . . . . . . 1A-192
Scan Tool Data List . . . . . . . . . . . . . . . . . . . . . 1A-36 DTC P0602 (Flash Code 154). . . . . . . . . . . . 1A-193
Scan Tool Data Definitions . . . . . . . . . . . . . . . 1A-40 DTC P0604, P0606 or P060B
Scan Tool Output Controls . . . . . . . . . . . . . . . 1A-46 (Flash Code 153, 51 or 36) . . . . . . . . . . . . . . 1A-195
Scan Tool Does Not Power Up . . . . . . . . . . . . 1A-47 DTC P0633 (Flash Code 176). . . . . . . . . . . . 1A-196
Scan Tool Does Not Communicate with DTC P0638 (Flash Code 61). . . . . . . . . . . . . 1A-197
CAN Device. . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-48 DTC P0641 (Flash Code 55). . . . . . . . . . . . . 1A-200
Engine Cranks but Does Not Run . . . . . . . . . . 1A-51 DTC P0650 (Flash Code 77). . . . . . . . . . . . . 1A-203
DTC P0045 (Flash Code 33). . . . . . . . . . . . . . 1A-56 DTC P0685 or P0687 (Flash Code 416) . . . . 1A-209
DTC P0089 (Flash Code 151). . . . . . . . . . . . . 1A-73 DTC P1261 or P1262 (Flash Code 34) . . . . . 1A-222
DTC P0091 or P0092 (Flash Code 247) . . . . . 1A-76 DTC P1404 (Flash Code 45). . . . . . . . . . . . . 1A-223
DTC P0101 (Flash Code 92). . . . . . . . . . . . . . 1A-85 DTC P1471 (Flash Code 149). . . . . . . . . . . . 1A-227
DTC P0102 or P0103 (Flash Code 91) . . . . . . 1A-88 DTC P161B (Flash Code 179) . . . . . . . . . . . 1A-230
DTC P0116 (Flash Code 23) . . . . . . . . . . . . . . 1A-96 DTC P1664 (Flash Code 76). . . . . . . . . . . . . 1A-232
DTC P0122 or P0123 (Flash Code 43) . . . . . 1A-102 DTC P2002 (Flash Code 127). . . . . . . . . . . . 1A-240
DTC P0201, P0202, P0203 or P0204 DTC P2138 (Flash Code 124). . . . . . . . . . . . 1A-251
(Flash Code 271, 272, 273 or 274) . . . . . . . . 1A-114 DTC P2146 or P2149
DTC P0217 (Flash Code 542). . . . . . . . . . . . 1A-123 (Flash Code 158 or 159) . . . . . . . . . . . . . . . . 1A-253
DTC P0219 (Flash Code 543). . . . . . . . . . . . 1A-125 DTC P215A (Flash Code 25) . . . . . . . . . . . . 1A-258
DTC P0299 (Flash Code 65). . . . . . . . . . . . . 1A-134 DTC P242F (Flash Code 131) . . . . . . . . . . . 1A-267

DTC P2454 or P2455 (Flash Code 47) . . . . . 1A-272
DTC P2456 (Flash Code 47). . . . . . . . . . . . . 1A-277
DTC P2458 (Flash Code 139). . . . . . . . . . . . 1A-279
DTC U0073 (Flash Code 84) . . . . . . . . . . . . 1A-289
DTC U0101 (Flash Code 85) . . . . . . . . . . . . 1A-292
DTC U0110 (Flash Code 87). . . . . . . . . . . . . 1A-294
DTC U0167 (Flash Code 177) . . . . . . . . . . . 1A-296
EGR Control System Check . . . . . . . . . . . . . 1A-297
Glow Control System Check . . . . . . . . . . . . . 1A-301
Exhaust Brake Control System Check . . . . . 1A-304
Cruise Control System Check . . . . . . . . . . . . 1A-310
Control System Check . . . . . . . . . . . . . . . . . 1A-315
Symptoms - Engine Controls . . . . . . . . . . . . . . 1A-321
Symptoms - Engine Controls . . . . . . . . . . . . 1A-321
Intermittent Conditions . . . . . . . . . . . . . . . . . 1A-323
Hard Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-326
Rough, Unstable, or Incorrect
Idle and Stalling. . . . . . . . . . . . . . . . . . . . . . . 1A-328
High Idle Speed. . . . . . . . . . . . . . . . . . . . . . . 1A-330
Cuts Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-331
Surges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-332
Lack of Power, Sluggishness or Sponginess 1A-334
Hesitation, Sag or Stumble . . . . . . . . . . . . . . 1A-336
Abnormal Combustion Noise . . . . . . . . . . . . 1A-338
Poor Fuel Economy. . . . . . . . . . . . . . . . . . . . 1A-339
Excessive Smoke (Black Smoke) . . . . . . . . . 1A-341
Excessive Smoke (White Smoke) . . . . . . . . . 1A-343
DPD System Manual Regeneration
Frequently . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-345
DPD System Regeneration Long Time . . . . . 1A-347
Repair Instructions . . . . . . . . . . . . . . . . . . . . . . 1A-349
Engine Control Module (ECM) Replacement 1A-349
Description . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-351
(Remote Procedure) . . . . . . . . . . . . . . . . . . . 1A-351
(Pass-Thru Procedure) . . . . . . . . . . . . . . . . . 1A-353
Description and Operation . . . . . . . . . . . . . . . . 1A-354
Engine Control Module (ECM) Description . . 1A-354
Engine Control Component Description . . . . 1A-357
Fuel System Description . . . . . . . . . . . . . . . . 1A-361
Fuel System Component Description . . . . . . 1A-362
Fuel Injection System Description. . . . . . . . . 1A-366
Exhaust Gas Recirculation (EGR)
Turbocharger Description . . . . . . . . . . . . . . . 1A-367
Special Tools and Equipment . . . . . . . . . . . . . . 1A-372
Special Tools and Equipment . . . . . . . . . . . . 1A-372
Specifications
Temperature vs. Resistance °C °F Ohms
Engine Coolant Temperature vs. Resistance Temperature vs. Resistance Value (Approximately)
°C °F Ohms 150 302 13900
Temperature vs. Resistance Value (Approximately) 100 212 33600
120 248 115 50 122 106000
110 230 150
Fuel Temperature vs. Resistance
100 212 190
°C °F Ohms
90 194 240
80 176 320
110 230 140
70 158 430
100 212 180
60 140 590
90 194 240
50 122 810
80 176 310
40 104 1150
70 158 420
30 86 1660
60 140 580
20 68 2450
50 122 810
10 50 3700
40 104 1150
0 32 5800
30 86 1660
-10 14 9300
20 68 2450
-20 -4 15480
10 50 3700
-30 -22 26700
0 32 5740
Exhaust Temperature vs. Resistance -10 14 9160
°C °F Ohms -20 -4 15000
Temperature vs. Resistance Value (Approximately) -30 -22 25400
1000 1832 120
Intake Air Temperature vs. Resistance
950 1742 135
°C °F Ohms
900 1652 155
850 1562 180
100 212 190
800 1472 205
90 194 240
750 1382 240
80 176 320
700 1292 290
70 158 430
650 1202 345
60 140 590
600 1112 425
50 122 810
550 1022 530
40 104 1150
500 932 675
30 86 1650
450 842 885
20 68 2430
400 752 1200
10 50 3660
350 662 1710
0 32 5650
300 572 2580
-10 14 8970
250 482 4300
-20 -4 14700
200 392 6900

Altitude vs. Barometric Pressure
Barometric
Altitude Measured Altitude Measured Pressure
in Meters (m) in Feet (ft) Measured in
Kilopascals (kPa)
Determine your altitude by contacting a local weather
station or by using another reference source.
4267 14000 56-64
3962 13000 58-66
3658 12000 61-69
3353 11000 64-72
3048 10000 66-74
2743 9000 69-77
2438 8000 71-79
2134 7000 74-82
1829 6000 77-85
1524 5000 80-88
1219 4000 83-91
914 3000 87-95
610 2000 90-98
305 1000 94-102
0 0 Sea Level 96-104
-305 -1000 101-105

Diagnostic Trouble Code (DTC) Type Definitions
Emission Related DTC • The ECM records the operating conditions at the
Action Taken When the DTC Sets - Type A time the diagnostic fails. The ECM stores this
• The ECM illuminates the malfunction indicator
lamp (MIL) when the diagnostic runs and fails. Conditions for Clearing the DTC - Type D
• The ECM records the operating conditions at the • A current DTC clears when the diagnostic runs and
time the diagnostic fails. The ECM stores this passes.
information in the Freeze Frame/ Failure Records.
Action Taken When the DTC Sets - Type B cycles, if no failures are reported.
• Use a scan tool to clear the DTC.
and fails.
time the diagnostic fails. The first time the
diagnostic fails, the ECM stores this information in
the Failure Records. If the diagnostic reports a
failure on the second consecutive driving cycle, the
ECM records the operating conditions at the time
of failure and stores this information in the Freeze
Frame and updates the Failure Records.
Conditions for Clearing the MIL/ DTC - Type A or

Type B
• The ECM turns OFF the MIL after 3 consecutive
driving cycles when the diagnostic runs and does
not fail.
passes.
• Use a scan tool to clear the MIL and the DTC.
Non-Emissions Related DTCs

Action Taken When the DTC Sets - Type C
• The ECM illuminates the Service Vehicle Soon
(SVS) lamp when the diagnostic runs and fails.
time the diagnostic fails. The ECM stores this
Conditions for Clearing the SVS Lamp/ DTC - Type

C
• The ECM turns OFF the SVS lamp after 1 driving
cycle when the diagnostic runs and does not fail.
passes.
• Use a scan tool to clear the SVS lamp and the
DTC.
Action Taken When the DTC Sets - Type D



P0016 16 A Crankshaft Position - Camshaft Position Correlation
P0045 33 A Turbocharger Boost Control Solenoid Circuit
P0079 38 A Exhaust Valve Control Solenoid Circuit Low
P0080 38 A Exhaust Valve Control Solenoid Circuit High
P0087 225 B Fuel Rail/ System Pressure Too Low
P0088 118 A Fuel Rail/ System Pressure Too High
P0089 151 B Fuel Pressure Regulator Performance
P0091 247 A Fuel Pressure Regulator Control Circuit Low
P0092 247 A Fuel Pressure Regulator Control Circuit High
P0093 227 B Fuel System Leak Detected
P0101 92 B Mass Air Flow Sensor Circuit Range/ Performance
P0102 91 A Mass Air Flow Sensor Circuit Low Input
P0103 91 A Mass Air Flow Sensor Circuit High Input
P0112 22 A Intake Air Temperature Sensor Circuit Low
P0113 22 A Intake Air Temperature Sensor Circuit High
P0116 23 B Engine Coolant Temperature Sensor Circuit Range/ Performance
P0117 23 A Engine Coolant Temperature Sensor Circuit Low
P0118 23 A Engine Coolant Temperature Sensor Circuit High
P0122 43 A Throttle Position Sensor Circuit Low
P0123 43 A Throttle Position Sensor Circuit High
P0182 211 A Fuel Temperature Sensor Circuit Low
P0183 211 A Fuel Temperature Sensor Circuit High
P0192 245 A Fuel Rail Pressure Sensor Circuit Low
P0193 245 A Fuel Rail Pressure Sensor Circuit High
P0217 542 D Engine Coolant Over Temperature Condition
P0219 543 D Engine Overspeed Condition
P0234 42 A Turbocharger Overboost Condition
P0237 32 A Turbo Charger Boost Sensor Circuit Low
P0238 32 A Turbo Charger Boost Sensor Circuit High
P0299 65 B Turbocharger Underboost
P0335 15 A Crankshaft Position Sensor Circuit
P0336 15 A Crankshaft Position Sensor Circuit Range/ Performance
P0340 14 A Camshaft Position Sensor Circuit
P0341 14 A Camshaft Position Sensor Circuit Range/ Performance
P0380 66 C Glow Plug Circuit

P0381 67 C Glow Plug Indicator Circuit
P0401 93 A EGR Flow Insufficient Detected
P0404 45 A EGR Control Circuit Range/ Performance
P0409 44 A EGR Sensor Circuit
P0426 143 C Catalyst Temperature Sensor Circuit Range/ Performance Sensor 1
P0427 48 A Catalyst Temperature Sensor Circuit Low Sensor 1
P0428 48 A Catalyst Temperature Sensor Circuit High Sensor 1
P042B 145 C Catalyst Temperature Sensor Circuit Range/ Performance Sensor 2
P042C 49 C Catalyst Temperature Sensor Circuit Low Sensor 2
P042D 49 C Catalyst Temperature Sensor Circuit High Sensor 2
P0477 46 A Exhaust Pressure Control Valve Low
P0478 46 A Exhaust Pressure Control Valve High
P0500 25 A Vehicle Speed Sensor
P0502 25 A Vehicle Speed Sensor Circuit Low Input
P0503 25 A Vehicle Speed Sensor Circuit High Input
P0560 155 A System Voltage
P0563 35 C System Voltage High
P0571 26 C Brake Switch Circuit
P0601 53 A Internal Control Module Memory Check Sum Error
P0602 154 C Control Module Programming Error
P0604 153 A Internal Control Module RAM Error
P0606 51 A ECM Processor
P060B 36 A Internal Control Module A/D Processing Performance
P0633 176 D Immobilizer not programmed
P0638 61 A Throttle Actuator Control Range/ Performance
P0650 77 A Malfunction Indicator Lamp (MIL) Control Circuit
P0685 416 C ECM Power Relay Control Circuit Open
P0687 416 C ECM Power Relay Control Circuit High
P0700 185 A Transmission Control System Emissions Related Malfunction
P1093 227 B Fuel Rail Pressure Too Low
P1404 45 A EGR Position Fault (Closed Position Error)
P1404 45 A EGR Position Fault (Learned Position Error)
P1455 132 A PM Over Accumulation
P1471 149 A DPD Insufficient Regeneration
P161B 179 D Immobilizer wrong response
P1621 54 A Control Module Long Term Memory Performance

P1664 76 C Service Vehicle Soon Lamp Control Circuit
P1669 75 C DPD Lamp Control Circuit
P2002 127 A Particulate Trap Efficiency Below Threshold
P2138 124 A Pedal Position Sensor 1-2 Voltage Correlation
P215A 25 A Vehicle Speed - Wheel Speed Correlation
P2227 71 B Barometric Pressure Sensor Circuit Range/ Performance
P2228 71 A Barometric Pressure Sensor Circuit Low
P2229 71 A Barometric Pressure Sensor Circuit High
P242F 131 A DPD Restriction
P2453 141 A DPD Differential Pressure Sensor Circuit Range/ Performance
P2454 47 A DPD Differential Pressure Sensor Circuit Low
P2455 47 A DPD Differential Pressure Sensor Circuit High
P2456 47 A DPD Differential Pressure Sensor Learned Position
P2458 139 A DPD Regeneration Duration
P253A 28 C PTO Sense Circuit
P256A 31 C Engine Idle Speed Selector Sensor
U0073 84 B Control Module Communication Bus Off
U0101 85 A Lost Communication with TCM
U0110 87 A Lost Communication with VNT System
U0167 177 D Lost Communication With Vehicle Immobilizer Control Module
Overview Wirings
Overview Wirings
1/2
Cruise control switch

(Combination switch)
Cruise resume/accel. switch 65
Cruise set/coast switch
42
PTO throttle sensor 70
41 A
Idle up sensor 66 24 Ignition switch(on)
Ignition switch (start)
46
21 Key position
Main relay
Accelerator pedal position sensor 1 63 40
2
61 5 Dropping
Accelerator pedal position sensor 2 64 resistor C
60 35
Battery 24V
39 B
BARO sensor 71 81 Case ground
43 Signal ground
23 62 Signal ground
69 Power ground
Mass air flow sensor 1
22 3 Power ground
4 Power ground
Intake air temperature sensor 72
MIL A
6
7 Exhaust brake lamp
17 SVS lamp
80 11 Glow plug lamp
67
79
ECM 9 DPD lamp
73 Oil pressure lamp
16
Exhaust temperature sensor 2 74 Oil pressure switch
Vehicle speed sensor 19
Speed sensor C/U Glow relay
10
C
25 Glow plug
47
Clutch pedal switch
26
Exhaust brake switch Starter cut relay B
A 45 14
Starter relay
15
Heater & A/C Refrigerant Exhaust brake solenoid valve
relay pressure switch
34
C A/C unit
8 Tachograph
A/C switch
Condenser
fan relay
Neutral switch
1 2 3 4 5 6 7 8
50
9 10 11 12 13 14 15 16
48 52
Parking brake switch 18
A PTO switch 44 37
Oil level switch

53 EHCU TCM IP cluster BCM VNT C/U Air sus C/U
55
Brake switch 2
Stop light relay
A 54
Brake switch 1
MFWB1AXF000301

2/2
1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
95
Crank shaft position sensor
107
58
109 Immobilizer
control unit
108 (ICU)
78
Boost pressure sensor 91 Transmission

CAN resistor
control module
ECM (TCM)

85
84 112 M+
Engine coolant temperature sensor
M Intake throttle
M-
104
Fuel temperature sensor 83
121
119
117
116
U 111 Cylinder #3
Fuel injector 2
M V 120
EGR motor 103 Cylinder #2
W Fuel injector 4
110 118
U 105
94 Fuel rail pressure regulator
V 113
EGR position sensor 93
W 89
99
97
102 B
87
Camshaft position sensor
98
101
100
Ground
68
82
Fuel rail pressure sensor
90
MFWA1AXF000201
Routing Diagrams
Fuel System Routing Diagram
2 5
3
1
11
9
8
7 6
10
MFW81AMF002601
Legend
1. Fuel rail 7. Fuel filter (with water separator)
2. Fuel rail pressure (FRP) sensor 8. Recirculation valve (with a built in fuel filter)
3. Leak off pipe 9. Fuel supply pump
4. Engine control module (ECM) 10. Fuel temperature (FT) sensor
5. Fuel injector 11. Fuel rail pressure (FRP) regulator
6. Fuel tank
Component Locator
Engine Controls Component Views
MFW81ASF000701
Legend
1. Speed sensor control unit 3. Barometric pressure (BARO) sensor
LNW81ASF001901
Legend
MFWB1ASF000201
Legend
1. Camshaft position (CMP) sensor 2. Variable nozzle turbocharger (VNT) actuator & sensor
1 2
MFWB1ASF000301
Legend
1. Engine coolant temperature (ECT) sensor 3. Intake throttle valve
2. Exhaust gas recirculation (EGR) valve
1 2 3
MFWB1ASF000401
Legend
1. Fuel temperature (FT) sensor 4. Crankshaft position (CKP) sensor
2. Pressure limiter valve 5. Fuel rail pressure (FRP) regulator
1
2
LNW76ESF001601
Legend
4
1
2
3
MFW76ESF000201
Legend
2. Exhaust temperature sensor 2 (in front of oxidation 5. Exhaust throttle valve
catalyst) 6. DPD assembly
MFWA1ASF000101
Legend
1. Mass air flow (MAF) sensor/ intake air temperature
(IAT) sensor
MFW76ESF000701
Legend
1. Sensor cover 2. Vehicle speed sensor (VSS)
MFWB1ASF000501
Legend
1. CAN resistor
MFW71AMF000801
Legend
1. Dropping resistor 2. Engine control module (ECM)
MFW71ASF000601
Legend
1. Variable nozzle turbocharger (VNT) control module

Engine Control Module (ECM) Connector Connector No. FB24
End Views Connector color Black
Engine Control Module (ECM)
20 – Not used
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 4 24 BLK/ BLU Ignition voltage
25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43
3 25 RED/ WHT Cruise control main switch signal
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 2 1
Clutch pedal switch signal
26 WHT/ BLU
27 – Not used
28 – Not used
29 – Not used
30 – Not used
LNW76ESH001501
31 – Not used
32 – Not used
Connector No. FB24
33 – Not used
34 BRN/ YEL A/C signal
35 GRN Dropping resistor
36 – Not used
2 WHT/ RED Battery voltage
38 – Not used
APP sensor 1, APP sensor 2,
PTO throttle sensor, idle up
39 GRY
5 WHT/ RED Battery voltage sensor and BARO sensor shield
ground
6 YEL/ BLK MIL control
7 BRN/ GRN Exhaust brake lamp control
APP sensor 1, idle up sensor,
8 LT GRN Engine speed signal output
41 BLK cruise control switch and PTO
LT GRN/ throttle sensor low reference
9 DPD amber lamp control
BLK
APP sensor 1, idle up sensor and
10 WHT/ GRN Glow relay control 42 WHT PTO throttle sensor 5 volts
reference
11 ORN/ BLU Glow plug lamp control
43 BLK/ YEL ECM signal ground
12 – Not used
44 VIO/ WHT PTO switch signal
13 – Not used
LT GRN/
14 BLK/ RED Starter cut relay control 45 Exhaust brake switch signal
RED
Exhaust brake solenoid valve 46 BLK/ WHT Ignition switch signal
15 GRN/ RED
control
47 RED/ GRN DPD regeneration switch signal
16 BLU/ YEL Engine oil level lamp control
48 YEL Parking brake switch signal
17 BLU/ BLK SVS lamp control
49 – Not used
18 BLU/ WHT CAN high signal
50 BLK/ GRN Neutral switch signal
Vehicle speed signal from speed
19 YEL/ GRN 51 – Not used
sensor control unit
Connector No. FB24

52 GRY/ WHT Diagnostic request switch
53 VIO/ YEL Engine oil level switch signal 121 120 119 113 112 111 110 109 108 107 106
105 104 103 102 101 100 99 98
54 GRN/ BLK Brake switch 1 signal 118 117
97 96 95 94 93 92 91 90
55 GRN/ ORN Brake switch 2 signal 116 115 114 89 88 87 86 85 84 83 82
56 – Not used
57 – Not used
58 GRN/ WHT CAN high signal
59 – Not used
APP sensor 2, BARO sensor and LNW76ESH001601
60 BLU
IAT sensor low reference
APP sensor 2 and BARO sensor
61 GRN Connector No. E26
5 volts reference
62 BLK/ YEL ECM signal ground Connector color Black
63 RED APP sensor 1 signal Test adapter No. J-35616-64A
64 YEL APP sensor 2 signal Pin No. Wire color Pin function
65 BRN/ BLU Cruise control switch signal 82 BLU/ GRN FRP sensor signal
66 YEL/ BRN Idle up sensor signal 83 RED/ GRN FT sensor signal
Exhaust differential pressure 84 RED/ BLK ECT sensor signal

67 RED
sensor signal Intake throttle position sensor
85 GRN/ YEL
68 BLK/ YEL Ground signal
69 WHT/ BLK MAF sensor signal 86 – Not used
70 RED PTO throttle sensor signal CMP sensor, FRP sensor and
87 BLU/ WHT EGR position sensor 5 volts
71 WHT/ RED BARO sensor signal reference
72 GRN/ WHT IAT sensor signal 88 – Not used
Exhaust temperature sensor 1 89 BLU FRP regulator low side
73 YEL/ RED
signal
90 BLU/ GRN FRP sensor signal
74 RED/ YEL 91 RED Boost pressure sensor signal
signal
76 – Not used 93 GRN/ ORN EGR position sensor signal 2
77 – Not used 94 YEL EGR position sensor signal 1
78 GRN CAN low signal CKP sensor, intake throttle

95 WHT position sensor and boost
Exhaust differential pressure pressure sensor 5 volts reference
sensor, exhaust temperature
79 BLK sensor 1 and exhaust 96 – Not used
temperature sensor 2 low 97 BLU FRP regulator low side
reference
LT GRN/
Exhaust differential pressure 98 CMP sensor signal
80 WHT RED
sensor 5 volts reference
99 PNK/ BLK EGR position sensor signal 3
81 BLK/ YEL ECM case ground
CMP sensor and FRP sensor
100 BLK
shield ground
Connector No. E26 Engine Control Connector End Views

Connector color Black Accelerator Pedal Position (APP) Sensor
101 BLK EGR position sensor low
reference
102 GRN/ ORN
control
LT GRN/ 1 2 3
103 EGR motor control 2 (PWM)
RED
Intake throttle motor low side
4 5 6
104 WHT/ GRN
(PWM)
105 WHT/ RED
(PWM)
106 – Not used
107 WHT/ RED CKP sensor signal
RTW76ESH001201
CKP sensor and boost pressure
108 BLK
sensor shield ground
CKP sensor, intake throttle Connector No. FL1
position sensor, FT sensor, ECT
109 BLK Connector color Gray
sensor and boost pressure
sensor low reference Test adapter No. J-35616-33
110 GRN EGR motor control 3 (PWM) Pin No. Wire color Pin function
111 BLK/ ORN EGR motor control 1 (PWM) APP sensor 2
1 GRN
5 volts reference
112 RED Intake throttle motor drive voltage
2 YEL APP sensor 2 signal
113 WHT/ RED
(PWM) 3 BLU APP sensor 2 low reference
114 – Not used APP sensor 1
4 WHT
5 volts reference
115 – Not used
5 RED APP sensor 1 signal
Common 2 (cylinder #2 and #3)
116 RED
fuel injector charge voltage 6 BLK APP sensor 1 low reference
117 BLK Cylinder #4 fuel injector control
Barometric Pressure (BARO) Sensor
118 BLU Cylinder #2 fuel injector control
119 GRN/ WHT Cylinder #1 fuel injector control
120 WHT/ YEL Cylinder #3 fuel injector control
Common 1 (cylinder #1 and #4)
121 WHT
fuel injector charge voltage
1 2 3
RTW76ESH000901

Brake Switch 1
Connector No. FL52
1 BLU Sensor low reference
3 GRN Sensor 5 volts reference
1 2
MFW81ASH001001
Connector No. FU159

123 Connector color Black
1 GRN/ BLK Switch signal
2 BLK Switch ground
LNW46ESH001501 Brake Switch 2
Connector No. E54

1 RED Sensor signal
1 2
MFW81ASH001001
Connector No. FB5

1 GRN/ ORN Switch signal
Connector No. FB5

Connector color Black Connector No. E48
Test adapter No. J-35616-42 Connector color Black
Pin No. Wire color Pin function Test adapter No. J-35616-33
2 BLK/ YEL Switch ground Pin No. Wire color Pin function
LT GRN/
1 Sensor signal
Clutch Pedal Switch RED
3 BLU/ WHT Sensor 5 volts reference
Crankshaft Position (CKP) Sensor
1
2
1 2 3
LNW46ESH000801
Connector No. FU179

RTW76ESH000701
Connector No. E50
1 BLK/ ORN Ignition voltage feed
2 WHT/ BLU Switch signal
Camshaft Position (CMP) Sensor Pin No. Wire color Pin function
1 2 3
RTW76ESH000701

Cruise Control Main Switch Data Link Connector (DLC)
1 2 3 4 5 6 7 8
1 2 3 4
5 6 7 8 9 10 9 10 11 12 13 14 15 16
LNW76ESH004201 LNW81ASH001401
Connector No. FU208 Connector No. FU23

Connector color Brown Connector color Light blue
2 – Not used LT GRN/ Class 2 serial data (EHCU [ABS
2
RED module])
3 BLK/ ORN
ignition voltage feed 3 – Not used
4 RED/ WHT Cruise control main switch signal 4 BLK Ground
5 – Not used 5 BLK Ground
6 – Not used 6 GRN/ WHT CAN high
7 BLK Illumination lamp ground Keyword serial data (air
suspension control unit, SRS
LT GRN/ 7 LT BLU
8 Illumination lamp voltage feed control unit, ICU, BCM and IP
RED
cluster)
9 – Not used
Class 2 serial data (ABS control
8 PNK
10 – Not used unit)
Keyword serial data (HSA control
9 RED/ WHT
unit)
10 – Not used
11 – Not used
Diagnostic request switch (ECM,
12 GRY/ WHT air suspension control unit, SRS
control unit and IP cluster)
LT GRN/ Diagnostic request switch (EHCU
BLU [ABS module])
13
Diagnostic request switch (ABS
WHT/ VIO
control unit)
14 GRN CAN low
15 – Not used
16 RED Battery voltage

DPD Regeneration Switch EGR Valve
1 2 3 4 1 2 3 4
5 6 7 8 9 10 5 6 7 8
LNW76ESH004201 RTW76ESH002801
Connector No. FU142 Connector No. E45

Connector color Blue Connector color Black
1 BLK/ ORN Switch voltage feed 1 BLU/ WHT Position sensor 5 volts reference
2 RED/ GRN Switch signal 2 PNK/ BLK Position sensor signal 3
3 – Not used 3 GRN/ ORN Position sensor signal 2
4 – Not used 4 YEL Position sensor signal 1
5 – Not used 5 BLK Position sensor low reference
6 – Not used 6 GRN Motor control 3
7 BLK Illumination lamp ground LT GRN/
7 Motor control 2
RED
LT GRN/
8 Illumination lamp voltage feed
RED 8 BLK/ ORN Motor control 1
9 – Not used
Engine Coolant Temperature (ECT) Sensor
10 – Not used
1 2
LNW46ESH001201

Connector No. E55
1 RED/ BLK Sensor signal
Exhaust Brake Solenoid Valve 1 2 3
RTW76ESH001301

2 RED Sensor signal
LNW66ESH001101
Connector No. FB41 Exhaust Temperature Sensor 1

2 GRN/ RED Solenoid valve control
2 1
RTW76ESH001601

Exhaust Throttle Solenoid Valve
Connector No. FB67
Connector color Light gray
2 YEL/ RED Sensor signal
Exhaust Temperature Sensor 2 1 2
LNW66ESH001101

1 GRN/ BLK Battery voltage feed
2 GRN/ ORN Solenoid valve ground
RTW76ESH000301
Fuel Injector #1 to #4 Cylinder

Connector No. FB68
Connector color Dark gray
Pin No. Wire color Pin function 3 2 1
2 RED/ YEL Sensor signal
LNW46ESH001001
E71, E72,
Connector No.
E73 and E74
1 #1 and #4: WHT
Charge voltage
2 #2 and #3: RED
E71, E72, Fuel Rail Pressure (FRP) Sensor

Connector No.
E73 and E74
#1: GRN
#2: BLU
3 Fuel injector control
#3: YEL
#4: BLK

123
LNW46ESH001501
1 2
Connector No. E49
LNW46ESH001101
2 BLU/ GRN Sensor signal
3 BLU/ WHT Sensor 5 volts reference
Connector No. E47
Regulator control high side
1 WHT/ RED
(PWM)
2 BLU Regulator low side
1 2
LNW46ESH001201
Connector No. E30 Connector No. J14, FB128 or FB196

Connector color Gray Connector color Black
1 BLK Sensor low reference 1 RED MAF sensor 12 volts reference
2 RED/ GRN Sensor signal 2 BLK MAF sensor low reference
3 WHT/ BLK MAF sensor signal
Glow Plug
4 GRN/ WHT IAT sensor signal
5 BLU IAT sensor low reference
1 2 3 4 5 6
LNW46ESH000701
Connector No. E31

Connector color – RTW76ESH000401

1 BLK/ WHT Power Supply Connector No. E46
Mass Air Flow (MAF)/ Intake Air Temperature (IAT)
Sensor
1 WHT/ GRN Motor control low side (PWM)
2 RED Motor drive voltage
3 – Not used
5 WHT Position sensor 5 volts reference
6 GRN/ YEL Position sensor signal
1 2 3 4 5
LNW46ESH001801

Idle Up Sensor
Connector No. FB129
2 RED Sensor signal
1 2 3
Variable Nozzle Turbocharger (VNT) Control
Module
LNW46ESH002601
Connector No. FL33

1 2 3 4
Connector color White 5 6 7 8
Test adapter No. J-35616-33 9 10 11 12
13 14 15 16
1 BLU/ RED Sensor low reference
2 YEL/ BRN Sensor signal
3 BLU Sensor 5 volts reference
LNW76ESH004101
PTO Throttle Sensor
Connector No. E9
1 BLU Position sensor signal 1
2 BLU/ WHT Position sensor signal 2
1 2 3
3 BRN Position sensor signal 3
5 BLK Position sensor shield ground
6 – Not used
7 – Not used
8 BRN Position sensor reference voltage
LNW81ASH001601
9 – Not used
10 VIO/ WHT VNT solenoid control 1
11 LT GRN VNT solenoid control 2
12 YEL VNT solenoid control 3
14 BLK Ground
Connector No. E9 Vehicle Speed Sensor (VSS)

15 BLU/ WHT CAN high signal
Variable Nozzle Turbocharger (VNT) Actuator &

Sensor 1 2 3
RTW76ESH000701
1 2 3 4
5 6 7 8 Connector No. J117 or FB156
1 GRN Ignition voltage feed
LNW76ESH002301
3 GRY Sensor signal
Connector No. E3
1 BRN Position sensor reference voltage
2 BRN Position sensor signal 3
3 BLU/ WHT Position sensor signal 2
4 BLU Position sensor signal 1
6 YEL Solenoid control 3
7 LT GRN Solenoid control 2
8 VIO/ WHT Solenoid control 1
Diagnostic Information and Procedures

Engine Control System Check Sheet
ENGINE CONTROL SYSTEM CHECK SHEET Inspectors Name

Customers Name Model & Model Year
Drivers Name Chassis No.
Date Vehicle Brought In Engine No.
License No. Odometer Reading km
Engine Does Engine does not crank No initial combustion No complete combustion
Not Run
Hard Start Engine cranks slowly Other ( )
Abnormal idling speed High idling speed ( RPM) Low idling speed ( RPM)
Problem Symptoms
Incorrect Idle Rough idling

Other ( )
Hesitation, sag, stumble Surge Cut out
Poor Lack of power, sluggishness, sponginess
Driveability
Other ( )
Soon after starting After accelerator pedal depressed
Engine Stall During A/C operation After accelerator pedal released Shifting from N to D
Other ( )
Black smoke White smoke Poor fuel economy
Others Abnormal combustion noise DPD manual regeneration frequently
DPD regeneration long time
Other ( )
Dates problem occurred
Problem frequency Constant Intermittently ( times per day/month) Once only
Other ( )
Weather Fine Cloudy Rainy Snow
Various/Other ( )
Outside Hot (approx. ) Warm Cool Cold (approx. )
Condition When Problem Occurs
Temperature Any temperature

Highway Suburbs City area Uphill
Place
Downhill Rough road Other ( )
Load Condition Over (approx. tons) No load
Other (approx. tons)
Engine Cold Warming up After warming up Any temperature
Temperature Other ( )
Starting Just after starting ( Min.) Idling
Engine Operation Racing Driving Constant speed Acceleration
Deceleration A/C switch On/Off
Other ( )
Fuel Amount Full Above 1/2 Below 1/2 Near empty
Fuel Bland
Condition of MIL or SVS lamp Remains On Intermittently turns On Does not turn On
Present Code Nothing P or U Code

No. ( )
Diagnostic Trouble
Code (DTC) or Flash
Code P or U Code
History Code Nothing No. ( )
DPD lamp or MID indicator Blinked Did not blink

DPD switch Pushed Did not push
DPD accumulation status 1 2 3 4 5
DPD System
DPD distance status 1 2 3 4
DPD incomplete regeneration status 0 1 2
DPD insufficient regeneration status 0 1 2
Exhaust differential pressure at instructed conditions kPa
Averaged MAF when exhaust differential pressure is measured g/s
MFWB1AXF000501

Diagnostic Starting Point - Engine Controls Reading Flash Diagnostic Trouble Codes (DTC)
Begin the system diagnosis with Diagnostic System The provision for communicating with the ECM is the
Check - Engine Controls. The Diagnostic System Data Link Connector (DLC). The DTC(s) stored in the
Check - Engine Controls will provide the following ECM memory can be read either through a hand-held
information: diagnostic scanner such as Tech 2 plugged into the
• The identification of the control modules which DLC or by counting the number of flashes of the
command the system. malfunction indicator lamp (MIL) or the service vehicle
soon (SVS) lamp when the diagnostic test terminal of
• The ability of the control modules to communicate the DLC is grounded. The DLC terminal "12"
through the serial data circuit. (diagnostic request) is pulled "Low" (grounded) by
• The identification of any stored diagnostic trouble jumped to DLC terminal "4", which is a ground wire.
codes (DTCs) and the their statuses. Once terminals "12" and "4" have been connected, turn
The use of the Diagnostic System Check - Engine the ignition switch ON, with the engine OFF. The SVS
Controls will identify the correct procedure for lamp will indicate a DTC three times is a DTC is
diagnosing the system and where the procedure is present and history. If more than one DTC has been
located. stored in the ECM's memory, the DTCs will be output
numerical order with each DTC being displayed three
Important: Engine Control System Check Sheet must times. The flash DTC display will continue as long as
be used to verify the customer complaint, you need to the DLC is shorted.
know the correct (normal) operating behavior of the
system and verify that the customer complaint is a valid
failure of the system.
Example:DTC 23 stored 2 3 Unit: Second
1.2 1.2 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 2.4
2nd digit number 1st digit number
Example:DTC 225 stored 2 2 5
0.3 0.3 1.2 1.2 0.3 0.3 0.3 0.3 0.3
ON
OFF
2.4 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 2.4
3rd digit 2nd digit number 1st digit number

number
LNW76ESF000101

Diagnostic System Check - Engine Con- Diagnostic System Check Engine Controls
trols Important:
Description • DO NOT perform this diagnostic if there is not a
driveability concern, unless another procedure
The Diagnostic System Check - Engine Controls is an
directs you to this diagnostic.
organized approach to identifying a condition that is
created by a malfunction in the electronic engine • Before you proceed with diagnosis, search for
control system. The Diagnostic System Check must be applicable service bulletins.
the starting point for any driveability concern. The • Unless a diagnostic procedure instructs you, DO
Diagnostic System Check directs the service technician NOT clear the DTCs.
to the next logical step in order to diagnose the • If there is a condition with the starting system, refer
concern. Understanding and correctly using the to Starting System in Section 1E Engine Electrical.
diagnostic table reduces diagnostic time, and prevents
• Ensure the battery has a full charge.
the replacement of good parts.
• Ensure the battery cables (+) (-) are clean and
Test Description tight.
The numbers below refer to the step numbers on the • Ensure the ECM grounds are clean, tight, and in
diagnostic table. the correct location.
2. Lack of communication may be because of a partial • Ensure the ECM harness connectors are clean
or a total malfunction of the serial data circuit. and correctly connected. DO NOT attempt to crank
7. The presence of DTCs which begin with U, indicate the engine with ECM harness connectors
that some other module is not communicating. disconnect.
10. If there are other modules with DTCs set, refer to • Ensure the ECM terminals are clean and correctly
the DTC list. The DTC list directs you to the appropriate mating.
diagnostic procedure. If the control module stores • Ensure the fuel injector ID code data is correctly
multiple DTCs, diagnose the DTCs in the following programmed in to the ECM.
order:
• Ensure the immobilizer security information is
• Component level DTCs, such as sensor DTCs, correctly programmed into the ECM and
solenoid DTCs, actuator DTCs, and relay DTCs. immobilizer control unit (ICU).
Diagnose the multiple DTCs within this category in
numerical order. Begin with the lowest numbered • If there are fuel system DTC’s (P0087, P0088,
DTC, unless the diagnostic table directs you P0089, P0093 or P1093), diagnose sensor DTCs,
otherwise. solenoid DTCs, actuator DTCs and relay DTCs
first.
• If there are DPD system DTC's (P1455, P1471,
P242F, P2453 or P2458), diagnose sensor DTCs
solenoid DTCs, actuator DTCs and relay DTCs
first.
Diagnostic System Check - Engine Controls

Install a scan tool.
1 — Go to Scan Tool
Does the scan tool turn ON? Go to Step 2 Does Not Power Up
2. Attempt to establish communication with the Go to Scan Tool
2 ECM. — Does Not
Communicate with
Does the scan tool communicate with the ECM? Go to Step 3 CAN Device
Notice: If an immobilizer system is active the ECM
will disable the fuel injection causing the engine to
stall immediately after starting and energize the
3 starter cut relay to disable cranking. Attempt to —
crank the engine.
Does the engine crank? Go to Step 4 Go to Step 5

Attempt to start the engine. Go to Engine
4 — Cranks but Does
Does the engine start and idle? Go to Step 6 Not Run

Does the scan tool display ECM DTCs P0633, Problem is relating
P161B or U0167? to starting system.
5 — Refer to Starting
Go to Applicable System in Section
DTC 1E Engine Electrical
Select the DTC display function for the following
control modules:
• ECM
• Transmission control module (TCM) (Smoother
6 only) —
• Electronic hydraulic control unit (EHCU) [ABS
module]
• Immobilizer control unit (ICU)
Does the scan tool display any DTCs? Go to Step 7 Go to Step 11

Does the scan tool display DTCs which begin with
7 U or other control module communication fault — Go to Applicable
DTCs? DTC Go to Step 8
Does the scan tool display ECM DTCs P0601, Go to Applicable
8 —
P0602, P0604, P0606, P060B or P1621? DTC Go to Step 9
Does the scan tool display ECM DTC P0563? Go to Applicable
9 —
DTC Go to Step 10
Is there any other code in any controller that has Go to Applicable
10 —
not been diagnosed? DTC Go to Step 11
Is the customer's concern with the transmission? Go to Diagnostic
System Check-
Transmission
11 —
Controls in Section
5A Transmission
Control System Go to Step 12
Is the customer's concern with the anti-lock brake Go to Diagnostic
Section 4C1 ABS/
ASR Go to Step 13
Is the customer’s concern with the immobilizer Go to Diagnostic
13 — Immobilizer
Controls in Section
9I Security and Lock Go to Step 14

1. Review the following symptoms.
2. Refer to applicable symptom diagnostic table:
• Hard Start
• Rough, Unstable, or Incorrect Idle and
Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or
14 Sponginess —
• DPD System Manual Regeneration
Frequently
Go to Intermittent
Did you find and correct the condition? System OK Conditions

Scan Tool Data List • The Engine Controls - Diagnostic System Check is
completed.
The Engine Scan Tool Data List contains all engine
related parameters that are available on the scan tool. • On-board diagnostics are functioning properly.
A given parameter may appear in any one of the data Scan tool values from a properly running engine may
lists, and in some cases may appear more than once, be used for comparison with the engine you are
or in more than one data list in order to group certain diagnosing. The Engine Scan Tool Data List represents
related parameters together. Use the Engine Scan Tool values that would be seen on a normal running engine.
Data List only after the following is determined: Only the parameters listed below are referenced in this
service manual for use in diagnosis.
Operating Conditions: Engine idling or 1700 RPM/ Engine coolant temperature is between 75 to 85°C (167 to 185°F)/
Accelerator pedal is constant/ Neutral or Park/ Accessories OFF/ Vehicle located at sea level/ DPD is not under regeneration
Engine Speed RPM Nearly 575 RPM Nearly 1700 RPM
Desired Idle Speed RPM 575 RPM 575 RPM
Calculated Engine Load % Less than 25% Less than 20%
Coolant Temperature °C/ °F 75 to 85°C/ 167 to 185°F 75 to 85°C/ 167 to 185°F
Engine Coolant Temperature Volts 0.4 to 0.6 volts 0.4 to 0.6 volts
Sensor
Intake Air Temperature °C/ °F 20 to 40°C/ 68 to 104°F 20 to 40°C/ 68 to 104°F
Intake Air Temperature Sensor Volts 1.4 to 2.3 volts 1.4 to 2.3 volts
Fuel Temperature °C/ °F 20 to 60°C/ 50 to 140°F 20 to 60°C/ 50 to 140°F
Fuel Temperature Sensor Volts 0.8 to 2.3 volts 0.8 to 2.3 volts
MAF (Mass Air Flow) g/ cyl More than 0.8 g/ cyl at sea level More than 0.8 g/ cyl at sea level
Averaged MAF (Mass Air Flow) g/ s More than 20 g/ s at sea level More than 50 g/ s at sea level
MAF Sensor (Mass Air Flow) Volts More than 1.5 volts at sea level More than 2.5 volts at sea level
Barometric Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Nearly 100 kPa/ 14.5 psi at sea
level level
Barometric Pressure Sensor Volts Nearly 2.3 volts at sea level Nearly 2.3 volts at sea level
Desired Turbocharger Position % 10 to 20% 25 to 35%
Desired Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure kPa/ psi Nearly 100 kPa/ 14.5 psi at sea Less than 115 kPa/ 16.7 psi at
level sea level
Boost Pressure Sensor Volts Nearly 1.0 volt at sea level Less than 1.3 volts at sea level
Desired Fuel Rail Pressure MPa/ psi Nearly 32 MPa/ 4,600 psi More than 90 MPa/ 13,000 psi
Fuel Rail Pressure MPa/ psi 28 to 35 MPa/ 4,000 to 5,000 psi More than 90 MPa/ 13,000 psi
Fuel Rail Pressure Sensor Volts 1.4 to 1.6 volts More than 2.4 volts
FRP Regulator Command (Fuel % 30 to 45% 25 to 35%
Rail Pressure)
FRP Regulator Commanded Fuel mm3/ sec More than 2000 mm3/ sec More than 3500 mm3/ sec
Flow
FRP Regulator Feedback Current mA 900 to 1100 mA 800 to 900 mA
(Fuel Rail Pressure)
Accelerator Pedal Position % 0% 23 to 30%
Position)
Position)
Desired EGR Position % 0% Less than 35%
EGR Position 1 % 0% Less than 35%
Intake Throttle Solenoid % 0% 0%
Command
Desired Intake Throttle Position % More than 90% More than 90%
Intake Throttle Position % More than 100% More than 100%
Intake Throttle Position Sensor Volts More than 3.9 volts More than 3.9 volts
Idle-Up Sensor Volts 0.3 to 0.6 volts 0.3 to 0.6 volts
Fuel Compensation Cyl. 1 mm3/ stk -5.0 to 5.0 mm3/ stk (varies) 0.0 mm3/ stk
Fuel Supply Pump Status Not Learned/ Learned Learned
Learned
Rail Pressure Feedback Mode Wait Mode/ Feedback Mode Feedback Mode
Feedback Mode/
Shutoff Mode/ Wait
to Restart
Engine Running Status Off/ Ignition On/ Running Running
Cranking/ Running
Engine Runtime Time (hour: Varies Varies
minute: second)
Vehicle Speed km/h / MPH 0 km/h / 0 MPH 0 km/h / 0 MPH
Starter Switch On/ Off Off Off
Ignition Switch On/ Off On On
Ignition Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Battery Voltage Volts 22.0 to 30.0 volts 22.0 to 30.0 volts
Clutch Pedal Switch Applied/ Released Applied or Released Applied or Released
Neutral Switch Neutral/ In Gear Neutral Neutral
Park Brake Switch Applied/ Released Applied or Released Applied or Released
Exhaust Brake Switch On/ Off Off Off
Exhaust Brake Valve Command On/ Off Off Off
ABS Module
TCM
ASR Commanded APP % 100% 100%
(Accelerator Pedal Position)
PTO Switch On/ Off Off Off
PTO Remote Throttle % 0% 0%
PTO Remote Throttle Sensor Volts Less than 0.4 volts Less than 0.4 volts
Engine Warm Up Switch On/ Off Off Off
A/C Request Signal (Air On/ Off Off Off
Conditioning)
Refrigerator Switch On/ Off Off Off
Oil Level Normal/ Low Normal Normal
Glow Plug Relay Command On/ Off Off Off
Malfunction Indicator Lamp (MIL) On/ Off Off Off
Distance While MIL is Activated km/ Miles 0 km/ 0 Miles 0 km/ 0 Miles
Engine Runtime With MIL Active minutes 0 0
Vane Control Solenoid Error No/ Stuck/ Short No No
Circuit
Vane Position Sensor Error No/ All Low/ All No No
High
Turbocharger Control Module No/ High Voltage No No
Error
Total Engine Overspeed Events Counter Varies Varies
Total Engine Coolant Counter Varies Varies
Total Fuel Temperature Counter Varies Varies
Total Intake Air Temperature Counter Varies Varies
DPD Regeneration Switch On/ Off Off Off
DPD Mode Varies 30 30
DPD Accumulation Status 0/ 1/ 2/ 3/ 4/ 5 0, 1, 2, 3 or 4 0, 1, 2, 3 or 4
DPD Distance Status 0/ 1/ 2/ 3/ 4 0, 1, 2 or 3 0, 1, 2 or 3
DPD Incomplete Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
DPD Insufficient Regeneration 0/ 1/ 2 0 or 1 0 or 1
Status
DPD LLIR Condition On Varies Varies Varies
Particulate Matter
DPD Trip km Varies Varies
DPD DIL Trip km Varies Varies
Exhaust Differential Pressure kPa/ psi Varies Varies
Exhaust Differential Pressure Volts Varies Varies
Sensor
Exhaust Throttle Status On/ Off Off Off
Brake Switch 1 (unsupported Applied/ Released Released Released
parameter)
Brake Switch 2 (unsupported Applied/ Released Released Released
parameter)
Cruise Main Switch On/ Off Off Off
Cruise Cancel Switch On/ Off Off Off
Cruise Resume/ Acceleration On/ Off Off Off
Switch
Cruise Set/ Coast Switch On/ Off Off Off
Immobilizer Signal Yes/ No Yes Yes
Wrong Immobilizer Signal Yes/ No No No
Immobilizer Function Yes/ No Yes Yes
Programmed
Security Wait Time Inactive/ Time Inactive Inactive
(hour: minute:
second)

Scan Tool Data Definitions Fuel Temperature Sensor
This information will assist in emission or driveability
ECM from the fuel temperature (FT) sensor. FT sensor
problems. The displays can be viewed while the vehicle
is a range of value indicating a low voltage when the
is being driven. Always perform the Diagnostic System
temperature is high, and a high voltage when the
Check - Engine Controls first. The Diagnostic System
temperature is low.
Check will confirm proper system operation.
MAF (Mass Air Flow)
Engine Speed
This parameter displays the air flow into the engine as
This parameter displays the speed of the crankshaft as
calculated by the ECM based on the mass air flow
calculated by the ECM based on inputs from the
crankshaft position (CKP) sensor or camshaft position
value at higher engine speeds, and a low value at lower
(CMP) sensor.
engine speed.
Desired Idle Speed
Averaged MAF (Mass Air Flow)
This parameter displays the idle speed requested by
This parameter displays the air flow averaged a second
the ECM. The ECM will change desired idle speed
as calculated by the ECM based on the mass air flow
based on engine coolant temperature and other inputs.
Calculated Engine Load value at higher engine speeds, and a low value at lower
This parameter displays the engine load in percent engine speed.
based on inputs to the ECM from various engine
MAF Sensor (Mass Air Flow)
sensors. The scan tool will display a lower percentage
when the engine is at idle with little or no load. The
ECM from the mass air flow (MAF) sensor. MAF sensor
scan tool will display a higher percentage when the
is a range of value indicating a low voltage at lower
engine is running at high engine speed under a heavy
engine speed, and a high voltage at a higher engine
load.
speeds.
Coolant Temperature
Barometric Pressure
This parameter displays the temperature of the engine
This parameter displays the barometric pressure
coolant as calculated by the ECM using the signal from
(BARO) as calculated by the ECM using the signal from
the engine coolant temperature (ECT) sensor. The
the BARO sensor. The scan tool will display a low
scan tool will display a low temperature when the ECT
barometric pressure in high altitude area.
sensor signal voltage is high, and a high temperature
when the ECT sensor signal voltage is low. Barometric Pressure Sensor
ECM from the barometric pressure (BARO) sensor.
BARO sensor is a range of value indicating a low
ECM from the engine coolant temperature (ECT)
voltage in high altitude area, and a middle voltage in
sensor. ECT sensor is a range of value indicating a low
sea level.
voltage when the temperature is high, and a high
voltage when the temperature is low. Desired Turbocharger Position
This parameter displays turbocharger nozzle position
Intake Air Temperature
desired by the ECM based on current boost pressure.
This parameter displays the temperature of the intake
air as calculated by the ECM using the signal from the Desired Boost Pressure
intake air temperature (IAT) sensor. The scan tool will This parameter displays boost pressure desired by the
display a low temperature when the IAT sensor signal ECM based on current driving conditions. This can be
voltage is high, and a high temperature when the IAT compared to the actual boost pressure to determine
sensor signal voltage is low. sensor accuracy or turbocharger control problems.
Intake Air Temperature Sensor Boost Pressure
This parameter displays the voltage signal sent to the This parameter displays the boost pressure in the
ECM from the intake air temperature (IAT) sensor. IAT intake duct as calculated by the ECM using the signal
sensor is a range of value indicating a low voltage from the boost pressure sensor. The scan tool will
when the temperature is high, and a high voltage when display a low boost pressure when the low engine load,
the temperature is low. and a high boost pressure when the high engine load.
Note that the true boost pressure is determined by
Fuel Temperature
subtracting barometric pressure from the actual
This parameter displays the temperature of the fuel as
reading.
calculated by the ECM using the signal from the fuel
temperature (FT) sensor. The scan tool will display a
low temperature when the FT sensor signal voltage is
high, and a high temperature when the FT sensor
signal voltage is low.

Boost Pressure Sensor APP Sensor 1 (Accelerator Pedal Position)
This parameter displays the voltage signal sent to the This parameter displays the voltage signal sent to the
ECM from the boost pressure sensor. Boost pressure ECM from the accelerator pedal position (APP) sensor
sensor is a range of value indicating a low voltage 1 of the APP sensor assembly. APP sensor 1 is a range
when the boost pressure is low (idle or lower engine of value indicating a low voltage when the accelerator
load) and a high voltage when the boost pressure is pedal is not depressed, and a high voltage when the
high (higher engine load). accelerator pedal is fully depressed.
Desired Fuel Rail Pressure APP Sensor 2 (Accelerator Pedal Position)
This parameter displays fuel rail pressure desired by This parameter displays the voltage signal sent to the
the ECM based on current driving conditions. This can ECM from the accelerator pedal position (APP) sensor
be compared to the actual fuel rail pressure to 2 of the APP sensor assembly. APP sensor 2 is a range
determine sensor accuracy or fuel pressure control of value indicating a high voltage when the accelerator
problems. pedal is not depressed, and a low voltage when the
accelerator pedal is fully depressed.
Fuel Rail Pressure
This parameter displays the fuel rail pressure as Desired EGR Position
calculated by the ECM using the signal from the fuel This parameter displays exhaust gas recirculation
rail pressure (FRP) sensor. The scan tool will display a (EGR) position desired by the ECM based on current
low pressure when the low engine load, and a high driving conditions. This can be compared to the actual
pressure when the high engine load. EGR position to determine sensor accuracy or motor
control problems.
Fuel Rail Pressure Sensor
This parameter displays the voltage signal sent to the EGR Position 1
ECM from the fuel rail pressure (FRP) sensor. FRP This parameter displays the exhaust gas recirculation
sensor is a range of value indicating a low voltage (EGR) valve position calculated by the ECM using the
when the fuel rail pressure is low, and a high voltage signal from the individual three EGR position sensors.
when the fuel rail pressure is high. The scan tool will display a low percentage when the
EGR valve is closed, and a high percentage when the
FRP Regulator Command (Fuel Rail Pressure)
EGR valve is opened.
This parameter displays the fuel rail pressure (FRP)
regulator control duty ratio based on inputs to the ECM EGR Position 1
from various engine sensors. The scan tool will display This parameter displays the input state of the exhaust
a lower percentage when the FRP regulator is gas recirculation (EGR) position sensor 1 to the ECM.
controlled to open (fuel supply quantity to the fuel rail is When the position sensor is opened, the scan tool
increased). The scan tool will display higher displays Low. When the position sensor is closed, the
percentage when the FRP regulator is controlled to scan tool displays High.
close (fuel supply quantity to the fuel rail is reduced).
EGR Position 2
FRP Regulator Commanded Fuel Flow This parameter displays the input state of the exhaust
This parameter displays the commanded fuel flow gas recirculation (EGR) position sensor 2 to the ECM.
quantity of the fuel rail pressure (FRP) regulator to the When the position sensor is opened, the scan tool
fuel rail. displays Low. When the position sensor is closed, the
scan tool displays High.
FRP Regulator Feedback Current (Fuel Rail
Pressure) EGR Position 3
This parameter displays the fuel rail pressure (FRP) This parameter displays the input state of the exhaust
regulator control feedback current as measured by the gas recirculation (EGR) position sensor 3 to the ECM.
ECM. The scan tool will display a low current when the When the position sensor is opened, the scan tool
FRP regulator is controlled to open (fuel supply displays Low. When the position sensor is closed, the
quantity to the fuel rail is increased). The scan tool will scan tool displays High.
display a high current when the FRP regulator is
Intake Throttle Solenoid Command
controlled to close (fuel supply quantity to the fuel rail is
This parameter displays the intake throttle motor
reduced).
control duty ratio based on inputs to the ECM from
Accelerator Pedal Position various engine sensors. The scan tool will display a
This parameter displays the angle of the accelerator lower percentage when the intake throttle motor is
pedal as calculated by the ECM using the signals from controlled to open. The scan tool will display a higher
the accelerator pedal position (APP) sensors. The scan percentage when the intake throttle motor is controlled
tool will display linearly from 0 to 100% according to the to close.
pedal operation.

Desired Intake Throttle Position Engine Runtime
This parameter displays intake throttle position desired This parameter displays the time elapsed since the
by the ECM based on current driving conditions. This engine start. The scan tool will display the time in
can be compared to the actual intake throttle position to hours, minutes and seconds.
determine sensor accuracy or motor control problems.
Vehicle Speed
Intake Throttle Position This parameter indicates the vehicle speed calculated
This parameter displays the intake throttle valve by the ECM using the signal from the vehicle speed
position calculated by the ECM using the signal from sensor (VSS). The scan tool will display a low value at
intake throttle position sensor. The scan tool will display lower vehicle speeds, and a high value at higher
a low percentage when the intake throttle valve is vehicle speeds.
closed, and a high percentage when the intake throttle
Starter Switch
valve is opened. Note that the intake throttle position
This parameter displays the input status of the starter
indicates over 100% if the motor is commanded OFF.
switch to the ECM. When the ignition switch is turned at
Intake Throttle Position Sensor START position, the scan tool displays On.
Ignition Switch
ECM from the intake throttle position sensor. Intake
This parameter displays the input status of the ignition
throttle position sensor is a range of value indicating a
switch to the ECM. When the ignition switch is turned
low voltage when the intake throttle valve is closed to a
ON position, the scan tool displays On.
high voltage when the intake throttle valve is opened.
Ignition Voltage
Idle Up Sensor
This parameter displays the ignition voltage measured
at the ignition feed circuit of the ECM. Voltage is
ECM from the idle up sensor. Idle up sensor is a range
applied to the ECM when the ignition switch is ON
of value indicating a low voltage when the idle up
position.
sensor rotates in a counterclockwise direction to a high
voltage when the idle up sensor rotates in a clockwise Battery Voltage
direction. This parameter displays the battery voltage measured
at the ECM main relay switched voltage feed circuit of
Fuel Compensation Cyl. 1 to 4
the ECM. Voltage is applied to the ECM when the ECM
This parameter displays the adjustment of fuel volume
main relay is energized.
for each cylinder at low engine speed area as
calculated by the ECM. The scan tool will display a Clutch Pedal Switch
negative value if the fuel volume is lowered. The scan This parameter displays the input state of the clutch
tool will display a positive value if the fuel volume is pedal switch to the ECM. When the clutch pedal is
increased. If there is a cylinder that is excessively high depressed, scan tool displays Applied. If the Smoother
or low value, it may indicate faulty fuel injector, weak or is installed, gearshift clutch input state from the TCM is
slightly seized cylinder or an incorrectly programmed displayed.
fuel injector ID code.
Neutral Switch
Fuel Supply Pump Status This parameter displays the input state of the neutral
This parameter displays the learning state of the fuel switch to the ECM. When the transmission gear is Park
supply pump. Not Learned indicates initialized state or Neutral, the scan tool displays Neutral.
that is replaced to a new ECM or adjustment value is
Park Brake Switch
reset. After engine is warm upped, leaning will start at
This parameter displays the input state of the park
idle speed. Learned indicates learning process is
brake switch to the ECM. When the park brake lever is
completed state.
pulled, scan tool displays Applied.
Rail Pressure Feedback Mode
Exhaust Brake Switch
This parameter displays the state of the fuel rail
This parameter displays the input state of the exhaust
pressure feedback to the ECM. Wait Mode indicates
brake switch to the ECM. On indicates the exhaust
the ignition switch is turned ON position. Feedback
brake switch is closed and allows energizing the
Mode indicates the engine is during crank or run.
exhaust brake solenoid valve and intake throttle
Shutoff Mode indicates the ignition switch is turned
depending upon driving condition. Off indicates the
OFF position.
exhaust brake switch is open and exhaust brake will
Engine Running Status not engage.
This parameter displays the state of engine. Ignition On
indicates the ignition switch is turned ON position.
Cranking indicates the engine is during crank. Running
indicates the engine is run. Off indicates the ignition
switch is tuned OFF position.

Exhaust Brake Valve Command Refrigerator Switch
This parameter displays the commanded state of the This parameter displays the state of the refrigerator
exhaust brake solenoid valve control circuit. On compressor engagement. On indicates the ECM
indicates the exhaust brake solenoid valve is being receiving a refrigerator compressor On signal. Off
grounded by the ECM, allowing air pressure to the indicates the ECM is not receiving a refrigerator
exhaust brake valve. compressor On signal.
Exhaust Brake Cut Request from ABS Module Oil Level
This parameter displays the state of the exhaust brake This parameter displays the state of the engine oil level
cut request to the ECM from the EHCU [ABS module] switch to the ECM. Normal indicators the engine oil
or ABS control unit. Active indicates the EHCU [ABS level is not too low for safe operation of the engine. Low
module] or ABS control unit is commanding to release indicators the engine oil level is abnormally low and has
the exhaust brake. opened the engine oil level switch.
Exhaust Brake Cut Request from TCM Glow Plug Relay Command
This parameter displays the state of the exhaust brake This parameter displays the commanded state of the
cut request to the ECM from the transmission control glow relay control circuit. On indicates the glow relay
module (TCM). Active indicates the TCM is control circuit is being grounded by the ECM, allowing
commanding to release the exhaust brake. voltage to the glow plugs.
ASR Commanded APP (Accelerator Pedal Position) Malfunction Indicator Lamp (MIL)
This parameter displays the controlled angle of the This parameter displays the commanded state of the
accelerator pedal calculated by the EHCU [ABS malfunction indicator lamp (MIL) control circuit. The
module] or ABS control unit when anti slip regulator MIL should be On when the scan tool indicates
(ASR) system operated. The scan tool will display command On. The MIL should be Off when the scan
100% when the ECM is not controlled to reduce fuel tool indicates command Off.
injection quantity. The scan tool will display a lower
Distance While MIL is Activated
percentage when the ECM is controlled to reduce fuel
This parameter displays the mileage since the
injection quantity to reduce drive wheels spinning.
malfunction indicator lamp (MIL) is turned ON.
PTO Switch
Engine Runtime With MIL Active
This parameter displays the state of the PTO switch to
This parameter displays the accumulated ignition
the ECM. When the PTO switch is operated by control
switch ON time elapsed since the malfunction indicator
lever or button, scan tool displays On.
lamp (MIL) is turned ON. The scan tool will display the
PTO Remote Throttle time in minutes.
This parameter displays the angle of the PTO remote
Vane Control Solenoid Error
throttle sensor as calculated by the ECM using the
This parameter displays an error state of the
signal from the PTO remote throttle sensor. The PTO
turbocharger nozzle control actuator from the variable
remote throttle angle is a range of values indicating a
nozzle turbocharger (VNT) control module. Stuck
low percentage when the throttle sensor is not operated
indicates the VNT control module detects an open
to a high percentage when the throttle sensor is
circuit on the solenoid circuit or a sticking the nozzle
operated.
control actuator. Short Circuit indicates the VNT control
PTO Remote Throttle Sensor module detects a short circuit on the solenoid circuit.
Vane Position Sensor Error
ECM from the PTO remote throttle sensor. PTO remote
This parameter displays an error status of the
throttle sensor is a range of values indicating a low
turbocharger nozzle position sensor from the variable
voltage when the throttle sensor is not operated to a
nozzle turbocharger (VNT) control module. All High or
high voltage when the throttle sensor is operated.
All Low indicates the VNT control module detects all
Engine Warm Up Switch nozzle position sensor signal are stuck low or high.
This parameter displays the input state of the engine
Turbocharger Control Module Error
warm up switch to the ECM. On indicates the engine
This parameter displays an error status of the variable
warm up switch is closed and allows energizing the
nozzle turbocharger (VNT) control module system
exhaust brake solenoid valve and intake throttle valve
voltage. High voltage indicates the VNT control module
depending upon engine condition.
detects system voltage is too high.
A/C Request Signal (Air Conditioning)
Total Engine Overspeed Events
This parameter displays the state of the air conditioning
This parameter indicates counter of engine overspeed
(A/C) compressor engagement. On indicates the ECM
event. Counter will be zero if any DTC is cleared.
receiving an A/C compressor On signal. Off indicates
the ECM is not receiving an A/C compressor On signal.

Total Engine Coolant Overtemperature Event DPD Trip
This parameter indicates counter of engine overheat This parameter displays the distance as calculated by
event. The counter is active if engine coolant is over the ECM based on regeneration control.
110°C (230°F). Counter will be zero if any DTC is
DPD DIL Trip
cleared.
This parameter displays the distance as one of the
Total Fuel Temperature Overtemperature Event factor to determine the automatic regeneration or
This parameter indicates counter of fuel temperature manual regeneration.
excessively high condition. The counter is active if fuel
Exhaust Differential Pressure
temperature is over 90°C (194°F). Counter will be zero
This parameter displays the exhaust differential
if any DTC is cleared.
pressure as calculated by the ECM using the signal
Total Intake Air Temperature Overtemperature from the exhaust differential pressure sensor. The scan
Event tool will display a low exhaust differential pressure at
This parameter indicates counter of intake air small PM accumulation, and a high exhaust differential
temperature excessively high condition. The counter is pressure at large PM accumulation.
active if intake air temperature is over 60°C (140°F).
Counter will be zero if any DTC is cleared.
This parameter displays the voltage signal set to the
DPD Regeneration Switch ECM from the exhaust differential pressure sensor.
This parameter displays the input state of the DPD Exhaust differential pressure sensor is a range of value
regeneration switch to the ECM. On indicates the DPD indicating a low voltage at a low differential pressure,
regeneration switch is closed and allows entering the such as small PM accumulation, and a high voltage at a
regeneration process depending upon PM high differential pressure, such as large PM
accumulation condition. accumulation.
DPD Mode Exhaust Temperature 1
This parameter displays the state of the DPD. It mainly This parameter displays the temperature of the exhaust
indicates an action request or status to the user during gas in front of filter as calculated by the ECM using the
regeneration event. 1 or 50 indicates DTC is set, which signal from the exhaust gas temperature sensor 1. The
is not allowing the DPD regeneration. 30 indicates scan tool will display a low temperature when the
under normal engine operation. exhaust gas temperature sensor 1 signal voltage is
high, and a high temperature when the exhaust gas
temperature sensor 1 signal voltage is low.
This parameter displays the state of the PM
accumulations. It indicates that the PM accumulative Exhaust Temperature Sensor 1
amount to the filter increases while parameter is This parameter displays the voltage signal sent to the
increasing from 0 to 5. This parameter uses together ECM from the exhaust gas temperature sensor 1.
with DPD Distance Status parameter to determine Exhaust gas temperature sensor 1 is a range of value
regeneration type manually. indicating a low voltage when the temperature is high,
DPD Distance Status
This parameter displays the state of the distance since Exhaust Temperature 2
last regeneration. It indicates that the accumulative This parameter displays the temperature of the exhaust
distance without regeneration event increases while gas in front of oxidation catalyst as calculated by the
parameter is increasing from 0 to 4. This parameter ECM using the signal from the exhaust gas
uses together with DPD Accumulation Status temperature sensor 2. The scan tool will display a low
parameter to determine regeneration type manually. temperature when the exhaust gas temperature sensor
2 signal voltage is high, and a high temperature when
DPD Incomplete Regeneration Status
the exhaust gas temperature sensor 2 signal voltage is
low.
regeneration. 1 or 2 indicates the frequency of the
regeneration event that did not finish within a Exhaust Temperature Sensor 2
predetermined time. This parameter displays the voltage signal sent to the
ECM from the exhaust gas temperature sensor 2.
DPD Insufficient Regeneration Status
regeneration. 1 or 2 indicates the frequency of
incomplete filter purification after the regeneration
event.
DPD LLIR Condition On Particulate Matter
This parameter displays the amount of the PM
accumulations at idle.

Exhaust Throttle Status Security Wait Time
This parameter displays the commanded state of the This parameter displays the security wait time length in
exhaust throttle solenoid valve control circuit. On the ECM. Inactive indicates not in security wait time.
indicates the exhaust throttle solenoid valve is being Time indicates under security wait time. This wait time
grounded by the ECM, allowing air pressure to the stage will prevent any further attempts to enter the
exhaust throttle valve. security code until the wait time has elapsed. Note that
this parameter is not count downed. It keeps displaying
Brake Switch 1
the same time until that wait time has elapsed. The
This parameter is unsupported and fixed at Released.
ignition switch must be kept at ON position during the
Parameter will not change even the brake pedal is
wait time period.
depressed and released.
Brake Switch 2
This parameter is unsupported and fixed at Released.
Parameter will not change even the brake pedal is
depressed and released.
Cruise Main Switch
main switch to the ECM. When the cruise control main
Cruise Cancel Switch
cancel switch to the ECM. When the cruise cancel
Cruise Resume/ Acceleration Switch
resume/ accel. switch to the ECM. When the cruise
resume/ accel. switch is applied, the scan tool displays
On.
Cruise Set/ Coast Switch
set/ coast switch to the ECM. When the cruise set/
coast switch is applied, the scan tool displays On.
Immobilizer Signal
This parameter displays the input state of the response
signal to the ECM. When the ECM received any
response signal from the immobilizer control unit (ICU),
the scan tool displays Yes.
Wrong Immobilizer Signal
This parameter displays the input state of the received
response signal to the ECM. When the ECM received
wrong response signal from the immobilizer control unit
(ICU), the scan tool displays Yes.
Immobilizer Function Programmed
This parameter displays the state of the immobilizer
function programming in the ECM. The scan tool will
display Yes or No. Yes indicates the immobilizer
security information is correctly programmed in the
ECM. No indicates the ECM is not programmed or
ECM is reset.

Scan Tool Output Controls
Scan Tool Output Control Descriptions

Fuel Pressure Control The purpose of this test is for checking whether the fuel rail pressure is changing when
commanded. Faulty fuel supply pump, fuel rail pressure (FRP) regulator, pressure limiter
valve or other fuel lines could be considered if the differential fuel rail pressure is large.
Pre Injection Control The purpose of this test is for checking whether the pre fuel injection is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine noise does not
change when commanded OFF.
Injection Timing Control The purpose of this test is for checking whether the main injection timing is changing when
commanded Retard/ Advance.
Injector Forced Drive The purpose of this test is for checking whether the fuel injector is correctly operating when
commanded ON. Faulty injector(s) could be considered if it does not create a clicking noise
(solenoid operating noise), contains an interrupted noise or has abnormal noise when
commanded ON.
Cylinder Balance Test Notice: If this test does not run, slightly increase the engine speed by pressing the
accelerator pedal.
The purpose of this test is for checking whether the fuel injector is operating when
commanded ON/ OFF. Faulty injector(s) could be considered if engine does not change
speed when commanded OFF.
Intake Throttle Solenoid Control The purpose of this test is for checking whether the intake throttle valve is correctly moved
with command. Restricted valve movement by foreign materials, excessive deposits or a
faulty valve could be considered if the position difference is large.
EGR Solenoid Control The purpose of this test is for checking whether the EGR valve is correctly moved with
command. Restricted valve movement by foreign materials, excessive deposits or a faulty
valve could be considered if the position difference is large.
Turbocharger Solenoid Control The purpose of this test is for checking whether the turbocharger nozzle control solenoid is
correctly moved with command. Restricted actuator movement by foreign materials,
excessive deposits, damaged linkage, a faulty solenoid or a faulty position sensor could be
considered if the solenoid is not moved correctly.
Glow Relay Control The purpose of this test is for checking whether the glow relay is operating when
commanded ON. Faulty circuit(s) or a faulty glow relay could be considered if not
energizing when commanded ON.
Exhaust Brake Control The purpose of this test is for checking whether the exhaust brake control solenoid is
operating when commanded ON. Faulty circuit(s) or a faulty solenoid could be considered if
not energizing when commanded ON.
Exhaust Throttle Control The purpose of this test is for checking whether the exhaust throttle solenoid valve is
operating when commanded ON. Faulty circuit(s) or a faulty exhaust throttle solenoid valve
could be considered if not energizing when commanded ON.
Fuel Supply Pump Learn Important: The fuel supply pump relearn procedure must be done when the fuel supply
Resetting pump or engine is replaced, or an ECM from another vehicle is installed. Refer to Fuel
Supply Pump in Section 1D Engine Fuel.
The purpose of this test to reset the fuel supply pump adjustment value.
DPD Status Resetting Important: DPD status must be reset before regeneration with a scan tool.
The purpose of this function to reset the DPD status parameters.
DPD Normal Regeneration Important: Do Not perform this test if the exhaust differential pressure is more than a
Control threshold.
The purpose of this test is for DPD filter force regeneration.
DPD Slow Regeneration Control Important: Do Not perform this test if the exhaust differential pressure is more than a
threshold. And, engine oil must be replaced after DPD slow regeneration is completed.
The purpose of this test is for DPD filter force regeneration in case of excessively
accumulated PM. This very slow regeneration compared with another one.

Scan Tool Does Not Power Up • Scan tool power ground at terminal 4.
Circuit Description • Common signal ground at terminal 5.
The scan tool will power up with the ignition OFF. Some
The data link connector (DLC) is a standardized 16- modules however, will not communicate unless the
cavity connector. Connector design and location is ignition is ON.
dictated by an industry wide standard, and is required
to provide the following: Connector End View Reference: Engine Controls
• Scan tool power battery positive voltage at Connector End Views or ECM Connector End Views
terminal 16.
Circuit/ System Testing Scan Tool Does Not Power Up

Important: Make sure the scan tool and 24 volts
adapter works properly on another vehicle before
using this chart.
1 1. Turn OFF the ignition. —

2. Inspect the Dome Light (15A) fuse in the cabin
fuse block.
Is the Dome Light (15A) fuse open? Go to Step 2 Go to Step 3

Replace the Dome Light (15A) fuse. If the fuse
continues to open, repair the short to ground on
one of the circuits that is fed by the Dome Light
2 (15A) fuse or replace the shorted attached —
component.

1. Check each circuit at the data link connector
(DLC) (FU23) for a backed out, spread or
missing terminal.
3 —
2. Repair the terminal as necessary.
Did you find and complete the repair? Go to Step 7 Go to Step 4

Connect a test lamp between the +B circuit (pin 16
4 of FU23) at the DLC and a known good ground. —
Repair the open in the battery voltage circuit to the
5 DLC. —
1. Test each ground circuit at the DLC (pins 4
and 5 of FU23) for an open circuit or high
resistance.
6 2. Repair the circuit(s), clean or tighten ground —
as necessary.
Go to Intermittent
Did you find and correct the condition? Go to Step 7 Conditions
1. Connect the scan tool to the DLC.
7 2. Attempt to turn ON the scan tool. —
Does the scan tool ON? System OK Go to Step 1

Scan Tool Does Not Communicate with Diagnostic Aids
CAN Device The following conditions will cause a loss of CAN serial
Circuit Description data communication between the scan tool and the
ECM.
The ECM communicates with the scan tool over the
• A CAN serial data circuit open
controller area network (CAN) link. The ECM, the
transmission control module (TCM) and the immobilizer • A CAN serial data circuit shorted to ground
control unit (ICU) communicate with each other over • A CAN serial data circuit shorted to voltage
the same CAN link. The ECM, the variable nozzle • An internal condition within a module or connector
turbocharger (VNT) control module, the electric on the CAN serial data circuit, that causes a short
hydraulic control unit (EHCU), the body control module to voltage or ground to the CAN serial data circuit
(BCM) or the data recording module (DRM), the
instrument panel (IP) cluster and the TCM Connector End View Reference: Engine Controls
communicate with each other over the separated CAN Connector End Views or ECM Connector End Views
link that does not affect to the scan tool communication.
Circuit/ System Testing Scan Tool Does Not Communicate with CAN Device

Important: Make sure the CAN-di module is not
malfunctioning. When functioning properly, the
CAN-di module LED will be flashing. In the event of
a problem, the LED will be continually illuminated
or not illuminated.
2 1. Install a scan tool. —
ECM.
Go to Intermittent
Does the scan tool communicate with the ECM? Conditions Go to Step 3
connections and for corrosion at the data link
connector (DLC) (pins 6 and 14 of FU23).
3 —

connections and for corrosion at the ECM E26
and FB24 connectors.
4 —

1. Check the ECM (40A) slow blow fuse and
ECM Main (15A) fuse in the chassis fuse
block, Engine Controller (10A) fuse in the
cabin fuse block. Replace and retest if open. If
any fuse continues to open, repair the short to
ground on each circuit fed by that fuse.
5 —
5. Connect a test lamp to ground and check for
voltage at ignition voltage supply circuit at the


Repair the open in the ignition voltage circuit to the
6 ECM. —
Notice: An open in a ground circuit at the ECM will
not cause a loss of communication.
1. Check ECM ground for corrosion and
7 tightness. —
2. Clean or tighten grounds as necessary.

2. Reconnect the ECM harness connector if
disconnected.
ECM.
Does the scan tool communicate with the ECM? Go to Step 13 Go to Step 9
4. Using a test lamp, check for both voltage
9 —
supply circuit to the ECM main relay (pins 1
and 3 of X18).
5. Repair the open circuit(s) as necessary.

1. Reinstall the ECM main relay.
2. Turn the ignition ON and OFF while listening
of feeling for the ECM main relay click. Wait 7
10 seconds between transitions. —
Does the ECM main relay click when the ignition

switch is turned ON or OFF? Go to Step 12 Go to Step 11
Repair the ECM main relay ground circuit between
the ECM main relay (pin 5 of X18) and chassis
ground terminal (FB20) for the following conditions:
11 • An open circuit —
• High resistance or a poor connection at the ECM
main relay or ground terminal

1. Test the battery voltage circuit between the
ECM (pins 2 and 5 of FB24) and the ECM
main relay for the following conditions:
• An open circuit
12 • High resistance or a poor connection at —
the ECM or ECM main relay

13 —

2. Reconnect the ECM FB24 harness connector.
3. Disconnect the scan tool from the DLC if
connected.
14 50 to 70 Ω
and High circuits by probing the DLC (pins 6
and 14 of FU23).

120 Ω CAN resistor should be 60 Ω)? Go to Step 16 Go to Step 15
FB24).
the ECM (pins 58 and 78 of FB24), the
transmission control module (TCM) (pins 14
15 and 15 of FU108), the immobilizer control unit —
(ICU) (pins 5 and 6 of FL34) or the CAN
resistor (pins 1 and 2 of FU200) for the
• An open circuit
• High resistance
necessary.

the ECM (pins 58 and 78 of FB24), the TCM
(pins 14 and 15 of FU108), the ICU (pins 5
and 6 of FL34) or the CAN resistor (pins 1 and
16 2 of FU200) for the following conditions: —
• A short to voltage


ECM.
Does the scan tool communicate with the ECM? System OK Go to Step 3

Engine Cranks but Does Not Run • Fuse and slow blow fuse are normal.
Description
Diagnostic Aids
The Engine Cranks but Does Not Run diagnostic table
is an organized approach to identifying a condition that
causes an engine to not start. The diagnostic table
directs the service technician to the appropriate system
Test Description
diagnosis. The diagnostic table assumes the following
conditions are met: The number below refers to the step number on the
• The battery is completely charged and terminals Circuit/ System Testing.
are cleaned and tight. 5. If the fuel rail pressure (FRP) regulator low side
circuits between the ECM and the FRP regulator are
• The engine cranking speed is normal. shorted to ground, FRP Regulator Feedback Current
• There is adequate fuel in the fuel tank. will be approximately 300 mA or more low as compared
• There is no fuel leak in the fuel line. with normal.
• There is no air in the fuel line.
• Filters (air, fuel) are clean.
Circuit/ System Testing Engine Cranks but Does Not Run

3. Crank the engine for the specified amount of
2 time. 15 seconds
Does the scan tool display any DTCs that failed this Go to Applicable
ignition? DTC Go to Step 3
2. Wait 1minute for the fuel pressure to bleed
3 3. Turn ON the ignition, with the engine OFF. 0 MPa (0 psi)
4. Observe the Fuel Rail Pressure parameter
with a scan tool.
Does the scan tool indicate the specified value? Go to Step 4 Go to Step 6
Notice: If the vehicle has run out of fuel, air may be
trapped in the fuel system.
1. Make sure the fuel tank have adequate fuel
and the fuel quality is good (take a sample).
2. Observe the Fuel Rail Pressure parameter on 25 MPa (3,600
4
psi)
the scan tool while cranking over the engine
for 5 seconds.

value during crank? Go to Step 9 Go to Step 5
parameter on the scan tool while cranking over the
engine for 5 seconds. Go to Fuel System
5 800 mA Check Chart in
Does the scan tool indicate more than the specified Section 1D Engine
value during crank? Fuel Go to Step 8

connector.
of E49).
101 of E26).
necessary.

Repair the short to ground between the ECM (pins
89 and 97 of E26) and the FRP regulator (pin 2 of
8 E47). —

1. Check for normal readings at key up for the
following sensor inputs: Use the Scan Tool
Data List or a known good vehicle to
determine nominal values.
• Engine Coolant Temperature Sensor
• Barometric Pressure (BARO) Sensor
9 —
• Boost Pressure Sensor
• Intake Throttle Position Sensor
2. Repair the circuit(s) or replace the sensor as
necessary.

1. Other possible causes for the no-start
condition:
• Engine mechanical timing
• Flywheel installed incorrectly causing the
crankshaft position (CKP) sensor to be
incorrectly timed to the engine.
Disconnect sensor and attempt to start
10 engine to verify. —
• Heavily restricted intake or exhaust
plugged solid
• Poor engine compression
• Water or gasoline contamination in fuel


3. Attempt to start the engine.
Does the engine start and continue to run? Go to Step 12 Go to Step 2


12 —

Crankshaft Position - Camshaft Position • The ignition switch is ON.
Correlation • The CKP sensor signal pulse is detected.
Circuit Description
The crankshaft position (CKP) sensor is located under Condition for Setting the DTC
the fuel supply pump. There are 56 notches spaced 6° • The ECM detects that the CKP sensor signal
apart and a 30° section that is open span. This open pulses and CMP sensor signal pulses are out of
span portion allows for the detection of top dead center synchronization during engine rotations.
(TDC).
The camshaft position (CMP) sensor is installed on the Action Taken When the DTC Sets
cylinder head at the rear of the camshaft gear. The
CMP sensor detects total of five projections per one
engine cycle (four projections arranged equally every
surface).
Detecting the open span portion from the CKP sensor
and one reference projection from the CMP sensor, the • Refer to DTC Type Definitions for Condition for
ECM determines cylinder #1 compression TDC to Clearing the MIL/ DTC - Type A.
ensure they correlate with each other. If the ECM
detects both signals are out of synchronization, this Diagnostic Aids
DTC will set. • This DTC is cause by an incorrect mechanical
timing condition, which is most likely caused by
Condition for Running the DTC wrong installation of timing gear, flywheel or
• DTCs P0335, P0336, P0340 and P0341 are not camshaft.
set.

Go to Applicable

1. Inspect the crankshaft position (CKP) sensor
and the camshaft position (CMP) sensor for
and sensor rotor or camshaft gear
• Physical damage of sensor rotor or
camshaft gear
3 —
rotor or camshaft gear
2. Inspect the engine mechanical timing for an
incorrectly installed timing gear or camshaft.
Notice: If the flywheel dowel pin is missing or

pushed in and the flywheel is incorrectly
installed, this DTC may set.

harness connector(s) if disconnected.
crank over the engine for 10 seconds.
4 —
Records.

5 —

Turbocharger Boost Control Solenoid Circuit • The VNT control module detects all nozzle position
sensor signal are stuck low or high.
Circuit Description • The VNT control module detects an open circuit,
The position of the turbocharger nozzle is controlled by short to ground or short to voltage circuit on the
the variable nozzle turbocharger (VNT) control module solenoid circuit.
based on the command from the ECM. The VNT • The VNT control module detects solenoid or
control module controls a drive signal to the nozzle control is stuck condition.
turbocharger nozzle control solenoid (installed to the
turbocharger assembly) by utilizing position sensor Action Taken When the DTC Sets
inputs to control the turbocharger nozzles. When the • The ECM illuminates the MIL when the diagnostic
engine is not under load, the turbocharger nozzles are runs and fails. Refer to DTC Type Definitions for
in an open position. When the engine is under load, the Action Taken When the DTC Sets - Type A.
VNT control module commands the control solenoid to
close the turbocharger nozzles, thus increasing the
boost. The ECM will vary the boost dependant upon the • The ECM inhibits cruise control.
load requirements of the engine. The VNT control
module has the ability to perform internal diagnostics Condition for Clearing the DTC
for voltage and signal input and output status. If the • Refer to DTC Type Definitions for Condition for
VNT control module detects an error in the nozzle Clearing the MIL/ DTC - Type A.
position signals, solenoid control signal or VNT control
module voltage error, the VNT control module will send Diagnostic Aids
a message to the ECM via the controller area network
(CAN) communication bus and sets this DTC.
Condition for Running the DTC • A sticking or intermittently sticking the
turbocharger nozzle control actuator may set this
• The battery voltage is between 20 to 32 volts. DTC.
Notice: If the VNT control module detects an open
Condition for Setting the DTC circuit on the solenoid circuit, the Vane Control
Either of following condition is met: Solenoid Error parameter on the scan tool indicates
Stuck.
• The VNT control module detects system voltage is
too high.

2 —
4. Observe the Turbocharger Control Module
Error parameter with a scan tool. Go to DTC P0563
for high system
Does the scan tool indicate High Voltage? voltage diagnosis Go to Step 3
Observe the Vane Control Solenoid Error
3 parameter with a scan tool. —
Does the scan tool indicate Stuck or Short Circuit? Go to Step 5 Go to Step 4
Observe the Vane Position Sensor Error parameter
4 with a scan tool. — Go to Diagnostic
Does the scan tool indicate All High or All Low? Go to Step 9 Aids

1. Inspect the turbocharger assembly for the
• Physical damage of turbocharger
• Turbocharger nozzle control linkage
damaged
5 • Physical damage of VNT actuator & —
sensor
• Loose or improper installation of VNT
actuator & sensor

2. Disconnect the VNT actuator & sensor
harness connector.
3. Connect a test lamp between the each
solenoid circuit (pins 6, 7 and 8 of E3) and a
known good ground.
Notice: Ignition switch must be cycled when

the test lamp is probed to other positions.
Is there circuit which did not illuminate, or

continuously illuminate the test lamp (note that the
test lamp illuminate then go out normally)? Go to Step 8 Go to Step 7
1. Test the solenoid circuit between the VNT
control module (pins 10, 11 and 12 of E9) and
the actuator & sensor (pins 6, 7 and 8 of E3)
7 for a short circuit each other. —

1. Test the solenoid circuits (which ever circuit
did not illuminate, or continuously illuminate at
Step 6) between the VNT control module (pins
10, 11 and 12 of E9) and the actuator &
sensor (pins 6, 7 and 8 of E3) for the following
conditions:
• An open circuit

• A short to the position sensor circuit
• High resistance

2. Connect a DMM between the position sensor
reference voltage circuit (pin 1 of E3) and a 8.0 to 10.0
9 known good ground. volts


Connect a DMM between the each position sensor
signal circuit (pins 2, 3 and 4 of E3) and a known
10 good ground. 4.0 to 6.0 volts
Is there circuit which did not voltage reading within
1. Test the position sensor signal circuits
between the VNT control module (pins 1, 2
and 3 of E9) and the actuator & sensor (pins
11 2, 3 and 4 of E3) for a short circuit each other. —

Connect a DMM across the position sensor
reference voltage circuit and the low reference 8.0 to 10.0
12 circuit (pins 1 and 5 of E3). volts
1. Test the position sensor reference voltage
circuit between the VNT control module (pin 8
of E9) and the actuator & sensor (pin 1 of E3)
• An open circuit
13 —
• High resistance

1. Test the position sensor signal circuits (which
ever voltage reading did not read within the
specified value at Step 10) between the VNT
control module (pins 1, 2 and 3 of E9) and the
actuator & sensor (pins 2, 3 and 4 of E3) for
• An open circuit
• A short to the reference voltage circuit
• High resistance

1. Test the position sensor low reference circuit
between the VNT control module (pin 4 of E9)
and the actuator & sensor (pin 5 of E3) for an
15 open circuit or high resistance. —

connector of the actuator & sensor (pins 1, 2,
16 3, 4, 5, 6, 7 and 8 of E3). —


2. Disconnect the VNT control module harness
connector.
connector of the VNT control module (pins 1,
2, 3, 4, 8, 10, 11 and 12 of E9).

Replace the turbocharger. Refer to Turbocharger
18 Assembly in Section 1J Induction. —
Replace the VNT control module. Refer to
Turbocharger Control Module in Section 1J
19 Induction. —

Records.

21 —

Exhaust Valve Control Solenoid Circuit Low or Action Taken When the DTC Sets
High • The ECM illuminates the MIL when the diagnostic
The ECM controls the exhaust throttle solenoid valve
based on the diesel particulate defuser (DPD) system Condition for Clearing the DTC
regeneration status. The exhaust throttle solenoid valve • Refer to DTC Type Definitions for Condition for
energizes to apply air pressure to the exhaust throttle Clearing the MIL/ DTC - Type A.
valve that is installed rear of the DPD housing. If the
ECM detects an improper voltage level on the exhaust Diagnostic Aids
throttle solenoid valve control circuit, DTC P0079 or • If an intermittent condition is suspected, refer to

• The battery voltage is between 18 to 32 volts. The number below refers to the step number on the
• The ignition switch is ON. Circuit/ System Testing.
DTC P0080
Condition for Setting the DTC 3. If the exhaust throttle solenoid valve control circuit
• The ECM detects a low voltage condition on the between the ECM and the solenoid valve is normal,
exhaust throttle solenoid valve control circuit for voltage level low DTC P0079 will set.
commanded OFF. (DTC P0079) Connector End View Reference: Engine Controls
exhaust throttle solenoid valve control circuit for
commanded ON. (DTC P0080)

2 scan tool. —
Go to Diagnostic
harness connector.
known good ground.

4 scan tool. —


5 —
the ECM Main (15A) fuse and the exhaust throttle

7 —

8 —

9 —


11 —

scan tool.
14 —


2 scan tool. —
Go to Diagnostic
harness connector.
Is DTC P0079 set, but not DTC P0080? Go to Step 5 Go to Step 4

FB112) for a short to battery or ignition
4 voltage. —

5 —

scan tool.
8 —

Fuel Rail/ System Pressure Too Low • The ECM inhibits pre injection.
Description • The ECM inhibits cruise control.
The common rail fuel system is comprised of two fuel
pressure sections: a suction side between the fuel tank Condition for Clearing the DTC
and the fuel supply pump and a high-pressure side • Refer to DTC Type Definitions for Condition for
between the fuel supply pump and the fuel injectors. Clearing the MIL/ DTC - Type B.
then pumped into the fuel rail by two plungers, all of Diagnostic Aids
pressure is regulated by the ECM using the fuel rail • An intermittently sticking FRP regulator may have
pressure (FRP) regulator dependant upon values from allowed the fuel pressure to become high enough
the FRP sensor attached to the fuel rail. In case of fuel to open the pressure limiter valve.
rail overpressure, a pressure limiter valve threaded into • A skewed FRP sensor value can set this DTC. The
the fuel rail will open to release overpressure and FRP Sensor on the scan tool should read 0.9 to
return fuel back to the fuel tank. If the ECM detects that 1.0 volt with the ignition switch ON and engine
the fuel rail pressure went excessively high, then OFF after the engine has stopped running for a
sharply decreased, this DTC will set indicating high fuel minimum of 1 minute.
pressure, which activated the pressure limiter valve.
Condition for Running the DTC might be allowed to go into the fuel system. With air in
set.
Test Description
The numbers below refers to the step number on the
• The ECM detects that the pressure limiter valve is Circuit/ System Testing.
activated with overpressure (more than 180 MPa 7. This step checks for a fuel restriction by determining
[26,000 psi]) in the fuel rail. if a high vacuum is being pulled on the fuel system
during normal operation.
Action Taken When the DTC Sets 8. This step checks for an air leak on the suction side of
• The ECM illuminates the MIL on the second the fuel system by determining if a vacuum can be
consecutive driving cycle when the diagnostic runs pulled when a fuel line is plugged.
Taken When the DTC Sets - Type B. Routing Reference: Fuel System Routing Diagram
• The ECM limits fuel injection quantity. Connector End View Reference: Engine Controls

2 —

P0193, P0201 - P0204, P2146 or P2149 set? DTC Go to Step 3

parking brake.
3 4. Accelerate the engine between idle and — An intermittent
W.O.T. (accelerator pedal full travel) many problem by foreign
times while observing the DTC Information material in the fuel
with a scan tool. system is
suspected. Go to
Does the DTC fail this ignition? Go to Step 4 Step 13
2. Wait 1 minute for the fuel pressure to bleed
4 0.9 to 1.0 volt

tool.


and load, which may set this DTC.
6 —
may occur.
rail.



2. Remove the rubber fuel hose from the fuel
filter housing (fuel supply pump side). Use a
pan to catch the fuel from the removed fuel
line.
Important: The fuel pressure/ vacuum gauge

connector and the adapter hose must be
cleaned before connecting to the fuel line.
Otherwise, foreign material internal to the
tools line may damage the fuel supply pump.
3. Connect the gauge adapter (5-8840-2844-0/
EN-47667) with fuel pressure/ vacuum gauge
assembly (5-8840-2844-0/ J-44638) in series
7 with the filter housing and the disconnected 5 inHg
fuel hose. Ensure the service tool and fuel line
connections are tight.
4. Bleed the fuel system by priming the priming
pump until it becomes firm, then crank over
the engine for a maximum of 5 seconds.
Repeat as necessary until the engine starts.
5. Let the engine run at idle for at least 1 minute.
6. Monitor the fuel pressure/ vacuum gauge
while holding the engine speed higher than
2500 RPM for a minimum of 1 minute.
Does the fuel pressure/ vacuum gauge ever

indicate a larger vacuum than the specified amount
during the test? Go to Step 9 Go to Step 8
1. Fully clamp off a fuel hose as close to the fuel
tank as possible (this will draw vacuum on the
fuel system). You can also disconnect a fuel
line and plug it.
2. Start the engine and turn the idle up control
knob to the highest position. (Full clockwise
direction. The idle speed is increased up to
8 1600 RPM.) 8 inHg
3. Monitor the fuel pressure/ vacuum gauge.
Notice: Release the clamp or open the plug

when the gauge is likely to be more than 8
inHg during the test.
Can a vacuum of at least the specified amount be

pulled on the fuel system? Go to Step 11 Go to Step 10
kinked.
condition.



connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
12 —
101 of E26).
necessary.

13 Element in Section 1D Engine Fuel. —
programmed.
Refer to Injector in Section 1D Engine Fuel.


to the ECM.

16 a fuel supply pump is replaced. —
element. Refer to Fuel Supply Pump and Fuel Filter
Element in Section 1D Engine Fuel.

Records.

18 —

Fuel Rail/ System Pressure Too High • The ECM inhibits pre injection.
Description • The ECM inhibits cruise control.
pressure sections: a suction side between the fuel tank Condition for Clearing the DTC
and the fuel supply pump and a high-pressure side • Refer to DTC Type Definitions for Condition for
between the fuel supply pump and the fuel injectors. Clearing the MIL/ DTC - Type A.
then pumped into the fuel rail by two plungers, all of Diagnostic Aids
pressure is regulated by the ECM using the fuel rail • An intermittently sticking FRP regulator may have
pressure (FRP) regulator dependant upon values from allowed the fuel pressure to become high enough
the FRP sensor attached to the fuel rail. to set this DTC.
If the ECM detects that during the same ignition cycle • Normal Fuel Rail Pressure readings on the scan
the fuel pressure rose even higher than the amount to tool with the engine running in neutral at idle is
set DTC P0088 for a certain length of time, the MIL will around 30 to 35 MPa (4,350 to 5,080 psi) after
be illuminated. If the MIL is illuminated, the fuel warm up.
pressure was too high and the pressure limiter valve • A skewed FRP sensor value can set this DTC. The
did not active or did not active quick enough. FRP Sensor on the scan tool should read 0.9 to
Condition for Running the DTC OFF after the engine has stopped running for a
• DTCs P0192, P0193, P060B and P0651 are not minimum of 1 minute.
set.
Test Description
• The engine is running. The numbers below refers to the step number on the
Circuit/ System Testing.
Condition for Setting the DTC 7. This step checks for a fuel restriction by determining
if a high vacuum is being pulled on the fuel system
• The ECM detects that the fuel rail pressure is more during normal operation.
than 198 MPa (28,700 psi) for longer than 5 8. This step checks for an air leak on the suction side of
seconds. the fuel system by determining if a vacuum can be
pulled when a fuel line is plugged.
• The ECM illuminates the MIL when the diagnostic Routing Reference: Fuel System Routing Diagram
runs and fails. Refer to DTC Type Definitions for Connector End View Reference: Engine Controls
Action Taken When the DTC Sets - Type A. Connector End Views or ECM Connector End Views

2 —


parking brake.
4. Accelerate the engine between idle and 180 MPa
3 An intermittent
W.O.T. (accelerator pedal full travel) many (26,000 psi)
times while observing the Fuel Rail Pressure problem by foreign
parameter with a scan tool. material in the fuel
system is
Does the Fuel Rail Pressure parameter ever suspected. Go to
exceed the specified value? Go to Step 4 Step 13
4 0.9 to 1.0 volt

tool.


6 —
may occur.
rail.



line.


line and plug it.
8 1600 RPM.) 8 inHg


kinked.
condition.



connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
12 —
101 of E26).
necessary.

programmed.


to the ECM.


Records.

18 —

Fuel Pressure Regulator Performance Action Taken When the DTC Sets
and the fuel supply pump and a high-pressure side • The ECM inhibits EGR control.
between the fuel supply pump and the fuel injectors. • The ECM inhibits cruise control.
then pumped into the fuel rail by two plungers, all of Condition for Clearing the DTC
pressure is regulated by the ECM using the fuel rail • Refer to DTC Type Definitions for Condition for
pressure (FRP) regulator dependant upon values from Clearing the MIL/ DTC - Type B.
detects that fuel pressure is a certain pressure higher Diagnostic Aids
than the desired pressure, this DTC will set. • An intermittently sticking FRP regulator may have
Condition for Running the DTC to set this DTC.
• DTCs P0091, P0092, P0192, P0193, P0201 - • Normal Fuel Rail Pressure readings on the scan
P0204, P060B, P0651, P1261, P1262, P2146 and tool with the engine running in neutral at idle is
P2149 are not set. around 30 to 35 MPa (4,350 to 5,080 psi) after
• The battery voltage is between 18 to 32 volts. warm up.
• The ignition switch is ON. • A skewed FRP sensor value can set this DTC. The
• The engine is running. 1.0 volt with the ignition switch ON and engine
Condition for Setting the DTC minimum of 1 minute.
is more than 40 MPa (5,800 psi) over the desired Routing Reference: Fuel System Routing Diagram
pressure for longer than 5 seconds. Connector End View Reference: Engine Controls

2 —
Is DTC P0091, P0092, P0192, P0193, P0201 - Go to Applicable

P0204, P2146 or P2149 set? DTC Go to Step 3
3 0.9 to 1.0 volt


connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
5 —
101 of E26).
necessary.

parking brake.
W.O.T. (accelerator pedal full travel) many ± 5 MPa (± 725
6
times while observing the Fuel Rail Pressure psi)
and Desired Fuel Rail Pressure parameter
with a scan tool.
Does the Fuel Rail Pressure parameter follow

within the specified value quick enough (compare
with a similar unit if available)? Go to Step 7 Go to Step 9
Notice: An intermittent problem by foreign material
in the fuel is suspected.
7 Replace the fuel filter element. Refer to Fuel Filter —


to the ECM.


Records.

11 —

Fuel Pressure Regulator Control Circuit Low Action Taken When the DTC Sets
or High • The ECM illuminates the MIL when the diagnostic
The fuel rail pressure (FRP) regulator is installed to the • The ECM limits fuel injection quantity.
fuel supply pump and controls the suction fuel quantity • The ECM inhibits pre injection.
into the fuel rail. The FRP regulator is fully opened in • The ECM inhibits EGR control.
the normal state and larger drive current results in
smaller opening. The ECM calculates desired fuel rail • The ECM inhibits cruise control.
pressure and fuel flow rate and it compares the
calculated desired fuel rail pressure to the actual value Condition for Clearing the DTC
to determine the FRP regulator position. When the • Refer to DTC Type Definitions for Condition for
actual fuel rail pressure is higher than the desired Clearing the MIL/ DTC - Type A.
value, the FRP regulator is closed to decease the flow
rate. If the ECM detects an excessively low or high FRP Diagnostic Aids
regulator solenoid feedback current, DTC P0091 or • If an intermittent condition is suspected, refer to

• DTC P060B is not set. The number below refers to the step number on the
• The battery voltage is between 18 to 32 volts. Circuit/ System Testing.
• The ignition switch is ON. 7. If the FRP regulator high side circuit is shorted to
voltage, engine stalls and will not start.
Condition for Setting the DTC 8. If the FRP regulator low side circuit is shorted to
ground, this DTC may not set. This will cause engine
• The ECM detects that the FRP regulator feedback
stall or no engine start.
current is less than 50 mA, or more than 1000 mA
below the desired current. (DTC P0091)
• The ECM detects that the FRP regulator feedback Connector End Views or ECM Connector End Views
current is more than 2400 mA, or more than 1000
mA over the desired current. (DTC P0092)

Go to Diagnostic
3 300 mA
4 900 mA
value at Step 3? Go to Step 7 Go to Step 8

connector.
3. Connect a test lamp between the high side
ground.

2. Connect a test lamp between the low side

regulator (pin 1 of E47) for a short to battery or
7 ignition voltage. —

(pin 2 of E47) for a short to ground.
8 —

regulator (pin 1 of E47) for the following
conditions:
• An open circuit
• A short to the low side circuit
• High resistance

Important: The ECM may be damaged if the FRP
regulator low side circuit is shorted to a voltage
source.
(pin 2 of E47) for the following conditions:
10 —
• An open circuit
• High resistance

FRP regulator (pins 1 and 2 of E47).
11 —


ECM (pins 89, 97, 105 and 113 of E26).

Replace the FRP regulator. Refer to Fuel Rail
Pressure (FRP) Regulator in Section 1D Engine
13 Fuel. —


Records.

16 —

Fuel System Leak Detected Condition for Clearing the DTC
Description Clearing the MIL/ DTC - Type B.
pressure sections: a suction side between the fuel tank Diagnostic Aids
and the fuel supply pump and a high-pressure side • An intermittently sticking FRP regulator may have
between the fuel supply pump and the fuel injectors. allowed the fuel pressure to become low enough to
Fuel is drawn from the fuel tank via a feed pump and set this DTC.
then pumped into the fuel rail by two plungers, all of • Normal Fuel Rail Pressure readings on the scan
which are internal to the fuel supply pump. This high tool with the engine running in neutral at idle is
pressure is regulated by the ECM using the fuel rail around 30 to 35 MPa (4,350 to 5,080 psi) after
pressure (FRP) regulator dependant upon values from warm up.
detects that the fuel rail pressure is certain pressure • A skewed FRP sensor value can set this DTC. The
low as compared with the engine speed, this DTC will FRP Sensor on the scan tool should read 0.9 to
set. 1.0 volt with the ignition switch ON and engine
Condition for Running the DTC minimum of 1 minute.
• DTCs P0087, P0091, P0092, P0192, P0193, Notice: This DTC most likely indicates a loss of fuel
P0201 - P0204, P060B, P0651, P1261, P1262, pressure by a fuel leak from the high pressure side.
P2146 and P2149 are not set. Inspect the high pressure side fuel leakage between
• The battery voltage is between 18 to 32 volts. the fuel supply pump and fuel injector first.
• The engine is running. Notice: If the fuel tank is empty or near empty, air
might be allowed to go into the fuel system. With air in
Condition for Setting the DTC the fuel system, smooth flow of fuel into the supply
• The ECM detects that the actual fuel rail pressure bleeding of fuel system after refilling.
is lower than 15 MPa (2,180 psi) for longer than 3
seconds. Test Description
Action Taken When the DTC Sets The numbers below refers to the step number on the
• The ECM illuminates the MIL on the second 8. This step checks for a fuel restriction by determining
consecutive driving cycle when the diagnostic runs if a high vacuum is being pulled on the fuel system
and fails. Refer to DTC Type Definitions for Action during normal operation.
Taken When the DTC Sets - Type B. 9. This step checks for an air leak on the suction side of
• The ECM inhibits EGR control. the fuel system by determining if a vacuum can be
• The ECM inhibits cruise control. pulled when a fuel line is plugged.



1. Inspect the high pressure side between the
fuel supply pump and the fuel injectors for fuel
leakage. The following components may
contain an external leak.
• Fuel supply pump
• Fuel rail
• Pressure limiter valve
• Fuel pipe between the fuel supply pump
and fuel rail
• Fuel pipe between the fuel rail and fuel
injectors
2 • Each fuel pipe sleeve nuts —

Notice: Remove and inspect the inlet high

pressure joint to the fuel injectors for fuel
leaking from the sleeve nut(s). Replace the
fuel injector and injection pipe when foreign
material was in contact.

1. Remove each glow plug from the cylinder
head.
2. Inspect for fuel leakage into the combustion
3 chamber. —
Is there a cylinder that fuel leakage into the

combustion chamber? Go to Step 16 Go to Step 4
4 —

5 0.9 to 1.0 volt


parking brake.
6 tool. —


may occur.
rail.


line.


line and plug it.
9 1600 RPM.) 8 inHg


kinked.
condition.



connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
13 —
101 of E26).
necessary.

programmed.
Replace the appropriate fuel injector that was
leaking fuel found at Step 3 and inspect the engine
16 mechanical for any damage or poor engine —
compression. Refer to Injector in Section 1D
Engine Fuel.


programmed.

to the ECM.


Records.

20 —

Mass Air Flow Sensor Circuit Range/ • The intake throttle control is commanded OFF.
Performance • The DPD filter regeneration is inactive.
• The engine run time is longer than 5 seconds.
Circuit Description
The mass air flow (MAF) sensor is an air flow meter Condition for Setting the DTC
that measures the amount of air that enters the engine. • The ECM detects that the MAF sensor signal
It is fitted between the air cleaner and turbocharger. A voltage is not within a predetermined range of the
small quantity of air that enters the engine indicates calculated MAF value for longer than 5 seconds.
deceleration or idle speed. A large quantity of air that
enters the engine indicates acceleration or a high load Action Taken When the DTC Sets
condition. The ECM will calculate a predicted MAF
value and compares the actual MAF sensor voltage
signal to the predicted MAF value. This comparison will
determine if the signal is stuck, or is too low or too high
for a given operating condition. If the ECM detects that
the actual MAF sensor signal voltage is not within a • The ECM inhibits EGR control.
predetermined range of the calculated MAF value, this
DTC will set. Condition for Clearing the DTC
• DTCs P0045, P0079, P0080, P0102, P0103,
P0112, P0113, P0116, P0117, P0118, P0122, Diagnostic Aids
P0123, P0234, P0237, P0238, P0404, P0409, • Any unmetered air that enters the engine
P0560, P060B, P0638, P0651, P0697, P1404, downstream of the MAF sensor will cause this
P2227, P2228, P2229, U0073 and U0110 are not DTC to set.
set. • High resistance in the MAF sensor circuit may set
• The battery voltage is between 18 to 32 volts. this DTC.
• The ignition switch is ON. • A short between the signal circuit of the MAF
AND following conditions are met longer than 3 sensor and the signal circuit of the intake air
seconds temperature (IAT) sensor will skew the MAF
• The engine speed is between 1500 to 2600 RPM. sensor lower than normal at higher air flows.
• The fuel injection is non injection state.
• The EGR control is commanded OFF. Connector End Views or ECM Connector End Views


system
2 system —
• A sticking turbocharger nozzle control
actuator
Exhaust.

connector.
connector of the MAF sensor (pins 1, 2 and 3
of J14, FB128 or FB196).
FB24).

(pins 22, 23 and 69 of FB24) and the MAF
sensor (pins 1, 2 and 3 of J14, FB128 or

Replace the MAF sensor. Refer to MAF Sensor in
5 Section 1J Induction. —

Records.

7 —

Mass Air Flow Sensor Circuit Low or High Condition for Setting the DTC
Input • The ECM detects that the MAF sensor signal
The mass air flow (MAF) sensor is an air flow meter • The ECM detects that the MAF sensor signal
that measures the amount of air that enters the engine. voltage is more than 4.9 volts for 3 seconds. (DTC
It is fitted between the air cleaner and turbocharger. A P0103)
small quantity of air that enters the engine indicates
deceleration or idle speed. A large quantity of air that Action Taken When the DTC Sets
enters the engine indicates acceleration or a high load • The ECM illuminates the MIL when the diagnostic
condition. The sensor has the following circuits. runs and fails. Refer to DTC Type Definitions for
• Low reference circuit • The ECM uses a MAF substitution of default value.
• MAF sensor signal circuit • The ECM limits fuel injection quantity.
The ECM monitors the MAF sensor signal voltage. This • The ECM inhibits EGR control.
output voltage will display on the scan tool as a voltage
parameter and as a grams per cylinder (g/cyl)
parameter. If the ECM detects an excessively low or
• DTCs P0560 and P060B are not set.
Diagnostic Aids
• The engine speed is less than 1500 RPM. (DTC Connector End View Reference: Engine Controls
P0102) Connector End Views or ECM Connector End Views


Observe the MAF (Mass Air Flow) Sensor
3 0.1 volts
Is the MAF Sensor parameter less than the Go to Diagnostic
connector.
3. Connect a test lamp between the 12 volts
4 reference circuit (pin 1 of J14, FB128 or —
FB196) and a known good ground.


12 volts reference circuit and the signal circuit (pins
5 1 and 3 of J14, FB128 or FB196). 4.9 volts
Is the MAF Sensor parameter more than the
(pin 1 of J14, FB128 or FB196) for an open
6 circuit or high resistance. —

69 of FB24) and the MAF sensor (pin 3 of J14,
FB128 or FB196) for the following conditions:
• An open circuit
7 —
• High resistance

MAF sensor (pins 1 and 3 of J14, FB128 or
8 FB196). —



Records.


13 —

2 4. Observe the MAF (Mass Air Flow) Sensor 4.9 volts
Is the MAF Sensor parameter more than the Go to Diagnostic

3 —
connector.

connector.

circuit (pin 2 of J14, FB128 or FB196) and battery
6 voltage. —

Important: The MAF sensor may be damaged if
source.
69 of FB24) and the MAF sensor (pin 3 of J14,
7 —


(pin 2 of J14, FB128 or FB196) for an open
8 circuit or high resistance. —

MAF sensor (pin 2 of J14, FB128 or FB196).
9 —



Records.

14 —

Intake Air Temperature Sensor Circuit Low or Condition for Setting the DTC
High • The ECM detects that the IAT sensor signal
The intake air temperature (IAT) sensor is fitted • The ECM detects that the IAT sensor signal
between the air cleaner and turbocharger. It is internal voltage is more than 4.85 volts for 3 seconds.
to the mass air flow (MAF) sensor. The IAT sensor is a (DTC P0113)
variable resistor and it measures the temperature of the
air entering the engine. The sensor has a signal circuit Action Taken When the DTC Sets
and a low reference circuit. The ECM supplies 5 volts to • The ECM illuminates the MIL when the diagnostic
the signal circuit and a ground for the low reference runs and fails. Refer to DTC Type Definitions for
circuit. When the IAT sensor is cold, the sensor Action Taken When the DTC Sets - Type A.
• The ECM uses an IAT substitution of default value.
resistance, the ECM detects a high voltage on the • The ECM inhibits EGR control.
detects a lower voltage on the signal circuit. If the ECM Condition for Clearing the DTC
detects an excessively low or high signal voltage, DTC • Refer to DTC Type Definitions for Condition for
P0112 or P0113 will set. Clearing the MIL/ DTC - Type A.

• DTCs P060B and P0651 are not set. • If an intermittent condition is suspected, refer to
the IAT sensor at various temperature levels to
• The engine run time is longer than 3 minutes.
(DTC P0113)
concerns.



3 0.1 volts


5 —

Replace the IAT sensor. Refer to MAF Sensor in
7 corrosion. —
necessary.


Records.

10 —



3 4.8 volts
connector.
(pin 4 of J14, FB128 or FB196) and a known
good ground.
Important: The IAT sensor may be damaged if the
5 —

6 and 5 of J14, FB128 or FB196). 0.1 volts
signal circuit (pin 4 of J14, FB128 or FB196) and a
FB128 or FB196) for an open circuit or high
8 resistance. —

Notice: The IAT sensor shares the low reference
share this circuit.
9 ECM (pin 60 of FB24) and the IAT sensor (pin —
5 of J14, FB128 or FB196) for an open circuit
or high resistance.


FB128 or FB196) for a short to any 5 volts
10 reference circuit. —

IAT sensor (pins 4 and 5 of J14, FB128 or
11 FB196). —


Replace the IAT sensor. Refer to MAF Sensor in

Records.

16 —

Engine Coolant Temperature Sensor Circuit Condition for Setting the DTC
Range/ Performance • The ECM detects that the difference of maximum
and minimum engine coolant temperature is less
Circuit Description than 1 to 15°C (1.8 to 27°F).
installed to the thermostat housing. The ECT sensor is Action Taken When the DTC Sets
a variable resistor and it measures the temperature of • The ECM illuminates the MIL on the second
the engine coolant. If the ECM detects that the consecutive driving cycle when the diagnostic runs
difference of engine coolant temperature is smaller and fails. Refer to DTC Type Definitions for Action
than the calculated range during the predetermined Taken When the DTC Sets - Type B.
conditions, this DTC will set. This DTC will only run
once per ignition cycle within the enabling condition. Condition for Clearing the DTC
• DTCs P0117, P0118, P0201 - P0204, P0500,
P0502, P0503, P060B, P0697, P1261, P1262, Diagnostic Aids
P2146, P2149 and P215A are not set. • After starting the engine, the ECT should rise
• The battery voltage is between 18 to 32 volts. steadily to about 80 to 85°C (176 to 185°F) then
• The ignition switch is ON. stabilize when the thermostat opens.
• The vehicle runtime is longer than 5 minutes with • Use the Temperature vs. Resistance table to test
the vehicle speed is more than 4 km/h. the ECT sensor at various temperature levels to
• The engine runtime is longer than 5 minutes with evaluate the possibility of a skewed sensor. A
the engine speed is more than 1400 RPM. skewed sensor could result in poor driveability
concerns.
• The accumulation fuel injection quantity since
engine start is more than a threshold. Connector End View Reference: Engine Controls

following conditions. Refer to Cooling System
2 —

2. Disconnect the engine coolant temperature
(ECT) sensor harness connector.
connector of the ECT sensor (pins 1 and 2 of
E55).
E26).


(pins 84 and 109 of E26) and the ECT sensor
(pins 1 and 2 of E55) for high resistance.
4 —

Replace the ECT sensor. Refer to Engine Coolant
5 Temperature Sensor in Section 1C Engine Cooling. —
Records.

7 —

Engine Coolant Temperature Sensor Circuit • The ECM detects that the ECT sensor signal
Low or High voltage is more than 4.85 volts for 3 seconds.
(DTC P0118)
Circuit Description
installed to the thermostat housing. The ECT sensor is • The ECM illuminates the MIL when the diagnostic
a variable resistor and it measures the temperature of runs and fails. Refer to DTC Type Definitions for
the engine coolant. The sensor has a signal circuit and Action Taken When the DTC Sets - Type A.
a low reference circuit. The ECM supplies 5 volts to the • The ECM uses an ECT substitution of default
signal circuit and a ground for the low reference circuit. value.
When the ECT sensor is cold, the sensor resistance is • The ECM inhibits EGR control.
high. When the engine coolant temperature increases,
the sensor resistance decreases. With high sensor Condition for Clearing the DTC
detects a lower voltage on the signal circuit. If the ECM
Diagnostic Aids
P0117 or P0118 will set.
• DTCs P060B and P0697 are not set. • Use the Temperature vs. Resistance table to test
the ECT sensor at various temperature levels to
• The ignition switch is ON. skewed sensor could result in poor driveability
• The engine run time is longer than 5 seconds. concerns.
(DTC P0118)
• The ECM detects that the ECT sensor signal
P0117)


3 0.1 volts
connector.
4 4.5 volts


5 —

7 corrosion. —
necessary.


Records.

10 —



3 4.8 volts
connector.
Important: The ECT sensor may be damaged if
source.
5 84 of E26) and the ECT sensor (pin 1 of E55) —

signal circuit (pin 1 of E55) and a known good
7 ground. 0.1 volts
8 —

Notice: The ECT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the ECT sensor —
resistance.

for a short to any 5 volts reference circuit.
10 —


ECT sensor (pins 1 and 2 of E55).
11 —



Records.

16 —

Throttle Position Sensor Circuit Low or High Condition for Setting the DTC
• The ECM detects that the intake throttle position
Circuit Description sensor signal voltage is less than 0.1 volts for 3
The intake throttle position sensor is installed on the seconds. (DTC P0122)
intake throttle valve body together with the control • The ECM detects that the intake throttle position
motor. The intake throttle position sensor changes sensor signal voltage is more than 4.9 volts for 3
output voltage according to intake throttle valve seconds. (DTC P0123)
position. The sensor has the following circuits.
• Intake throttle position sensor signal circuit runs and fails. Refer to DTC Type Definitions for
The intake throttle position sensor provides a signal to Action Taken When the DTC Sets - Type A.
the ECM on the signal circuit, which is relative to the • The ECM inhibits EGR control.
position changes of the intake throttle valve. If the ECM
detects an excessively low or high signal voltage, DTC Condition for Clearing the DTC
P0122 or P0123 will set. • Refer to DTC Type Definitions for Condition for



Observe the Intake Throttle Position Sensor
3 0.1 volts
connector.
ground.

the 5 volts reference circuit with other sensors. A
fault condition in the 5 volts reference circuit may
set DTCs on sensors that share this circuit.
resistance.

85 of E26) and intake throttle valve (pin 6 of
E46) for the following conditions:
• An open circuit
7 —
• High resistance

intake throttle valve (pins 5 and 6 of E46).
8 —


Replace the intake throttle valve. Refer to Intake
10 Throttle Valve in Section 1B Engine Mechanical. —

Records.

13 —

2 4. Observe the Intake Throttle Position Sensor 4.9 volts

3 —
connector.
4 0.1 volts

less than the specified value? Go to DTC P0697 Go to Step 7
connector.
5 0.1 volts

Important: The intake throttle position sensor may
a voltage source.
85 of E26) and the intake throttle valve (pin 6
7 of E46) for the following conditions: —

resistance.


intake throttle valve (pin 4 of E46).
9 —



Records.

14 —

Fuel Temperature Sensor Circuit Low or High • The ECM detects that the FT sensor signal voltage
is more than 4.85 volts for 3 seconds. (DTC
The fuel temperature (FT) sensor is installed to the fuel
supply pump. The FT sensor is a variable resistor and it
measures the temperature of the fuel entering the fuel • The ECM illuminates the MIL when the diagnostic
supply pump. The sensor has a signal circuit and a low runs and fails. Refer to DTC Type Definitions for
reference circuit. The ECM supplies 5 volts to the Action Taken When the DTC Sets - Type A.
signal circuit and a ground for the low reference circuit. • The ECM uses a FT substitution of default value.
high. When the fuel temperature increases, the sensor Condition for Clearing the DTC
resistance decreases. With high sensor resistance, the • Refer to DTC Type Definitions for Condition for
ECM detects a high voltage on the signal circuit. With Clearing the MIL/ DTC - Type A.
voltage on the signal circuit. If the ECM detects an Diagnostic Aids
P0183 will set. • Before starting a cold engine, FT sensor and
engine coolant temperature (ECT) sensor
Condition for Running the DTC temperature should be relatively close to each
other.
• The engine run time is longer than 3 minutes. the FT sensor at various temperature levels to
(DTC P0183) evaluate the possibility of a skewed sensor. A
Condition for Setting the DTC concerns.
• The ECM detects that the FT sensor signal voltage
is less than 0.1 volts for 3 seconds. (DTC P0182) Connector End View Reference: Engine Controls


with a scan tool.
3 0.1 volts
Is the Fuel Temperature Sensor parameter less Go to Diagnostic
Is the Fuel Temperature Sensor parameter more


5 —

7 corrosion. —
necessary.


Records.

10 —



with a scan tool.
3 4.8 volts
Is the Fuel Temperature Sensor parameter more Go to Diagnostic
3. Connect a DMM between the signal circuit
4 (pin 2 of E30) and a known good ground. 5.5 volts
Important: The FT sensor may be damaged if the
5 83 of E26) and the FT sensor (pin 2 of E30) for —

signal circuit of the sensor harness (pin 2 of E30)
7 and a known good ground. 0.1 volts
8 —

Notice: The FT sensor shares the low reference
share this circuit.
9 ECM (pin 109 of E26) and the FT sensor (pin —
resistance.

a short to any 5 volts reference circuit.
10 —

FT sensor (pins 1 and 2 of E30).
11 —




Records.

16 —

Fuel Rail Pressure Sensor Circuit Low or High • The ECM detects that the FRP sensor signal
voltage is more than 4.75 volts. (DTC P0193)
Circuit Description
The fuel rail pressure (FRP) sensor is installed to the
fuel rail and it detects the fuel pressure in the fuel rail, • The ECM illuminates MIL when the diagnostic runs
converts the pressure into a voltage signal, and sends and fails. Refer to DTC Type Definitions for Action
the signal to the ECM. The sensor has the following Taken When the DTC Sets - Type A.
circuits. • The ECM uses a FRP substitution of default value.
• 5 volts reference circuit • The ECM limits fuel injection quantity.
• Low reference circuit • The ECM inhibits pre injection.
• FRP sensor signal circuit • The ECM inhibits EGR control.
The ECM monitors the FRP sensor signal voltage. • The ECM inhibits cruise control.
Higher fuel rail pressure provides higher signal voltage
while lower pressure provides lower signal voltage. The Condition for Clearing the DTC
ECM calculates actual fuel rail pressure (fuel pressure)
from the voltage signal and uses the result in fuel • Refer to DTC Type Definitions for Condition for
injection control and other control tasks. If the ECM Clearing the MIL/ DTC - Type A.
P0192 or P0193 will set. Diagnostic Aids
• DTCs P060B and P0651 are not set. • Electromagnetic interference may affect
• The battery voltage is between 18 to 32 volts. intermittent condition.
• The ECM detects that the FRP sensor signal


with a scan tool.
3 0.7 volts
Is the Fuel Rail Pressure Sensor parameter less Go to Diagnostic
connector.
Is the Fuel Rail Pressure Sensor parameter more


of E49) for the following conditions:
6 —

Notice: The FRP sensor shares the 5 volts
7 ECM (pin 87 of E26) and the FRP sensor (pin —
resistance.

FRP sensor (pin 3 of E49).
8 —


programmed.

Records.


13 —

Did you perform the Diagnostic System Check- Go to Diagnostic

with a scan tool.
3 4.5 volts
Is the Fuel Rail Pressure Sensor parameter more Go to Diagnostic
connector.
signal circuit and the low reference circuit of the
6 sensor harness (pins 1 and 2 of E49). 0.1 volts
Is the Fuel Rail Pressure Sensor parameter less
Notice: The FRP sensor shares the low reference
share this circuit.
7 ECM (pin 101 of E26) and the FRP sensor —
resistance.

1. Test the signal circuit between the ECM (pins
8 —


of E49) for a short to any 5 volts reference
9 circuit. —

Important: The FRP sensor may be damaged if
source.
10 82 and 90 of E26) and the FRP sensor (pin 2 —
of E49) for a short to battery or ignition
voltage.

FRP sensor (pins 1 and 2 of E49).
11 —

ECM (pins 82, 90 and 101 of E26).


Records.

16 —

DTC P0201, P0202, P0203 or P0204 (Flash Code 271, 272, 273 or 274)
Injector Circuit Open - Cylinder 1, 2, 3 or 4 • The ECM detects an open circuit on the fuel
injector solenoid circuits.
Circuit Description • The ECM detects that the fuel injector solenoid
The ECM calculates the optimum fuel injection ON time control circuit is shorted to voltage circuit or charge
using data sent from various engine sensors. The voltage circuit.
common 1 and 2 fuel injector charge voltage circuits
are high-voltage supply, which drives fuel injectors for Action Taken When the DTC Sets
each cylinder in conjunction with the ECM grounding • The ECM illuminates the MIL when the diagnostic
the fuel injector solenoid control circuit. The common 1 runs and fails. Refer to DTC Type Definitions for
covers fuel injectors in cylinders #1 and #4, and the Action Taken When the DTC Sets - Type A.
common 2 covers fuel injectors in cylinders #2 and #3. • The ECM limits fuel injection quantity.
If the fuel injector charge voltage circuit or solenoid
control circuit is open circuit, DTC P0201 - P0204 will
set depending upon which cylinder injector circuit
failed. If the fuel injector solenoid control circuit is
shorted to voltage circuit or common charge voltage • Refer to DTC Type Definitions for Condition for
circuit, this DTC will also set. Clearing the MIL/ DTC - Type A.

• DTCs P1261 and P2146 are not set. (DTC P0201 • If an intermittent condition is suspected, refer to
or P0204) Intermittent Conditions in this section.
• DTCs P1262 and P2149 are not set. (DTC P0202
or P0203) Notice: Each DTC agrees with engine cylinder order.
• The battery voltage is between 18 to 32 volts. • P0201: Cylinder #1
• The ignition switch is ON. • P0202: Cylinder #2
• The engine is running. • P0203: Cylinder #3
• P0204: Cylinder #4

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Cylinder Head Cover in Section 1B Engine
Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.
Injector in Section 1D Engine Fuel.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




1. Test the cylinder #2 fuel injector circuits
• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




1. Test the cylinder #3 fuel injector circuits
• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Go to Diagnostic
3 1.0 volt

5 12.0 volts
6 —

Mechanical.
terminals.
7 —




• An open circuit
11 —
• High resistance



programmed.


Records.

16 —

Engine Coolant Over Temperature Condition Action Taken When the DTC Sets
The engine coolant temperature (ECT) sensor is When the DTC Sets - Type D.
installed to the thermostat housing. The ECT sensor is
a variable resistor and it measures the temperature of Condition for Clearing the DTC
the engine coolant. If the ECM detects an excessive • Refer to DTC Type Definitions for Condition for
high coolant temperature, this DTC will set. Clearing the DTC - Type D.

• DTCs P0116, P0117, P0118, P060B and P0697 • After starting the engine, the ECT should rise
are not set. steadily to about 80 to 85°C (176 to 185°F) then
• The battery voltage is between 18 to 32 volts. stabilize when the thermostat opens.
• The engine is running. the ECT sensor at various temperature levels to
Condition for Setting the DTC skewed sensor could result in poor driveability
concerns.
• The Total Engine Coolant Overtemperature Events
• The ECM detects that the engine coolant parameter on the scan tool indicates number of
temperature is more than 110°C (230°F) for 5 overheat events.
seconds.
• The ECM detects that the engine coolant Notice: This DTC is caused by an engine overheat
temperature is more than 120°C (248°F) for 5 condition (e.g. low engine coolant level). Since this
seconds during the DPD filter regeneration. DTC does not illuminate any lamps, clear the DTC and
ensure there are no signs of engine damage.
Excessive engine overheat may damage internal
engine components.


following condition. Refer to Cooling System
• Cooling fan belt slippage
3 • Cooling fan clutch working —
• Thermostat working
• Water pump working
• Radiator clogging


Start the engine and wait until engine is fully warm
upped while observing the Coolant Temperature
4 parameter with a scan tool. 110°C (230°F)
Ask the driver if overheat is caused by low engine
coolant level, etc.
5 If engine overheat has experienced, the engine —
must be inspected and repaired as necessary.

1. Test the engine coolant temperature (ECT)
sensor at various temperature levels to
evaluate the possibility of a skewed sensor.
6 —
2. Replace the ECT sensor as necessary.
Go to Diagnostic
7 4. Start the engine and wait until engine is fully 110°C (230°F)
warm upped while observing the Coolant
Temperature parameter with a scan tool.

8 —

Engine Overspeed Condition Condition for Clearing the DTC
Circuit Description Clearing the DTC - Type D.
The crankshaft position (CKP) sensor is located on the
flywheel housing. The ECM calculates the engine Diagnostic Aids
speed and exact position of the crankshaft based on • Make sure the CKP sensor is tight and the sensor
the signal pulse from the CKP sensor. If the ECM rotor teeth are not damaged.
detects an engine overrun condition, this DTC will set. • Electromagnetic interference in the CKP sensor
• The Total Engine Overspeed Events parameter on
• The ECM detects that the engine speed is more the scan tool indicates number of overrun events.
than 3640 RPM.
Notice: This DTC is caused by an engine overspeed
Action Taken When the DTC Sets condition, which was most likely caused by driver error
• The ECM will not illuminate the MIL or SVS lamp. (i.e. downshifting a manual transmission on a steep
Refer to DTC Type Definitions for Action Taken grade). Since the DTC does not illuminate any lamps,
When the DTC Sets - Type D. clear the DTC and ensure there are no sign of engine
damage. Excessive engine overspeed may damage
internal engine components.

Important: If DTC P0335 or P0336 is set, diagnose
that DTC first.
2 3. Observe the Engine Speed parameter with a 3700 RPM
scan tool.
4. Accelerate the engine as necessary.

Ask the driver if overrun is caused by gear slip-out,
shift error, down-slope driving, etc. If engine
3 overrun has experienced, the engine must be —
inspected and repaired as necessary.

rotor


Replace the CKP sensor. Refer to Crankshaft
5 Position Sensor in Section 1B Engine Mechanical. —
6 5. Accelerate the engine between idle and 3700 RPM
times while observing the Engine Speed

7 —

Turbocharger Overboost Condition Condition for Clearing the DTC
Circuit Description Clearing the MIL/ DTC - Type A.
voltage according to changes in the air pressure inside • An open circuit or high resistance in the boost
the air tubing. The ECM monitors the boost pressure pressure low reference circuit may set this DTC.
sensor signal for abnormal values. If the ECM detects • Check the turbocharger nozzle control solenoid for
that the sensor signal is excessively high, this DTC will a sticking.
set. This indicates excessive high boost pressure.
Condition for Running the DTC pressure sensor signal. Compare the sensor
• DTCs P0045, P0237, P0238, P060B, P0697, high value.
U0073 and U0110 are not set.
• The fuel with which gasoline was mixed may set
• The ignition switch is ON. this DTC.

• The ECM detects an excessive boost pressure for The numbers below refer to the step number on the
longer than 5 seconds. Circuit/ System Testing.
3. A skewed boost pressure sensor value (shifted to a
Action Taken When the DTC Sets higher pressure) can set this DTC. The Boost Pressure
• The ECM illuminates the MIL when the diagnostic on the scan tool should read near Barometric Pressure
runs and fails. Refer to DTC Type Definitions for with the ignition switch ON and engine OFF.
Action Taken When the DTC Sets - Type A. 4. A skewed Barometric Pressure sensor value (shifted
• The ECM limits fuel injection quantity. to a lower pressure) may indicate a wrong boost
pressure. The Barometric Pressure on the scan tool

2 —

P2228 or P2229 also set? DTC Go to Step 3
3
psi)
between the Boost Pressure and Barometric
Pressure is more than the specified value? Go to Step 4 Go to Step 5
Compare the BARO value to the range specified in
the altitude vs. barometric pressure table. Refer to
4 Altitude vs. Barometric Pressure. —

high boost pressure.
• Turbocharger nozzle control solenoid
valve for a stuck condition. Perform the
Turbocharger Solenoid Control with a
scan tool.
5 scan tool. —
Go to Diagnostic
Did you find and correction the condition? Go to Step 10 Aids
harness connector.
connector of the ECM (pin 109 of E26).
circuit.
necessary.

connector.
FB24).
necessary.

Replace the boost pressure sensor. Refer to Boost
8 Pressure Sensor in Section 1J Induction. —
9 —

Records.

11 —

Turbo Charger Boost Sensor Circuit Low or Condition for Setting the DTC
High • The ECM detects that the boost pressure sensor
signal voltage is less than 0.1 volts for 3 seconds.
Circuit Description (DTC P0237)
The boost pressure sensor is located in the air • The ECM detects that the boost pressure sensor
induction tubing. The boost pressure sensor is a signal voltage is more than 4.9 volts for 3 seconds.
transducer that varies voltage according to changes in (DTC P0238)
the air pressure inside the air tubing. The sensor has
the following circuits. Action Taken When the DTC Sets
• Boost pressure sensor signal circuit
The boost pressure sensor provides a signal to the • The ECM uses a boost pressure substitution of
ECM on the signal circuit, which is relative to the default value.
pressure changes in the air tubing. The ECM should • The ECM inhibits EGR control.
detect a low signal voltage at a low boost pressure,
such as low engine load. The ECM should detect high Condition for Clearing the DTC
signal voltage at a high boost pressure, such as high • Refer to DTC Type Definitions for Condition for
engine load. If the ECM detects an excessively low or Clearing the MIL/ DTC - Type A.
Diagnostic Aids


Observe the Boost Pressure Sensor parameter
with a scan tool.
3 0.1 volts
Is the Boost Pressure Sensor parameter less than Go to Diagnostic
harness connector.
ground.

Is the Boost Pressure Sensor parameter more than
Notice: The boost pressure sensor shares the 5
high resistance.

1 of E54) for the following conditions:
• An open circuit
7 —
• High resistance

8 —




Records.

13 —

2 4. Observe the Boost Pressure Sensor 4.9 volts
Is the Boost Pressure Sensor parameter more than Go to Diagnostic

3 —
harness connector.
4 0.1 volts

the specified value? Go to DTC P0697 Go to Step 7
harness connector.
5 0.1 volts


Important: The boost pressure sensor may be
voltage source.
7 1 of E54) for the following conditions: —

Notice: The boost pressure sensor shares the low
high resistance.

9 —



Records.

14 —

Turbocharger Underboost Condition for Clearing the DTC
Circuit Description Clearing the MIL/ DTC - Type B.
voltage according to changes in the air pressure inside • Induction air leakage can cause a low boost
the air tubing. The ECM monitors the boost pressure pressure condition. A whistling noise may be heard
sensor signal for abnormal values. If the ECM detects if a component is allowing air to enter the induction
that the sensor signal is excessively low, this DTC will system.
set. This indicates excessive low boost pressure. • Check for cracked air tubing that may only open
during certain engine movement conditions.
• Check the turbocharger nozzle control solenoid for
• DTCs P0045, P0079, P0080, P0087, P0089, a sticking.
P0091, P0092, P0093, P0102, P0103, P0116,
P0117, P0118, P0122, P0123, P0192, P0193,
pressure sensor signal. Compare the sensor
P0201 - P0204, P0237, P0238, P0401, P0404,
P0409, P0560, P060B, P0638, P0651, P0697,
low value.
P1093, P1261, P1262, P1404, P2146, P2149,
P2227, P2228, P2229, P2453, U0073 and U0110 • Fuel system problem (low fuel pressure condition)
are not set. may set this DTC.
Test Description
• The engine speed is between 1000 to 2600 RPM.
The numbers below refer to the step number on the
• The fuel injection quantity is higher than a Circuit/ System Testing.
predetermined range. 4. A skewed boost pressure sensor value (shifted to a
lower pressure) can set this DTC. The Boost Pressure
Condition for Setting the DTC on the scan tool should read near Barometric Pressure
• The ECM detects that the actual boost pressure is with the ignition switch ON and engine OFF.
more than specified value below the desired boost 5. A skewed Barometric Pressure sensor value (shifted
pressure under certain conditions for longer than 5 to a higher pressure) may indicate a wrong boost
seconds. pressure. The Barometric Pressure on the scan tool
• The ECM illuminates the MIL on the second Connector End View Reference: Engine Controls
consecutive driving cycle when the diagnostic runs Connector End Views or ECM Connector End Views

2 —


low boost pressure.
• Air leakage around the boost pressure
sensor or objects that block the sensor
hole.
• Air leaking around any of the air induction
tubing between the turbocharger and
intake manifold. Check for damaged
components and for loose clamps.
• Turbine shaft binding causing lower
turbocharger shaft spinning speeds.
Refer to Turbocharger Assembly in
Section 1J Induction.
• Turbocharger nozzle control solenoid
valve for a stuck condition. Perform the
3 Turbocharger Solenoid Control with a —
scan tool.
scan tool.
cleaner and the boost pressure sensor.

4
psi)
between the Boost Pressure and Barometric Go to Diagnostic
Pressure is more than the specified value? Go to Step 5 Aids
Compare the BARO value to the range specified in
the altitude vs. barometric pressure table. Refer to
5 Altitude vs. Barometric Pressure. —
harness connector.
connector of the ECM (pins 91 and 95 of E26).
necessary.


connector.
circuit.
necessary.

9 —
Records.

11 —

Crankshaft Position Sensor Circuit Condition for Setting the DTC
• The ECM detects that the CKP sensor signal
the fuel supply pump. There are 56 notches spaced 6° Action Taken When the DTC Sets
apart and a 30° section that is open span. This open • The ECM illuminates the MIL when the diagnostic
span portion allows for the detection of top dead center runs and fails. Refer to DTC Type Definitions for
(TDC). The CKP sensor is a magnetic resistance Action Taken When the DTC Sets - Type A.
element (MRE) type sensor, which generates a square
wave signal pulse. The sensor has the following Condition for Clearing the DTC
circuits.
• 5 volts reference circuit Clearing the MIL/ DTC - Type A.
• CKP sensor signal circuit Diagnostic Aids
The ECM monitors both CKP sensor and camshaft • If an intermittent condition is suspected, refer to
position (CMP) sensor signal pulses to ensure they Intermittent Conditions in this section.
correlate with each other. If the ECM receives a certain • Electromagnetic interference in the CKP sensor
amount of CMP sensor signal pulses without a CKP circuits may set this DTC.
sensor signal pulse, this DTC will set.
Condition for Running the DTC this DTC.
set.
• The ignition switch is ON. Notice: If the CKP sensor signal pulse is lost while
• The CMP sensor signal pulse is detected. running, the engine will stop.


2 be noticed). —
Go to Diagnostic
Is DTC P0340, P0341 or P0697 also set? Go to Applicable
3 —
DTC Go to Step 4
ground.

6 4.5 volts
8 circuit and low reference (pins 2 and 3 of E50). 4.5 volts
Notice: The CKP sensor shares the 5 volts
9 ECM (pin 95 of E26) and the CKP sensor (pin —
resistance.

Notice: The CKP sensor shares the low reference
share this circuit.
10 ECM (pin 109 of E26) and the CKP sensor —
resistance.

• An open circuit
11 —
• High resistance

Important: The CKP sensor may be damaged if
source.
12 107 of E26) and the CKP sensor (pin 1 of E50) —


13 —

CKP sensor (pins 1, 2 and 3 of E50).
14 —

ECM (pins 95, 107, 108 and 109 of E26).

rotor


Records.

20 —

Crankshaft Position Sensor Circuit Range/ Action Taken When the DTC Sets
the fuel supply pump. There are 56 notches spaced 6° Condition for Clearing the DTC
apart and a 30° section that is open span. This open • Refer to DTC Type Definitions for Condition for
span portion allows for the detection of top dead center Clearing the MIL/ DTC - Type A.
(TDC). The ECM monitors both CKP sensor and
camshaft position (CMP) sensor signal pulses to Diagnostic Aids
ensure they correlate with each other. If the ECM • If an intermittent condition is suspected, refer to
receives extra or missing CKP sensor signal pulse, this Intermittent Conditions in this section.
DTC will set.
• Electromagnetic interference in the CKP sensor
this DTC.
set.
• The CKP sensor signal pulse is detected.
• The ECM detects extra or missing CKP sensor

2 be noticed). —
Go to Applicable
1. Inspect all of the circuits going to the
crankshaft position (CKP) sensor for the
or components
relays
harness routing.


109 of E26).
4. Disconnect the CKP sensor harness
4 connector. —
connector of the CKP sensor (pins 1, 2 and 3
of E50).

rotor

Records.

8 —

Camshaft Position Sensor Circuit Condition for Setting the DTC
• The ECM detects that the CMP sensor signal
cylinder head at the rear of the camshaft gear. The Action Taken When the DTC Sets
CMP sensor detects total of five projections per one • The ECM illuminates the MIL when the diagnostic
engine cycle (four projections arranged equally every runs and fails. Refer to DTC Type Definitions for
90° and one reference projection on the camshaft gear Action Taken When the DTC Sets - Type A.
surface). The CMP sensor is a magnetic resistance
element (MRE) type sensor, which generates a square Condition for Clearing the DTC
wave signal pulse. The sensor has the following
circuits.
• Low reference circuit Diagnostic Aids
• CMP sensor signal circuit • If an intermittent condition is suspected, refer to
The ECM monitors both crankshaft position (CKP) Intermittent Conditions in this section.
sensor and CMP sensor signal pulses to ensure they • Electromagnetic interference in the CMP sensor
correlate with each other. If the ECM receives a certain circuits may set this DTC.
amount of CKP sensor signal pulses without a CMP
sensor signal pulse, this DTC will set. • An intermittent CMP sensor signal pulse may set
this DTC.
Condition for Running the DTC • Ensure the sensor is tight and the camshaft gear is
not damaged.
set.
Notice: If the CMP sensor signal pulse is lost while
• The ignition switch is ON. running, the engine will operate normally. If the CMP
• The CKP sensor signal pulse is detected. sensor signal pulse is not present on start-up, the
engine will not start.


Go to Applicable
3 Is DTC P0651 also set? — Go to DTC P0651 Go to Step 4
ground.

6 4.5 volts
8 E48). 4.5 volts
Notice: The CMP sensor shares the 5 volts
9 ECM (pin 87 of E26) and the CMP sensor (pin —
resistance.

Notice: The CMP sensor shares the low reference
share this circuit.
10 ECM (pin 101 of E26) and the CMP sensor —
resistance.

• An open circuit
11 —
• High resistance

Important: The CMP sensor may be damaged if
source.
12 98 of E26) and the CMP sensor (pin 1 of E48) —


98 of E26) and the CMP sensor (pin 1 of E48)
13 —

CMP sensor (pins 1, 2 and 3 of E48).
14 —

ECM (pins 87, 98, 100 and 101 of E26).

camshaft gear

Replace the CMP sensor. Refer to Camshaft

Records.

20 —

Camshaft Position Sensor Circuit Range/ Action Taken When the DTC Sets
cylinder head at the rear of the camshaft gear. The Condition for Clearing the DTC
CMP sensor detects total of five projections per one • Refer to DTC Type Definitions for Condition for
engine cycle (four projections arranged equally every Clearing the MIL/ DTC - Type A.
surface). The ECM monitors both crankshaft position Diagnostic Aids
(CKP) sensor and CMP sensor signal pulses to ensure • If an intermittent condition is suspected, refer to
they correlate with each other. If the ECM receives Intermittent Conditions in this section.
extra or missing CMP sensor signal pulse, this DTC will
• Electromagnetic interference in the CMP sensor
set.
Condition for Running the DTC • An intermittent CMP sensor signal pulse may set
this DTC.
set. • Ensure the sensor is tight and the camshaft gear is
not damaged.
• The CMP sensor signal pulse is detected. Connector End View Reference: Engine Controls
• The ECM detects extra or missing CMP sensor

Go to Applicable
1. Inspect all of the circuits going to the camshaft
position (CMP) sensor for the following
conditions:
or components
relays
harness routing.


2. Disconnect the CMP sensor harness
connector.
connector of the CMP sensor (pins 1, 2 and 3
of E48).
101 of E26).

camshaft gear

Records.

8 —

Glow Plug Circuit Action Taken When the DTC Sets
The ECM controls the glow relay which supplies power Definitions for Action Taken When the DTC Sets -
to the glow plugs based on engine coolant Type C.
temperature. In the after glow phase, the glow plug
lamp is not illuminated but glow plugs remain active for Condition for Clearing the DTC
a certain period. If the ECM detects an open circuit or • Refer to DTC Type Definitions for Condition for
short circuit on the relay control circuit, this DTC will Clearing the SVS Lamp/ DTC - Type C.
set.
Diagnostic Aids
Test Description
Condition for Setting the DTC The numbers below refers to the step number on the
Either of following condition is met: Circuit/ System Testing.
• The ECM detects a low voltage condition on the 2. Listen for an audible click when the glow relay
glow relay control circuit for longer than 3 seconds operates. Command both the ON and OFF states.
when the relay is commanded OFF.
glow relay control circuit for longer than 3 seconds
when the relay is commanded ON.

2 tool. —
Go to Diagnostic
Does the glow relay click with each command? Aids Go to Step 3
3 replace with a known good relay. —
4 4. Connect a test lamp between the ignition —
voltage feed circuit of the relay coil side (pin 3
of X19) and a known good ground.


10 of FB24) and the relay (pin 5 of X19) for the
• An open circuit
5 —
• High resistance

the Engine Controller (10A) fuse and the glow relay
6 coil side (pin 3 of X19). Check the Engine —
Controller (10A) fuse first.

7 connection on each relay terminal. —


9 —

11 3. Perform the Glow Relay Control with a scan —
tool.
12 —

Glow Plug Indicator Circuit Condition for Setting the DTC
The glow plug lamp is located on the instrument panel glow plug lamp control circuit for longer than 3
(IP) cluster. The glow control system is operated when seconds when the lamp is commanded OFF.
the engine coolant temperature is low, which allows • The ECM detects a high voltage condition on the
easier engine starting. If the ignition switch is turned glow plug lamp control circuit for longer than 3
ON when the engine coolant temperature is low, the seconds when the lamp is commanded ON.
ECM illuminates the glow plug lamp and turns ON the
glow plugs. After a fixed time passes, the ECM turns Action Taken When the DTC Sets
OFF the glow plug lamp and the glow plugs. The ECM
monitors the glow plug lamp control circuit for • The ECM illuminates the SVS lamp when the
conditions that are incorrect for the commanded state diagnostic runs and fails. Refer to DTC Type
of the glow plug lamp. For example, a failure condition Definitions for Action Taken When the DTC Sets -
exists if the ECM detects low voltage when the glow Type C.
plug lamp is commanded OFF, or high voltage when
the glow plug lamp is commanded ON. If the ECM Condition for Clearing the DTC
detects an improper voltage level on the control circuit, • Refer to DTC Type Definitions for Condition for
this DTC will set. Clearing the SVS Lamp/ DTC - Type C.



Go to Diagnostic
3 block. —



Is the glow plug lamp OFF? Go to Step 6 Go to Step 12

voltage to the glow plug lamp.
6 3. Measure the voltage from the glow plug lamp 1 volt

Is the glow plug lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 —

11 —




15 Driver Info. —



18 —

EGR Flow Insufficient Detected Condition for Setting the DTC
• The ECM detects that the MAF amount is not
Circuit Description within the calculated range during the EGR flow
The ECM controls the EGR valve opening based on the test. This indicates insufficient amount of EGR
engine running condition and by controlling the EGR flow.
motor. The EGR valve position is detected by the
position sensor, and relayed to the ECM. When the Action Taken When the DTC Sets
proper enabling conditions are met, the ECM will open • The ECM blinks the MIL when the diagnostic runs
the EGR valve while monitoring the mass air flow and fails. Refer to DTC Type Definitions for Action
(MAF) signal. An expected MAF difference should be Taken When the DTC Sets - Type A.
detected between the closed and open positions. If the • The ECM limits fuel injection quantity.
ECM detects the MAF difference less than expected,
this DTC will set. This DTC will only run once per • The ECM inhibits cruise control.
ignition cycle within the enabling conditions.
Condition for Running the DTC • Refer to DTC Type Definitions for Condition for
P0113, P0116, P0117, P0118, P0122, P0123,
P0404, P0409, P0500, P0502, P0503, P0560, Notice: A history DTC remains 9,600 hours
P060B, P0638, P0651, P0697, P1404, P215A, (accumulated engine runtime) and will not clear with a
P2227, P2228 and P2229 are not set. scan tool.
may set this DTC.

Go to Applicable
Warm up the engine (allow engine coolant
temperature to reach at least 75°C [167°F]) and let
3 idle for at least 3 minutes while observing the DTC —
Information with a scan tool.
Go to Diagnostic

damaged
• EGR gas leakage from any of the EGR
passages between the exhaust manifold
and intake manifold
EGR valve
system
4 • Any air induction leak —
system
• Skew or slow MAF sensor
Exhaust.
• A ventilation duct that is connected to the
exhaust tail pipe. Retest without the duct
if connected.

tool several times.
5 Position 1. ± 5%

Replace the EGR valve. Refer to EGR Valve and
6 EGR Cooler in Section 1F Emission Control. —

7 —
4. Start the engine and warm up (allow engine
[167°F])
5. Let idle for at least 3 minutes while observing
the DTC Information with a scan tool.


8 —

EGR Control Circuit Range/ Performance Action Taken When the DTC Sets
• The ECM blinks the MIL when the diagnostic runs
Circuit Description and fails. Refer to DTC Type Definitions for Action
The ECM controls the EGR valve opening based on the Taken When the DTC Sets - Type A.
engine running condition and by controlling the EGR • The ECM limits fuel injection quantity.
motor. The EGR valve position is detected by the • The ECM inhibits EGR control.
position sensor, and relayed to the ECM. If the ECM
detects a variance between the actual EGR valve
position and desired EGR valve position for a
calibrated amount of time while the EGR valve is
commanded ON, this DTC will set. • Refer to DTC Type Definitions for Condition for
• DTCs P0112, P0113, P0116, P0117, P0118,
P0409, P060B, P0651, P0697, P2227, P2228 and
scan tool.
P2229 are not set.
• The EGR control is commanded ON. Intermittent Conditions in this section.
• The ECM detects that the actual EGR valve
position is more than 10% below the desired valve Connector End View Reference: Engine Controls
position for longer than 5 seconds. Connector End Views or ECM Connector End Views


tool several times.
3 Position 1. ± 5%


engine.
conditions:
4 materials —

6, 7 and 8 of E45).
5 —
101, 103, 110 and 111 of E26).
each circuit.
necessary.

conditions:
6 —
circuit(s)


Records.




Records.

11 —

EGR Sensor Circuit Condition for Setting the DTC
• The ECM detects that all EGR valve position
Circuit Description sensor signals are stuck low or high for longer than
The exhaust gas recirculation (EGR) position sensor is 3 seconds.
installed on the EGR valve body together with the
control motor. The sensor is made up three individual Action Taken When the DTC Sets
sensors within one housing. The EGR position sensor • The ECM blinks the MIL when the diagnostic runs
1, EGR position sensor 2 and EGR position sensor 3 and fails. Refer to DTC Type Definitions for Action
are hall element type sensors, each with the following Taken When the DTC Sets - Type A.
circuits. • The ECM limits fuel injection quantity.
• 5 volts reference circuit • The ECM inhibits EGR control.
• Signal circuit
The EGR position sensor provides a low or high signal Condition for Clearing the DTC
state to the ECM on the signal circuits, which is relative
to the position changes of the EGR valve. If the ECM
detects that each EGR position sensor signal state is
out of correlation such as all low signal state or high
signal state, this DTC will set.
scan tool.



3 —
4. Observe the EGR Position 1, 2 and 3
parameters with a scan tool.
Is there parameter which indicate High? Go to Step 7 Go to Step 4

5 E45). 4.5 volts

Observe the EGR Position 1, 2 and 3 parameter
with a scan tool while momentarily jumping a 3-
amp fused jumper wire across the EGR valve
harness connector between each signal circuit and
the 5 volts reference circuit.
6 • EGR position 1: pins 1 and 4 of E45 —
Is there parameter which did not indicate High

when the circuit is jumpered? Go to Step 10 Go to Step 11
Important: The EGR position sensor may be
voltage source.
1. Test the signal circuits (which ever parameter
indicates High at Step 3) between the ECM
(pins 93, 94 and 99 of E26) and the EGR
7 valve (pins 2, 3 and 4 of E45) for the following —
conditions:

Notice: The EGR position sensor shares the 5
8 1. Test the 5 volts reference circuit between the —

ECM (pin 87 of E26) and the EGR valve (pin 1

Notice: The EGR position sensor shares the low
9 ECM (pin 101 of E26) and the EGR valve (pin —
resistance.

1. Test the position sensor circuits (which ever
parameter did not indicate High at Step 6)
between the ECM (pins 93, 94 and 99 of E26)
and the EGR valve (pins 2, 3 and 4 of E45) for
• An open circuit
10 —
• High resistance


EGR valve (pins 1, 2, 3, 4 and 5 of E45).
11 —

(pins 6, 7 and 8 of E45) for a short to the EGR
12 position sensor circuit(s). —

ECM (pins 87, 93, 94, 99 and 101 of E26).



Records.

17 —

DPD filter. If the ECM detects an excessively high Condition for Clearing the DTC
exhaust temperature, this DTC will set.
• DTCs P0427, P0428, P060B and P0697 are not Diagnostic Aids
set.
front of filter) is higher than 880°C (1616°F) for 5 may set this DTC.
seconds.
temperature may damage DPD filter or oxidation
catalyst.

Go to Applicable
necessary. Refer to Exhaust Temperature
Sensor in Section 1G Engine Exhaust.


1G Engine Exhaust.

Go to Diagnostic
5 —

6 —

Catalyst Temperature Sensor Circuit Low or • The engine run time is longer than 5 to 10 minutes.
High Sensor 1 (DTC P0428)
The exhaust temperature sensor 1 is installed to the • The ECM detects that the exhaust temperature
diesel particulate defuser (DPD) housing. The exhaust sensor 1 signal voltage is less than 0.2 volts for 3
temperature sensor 1 is a variable resistor and it seconds. (DTC P0427)
measures the temperature of the exhaust gas in front of • The ECM detects that the exhaust temperature
DPD filter. The sensor has a signal circuit and a low sensor 1 signal voltage is more than 4.85 volts for
reference circuit. The ECM supplies 5 volts to the 5 seconds. (DTC P0428)
signal circuit and a ground for the low reference circuit.
When the exhaust temperature sensor 1 is cold, the Action Taken When the DTC Sets
sensor resistance is high. When the exhaust • The ECM illuminates MIL when the diagnostic runs
temperature increases, the sensor resistance and fails. Refer to DTC Type Definitions for Action
decreases. With high sensor resistance, the ECM Taken When the DTC Sets - Type A.
the signal circuit. If the ECM detects an excessively low • The ECM inhibits pre injection.
or high signal voltage, DTC P0427 or P0428 will set. • The ECM inhibits cruise control.
• DTCs P060B and P0697 are not set. (DTC P0427) • Refer to DTC Type Definitions for Condition for
P060B, P0651, P0697, P2227, P2228 and P2229
are not set. (DTC P0428) Diagnostic Aids
• The engine coolant temperature is more than 80°C
the exhaust temperature sensor 1 at various
(176°F). (DTC P0428)
• The engine speed is more than 1400 RPM. (DTC skewed sensor.
P0428)
• The fuel injection quantity is more than a Connector End View Reference: Engine Controls
predetermined value. (DTC P0428) Connector End Views or ECM Connector End Views
• The vehicle is running or the PTO control is
inactive.


3 0.2 volts

harness connector.
4 4.5 volts

conditions:

to Exhaust Temperature Sensor in Section 1G
6 Engine Exhaust. —

7 corrosion. —
necessary.


Records.

10 —



80°C [176°F]).
tool.

harness connector.
a voltage source.

7 ground. 0.1 volts




11 FB67). —




80°C [176°F]).
15 4.8 volts
tool.


16 —

oxidation catalyst. If the ECM detects an excessively Condition for Clearing the DTC
high exhaust temperature, this DTC will set.
• DTCs P042C, P042D, P060B and P0697 are not Diagnostic Aids
set.
front of oxidation catalyst) is higher than 870°C may set this DTC.
(1600°F) for 5 seconds.
temperature may damage DPD filter.

Go to Applicable
Is DTC P0093, P042C or P1093 also set? DTC Go to Step 3
necessary. Refer to Exhaust Temperature
Sensor in Section 1G Engine Exhaust.


1G Engine Exhaust.

Go to Diagnostic
5 —

6 —

DTC P042C or P042D (Flash Code 49)
Catalyst Temperature Sensor Circuit Low or • The vehicle is running or the PTO control is
High Sensor 2 inactive.
• The engine run time is longer than 5 to 10 minutes.
Circuit Description (DTC P042D)
The exhaust temperature sensor 2 is installed to the
diesel particulate defuser (DPD) housing. The exhaust
temperature sensor 2 is a variable resistor and it • The ECM detects that the exhaust temperature
measures the temperature of the exhaust gas in front of sensor 2 signal voltage is less than 0.2 volts for 3
oxidation catalyst. The sensor has a signal circuit and a seconds. (DTC P042C)
low reference circuit. The ECM supplies 5 volts to the • The ECM detects that the exhaust temperature
signal circuit and a ground for the low reference circuit. sensor 2 signal voltage is more than 4.85 volts for
When the exhaust temperature sensor 2 is cold, the 5 seconds. (DTC P042D)
sensor resistance is high. When the exhaust
temperature increases, the sensor resistance Action Taken When the DTC Sets
decreases. With high sensor resistance, the ECM
Definitions for Action Taken When the DTC Sets -
the signal circuit. If the ECM detects an excessively low
Type C.
or high signal voltage, DTC P042C or P042D will set.
• DTCs P060B and P0697 are not set. (DTC P042C)
• DTCs P0112, P0113, P0116, P0117, P0118,
P060B, P0651, P0697, P2227, P2228 and P2229 Diagnostic Aids
are not set. (DTC P042D)
• The engine speed is more than 1400 RPM. (DTC the exhaust temperature sensor 2 at various
P042D) temperature levels to evaluate the possibility of a
• The engine coolant temperature is more than 80°C skewed sensor.
(176°F). (DTC P042D)
• The fuel injection quantity is more than a Connector End View Reference: Engine Controls
predetermined value. (DTC P042D) Connector End Views or ECM Connector End Views
Circuit/ System Testing DTC P042C (Flash Code 49)


3 0.2 volts

harness connector.
4 4.5 volts

conditions:


7 corrosion. —
necessary.


9 —

10 —
Circuit/ System Testing DTC P042D (Flash Code 49)



80°C [176°F]).
tool.

harness connector.
a voltage source.

7 ground. 0.1 volts




11 FB68). —




80°C [176°F]).
15 4.8 volts
tool.


16 —

Exhaust Pressure Control Valve Low or High Action Taken When the DTC Sets
The ECM controls the exhaust brake, which supplies Action Taken When the DTC Sets - Type A.
air pressure to the exhaust brake valve based on the • The ECM blinks the exhaust brake indicator lamp
vehicle running condition. The exhaust brake solenoid when the diagnostic runs and fails.
valve energizes to apply air pressure to the exhaust • The ECM inhibits exhaust brake control.
brake valve. If the ECM detects an improper voltage
level on the exhaust brake solenoid valve control Condition for Clearing the DTC
circuit, DTC P0477 or P0478 will set.


• The ECM detects a low voltage condition on the The number below refers to the step number on the
exhaust brake solenoid control circuit for longer Circuit/ System Testing.
than 3 seconds when the solenoid is commanded DTC P0478
OFF. (DTC P0477) 3. If the exhaust brake solenoid control circuit between
• The ECM detects a high voltage condition on the the ECM and the solenoid valve is normal, voltage level
exhaust brake solenoid control circuit for longer low DTC P0477 will set.
than 3 seconds when the solenoid is commanded
ON. (DTC P0478) Connector End View Reference: Engine Controls

2 scan tool. —
Go to Diagnostic
harness connector.
3. Connect the test lamp between the ignition
known good ground.

4 scan tool. —


5 —
the ECM Main (15A) fuse and the exhaust brake

15 of FB24) and the solenoid valve (pin 2 of
7 —

8 —

9 —

10 connection at harness connector of the ECM —
(pin 15 of FB24).

11 —

scan tool.
14 —


2 scan tool. —
Go to Diagnostic
harness connector.
Is DTC P0477 set, but not P0478? Go to Step 5 Go to Step 4

FB41) for a short to battery or ignition voltage.
4 —

5 —

scan tool.
8 —

Vehicle Speed Sensor Action Taken When the DTC Sets
The vehicle speed sensor (VSS) is used by the ECM Action Taken When the DTC Sets - Type A.
and other modules, which generates a speed signal • The ECM limits fuel injection quantity.
from the transmission output shaft rotational speed. • The ECM inhibits pre injection.
The sensor has the following circuits.
• Ignition voltage feed circuit
• Low reference circuit Condition for Clearing the DTC
• VSS signal circuit • Refer to DTC Type Definitions for Condition for
The VSS uses a hall effect element or magnetic Clearing the MIL/ DTC - Type A.
resistance element (MRE). It interacts with the
magnetic field created by the rotating magnet and Diagnostic Aids
the vehicle speed by the VSS. If the ECM detects VSS
signals are not generated for a certain length of time,
this DTC will set. • Electromagnetic interference in the vehicle speed
signal circuit may set this DTC.
Condition for Running the DTC • An aftermarket signal pulse pickup device may
• The battery voltage is between 18 to 32 volts. affect intermittent condition.
• The ignition switch is ON. Notice: If this DTC set, the Vehicle Speed parameter
• The commanded fuel injection quantity is OFF on the scan tool will display 10 km/h.
(accelerator pedal is not depressed).
• The engine speed is more than 2000 RPM. Connector End View Reference: Engine Controls
pulses are not generated for longer than 7
seconds.

Go to Applicable
Drive the vehicle while observing the Vehicle
3 Speed parameter with a scan tool. — Go to Diagnostic
Does the scan tool indicate correct vehicle speed? Aids Go to Step 4

1. Inspect the VSS, drive gear, driven gear or
output shaft for the following conditions:
• Physical damage of sensor, drive gear or
driven gear
• Loose or improper installation of sensor,
drive gear or driven gear
4 • Transmission output shaft teeth damage —
• Excessive transmission output shaft play
2. Disconnect the aftermarket signal pulse
pickup device and retest if installed.

1. Remove the VSS.
vehicle speed sensor and the battery voltage.
Wiring System.
vehicle speed sensor and a known good
ground. Refer to IP Cluster and Warning in 0.5 to 1.5 volts
5 Section 9D Wiring System. or 12 to 15
4. Connect a DMM between the vehicle speed volts
sensor and a known good ground. Refer to IP
System.
5. Rotate the shaft of the vehicle speed sensor
slowly.

6 Warning in Section 9D Wiring System. —

Replace the VSS. Refer to Vehicle Speed Sensor in
7 Section 9E Instrumentation/ Driver Info. —

4. Drive the vehicle while observing the Vehicle
Speed parameter with a scan tool.
Does the scan tool indicate correct vehicle speed? Go to Step 10 Go to Step 2
10 —

Vehicle Speed Sensor Circuit Low or High • The ECM detects that the vehicle speed signal
Input voltage is more than 20 volts. (DTC P0503)
Circuit Description Action Taken When the DTC Sets
The vehicle speed sensor (VSS) is used by the ECM • The ECM illuminates the MIL when the diagnostic
and other modules, which generates a speed signal runs and fails. Refer to DTC Type Definitions for
from the transmission output shaft rotational speed. Action Taken When the DTC Sets - Type A.
The sensor has the following circuits. • The ECM limits fuel injection quantity.
• Ignition voltage circuit • The ECM inhibits pre injection.
• VSS signal circuit
The VSS uses a hall effect element or magnetic Condition for Clearing the DTC
resistance element (MRE). It interacts with the • Refer to DTC Type Definitions for Condition for
magnetic field created by the rotating magnet and Clearing the MIL/ DTC - Type A.
the vehicle speed by the VSS. If the ECM detects an Diagnostic Aids
excessively low or high signal voltage, DTC P0502 or • If an intermittent condition is suspected, refer to
• An aftermarket signal pulse pickup device may
• The battery voltage is between 18 to 32 volts. Notice: If this DTC set, the Vehicle Speed parameter
• The ignition switch is ON. on the scan tool will display 10 km/h.

Go to Diagnostic
2. Observer the Vehicle Speed parameter with
3 the scan tool. —
Does the Vehicle Speed parameter indicate correct Go to Diagnostic
vehicle speed? Aids Go to Step 4
Observer the speedometer in the instrument panel
(IP) cluster.
4 —
Does the speedometer indicate correct vehicle

between the engine control module (ECM)
(pin 19 of FB24) and the speed sensor control
unit (pin 3 of FU173) for the following
conditions:
• An open circuit
5 —
• High resistance

6 2. Inspect the Meter (10A) fuse. —
circuits that fed by the Meter (10A) fuse or replace
7 the shorted attached component fed by the Meter —
(10A) fuse.

• Physical damage
damage

connector.
voltage feed circuit of the vehicle speed
9 sensor and a known good ground. Refer to IP —
System.

1. Test the vehicle speed sensor power supply
circuit between the speed sensor control unit
and the vehicle speed sensor for open circuits
or high resistance. Refer to IP Cluster and
10 —


reference circuit of the vehicle speed sensor
11 and battery voltage. Refer to IP Cluster and —

vehicle speed sensor with a test lamp that is
connected to 12 volts (apply form a battery)
12 while monitoring the Vehicle Speed parameter —
with the scan tool. Refer to IP Cluster and

2. Disconnect the speed sensor control unit
harness connector.
13 voltage feed circuit of the speed sensor —
control unit harness (pin 1 of FU173) and a
known good ground.

reference circuit of the speed sensor control
14 unit harness (pin 5 of FU173) and battery —
voltage.

speed sensor control unit (pin 3 of FU173)
with a test lamp that is connected to 12 volts
15 (apply form a battery) while monitoring the —
Vehicle Speed parameter with the scan tool.

vehicle speed sensor ground circuit between the
vehicle speed sensor and the chassis ground
16 (FU51). Refer to IP Cluster and Warning in Section —
9D Wiring System.

speed sensor control unit power supply circuit
17 between the Meter (10A) fuse and the speed —
sensor control unit (pin 1 of FU173).


speed sensor control unit ground circuit between
18 the speed sensor control unit (pin 5 of FU173) and —
the chassis ground (FU51).

vehicle speed sensor for the following
conditions:
• An open circuit
• High resistance
Wiring System.

between the ECM (pin 19 of FB24) and the
speed sensor control unit (pin 3 of FU173) for
• An open circuit
• High resistance

speed sensor control unit (pins 3 and 7 of
21 FU173). —

connector.
output shaft speed sensor. Refer to IP Cluster
and Warning in Section 9D Wiring System.

connection on the vehicle speed sensor signal
23 circuit at the harness connector of the ECM —
(pin 19 of FB24).



25 Driver Info. —


27 —
5. Select the data display function of ECM.
6. Observe the Vehicle Speed parameter with
the scan tool.
Does the Vehicle Speed parameter indicate correct

vehicle speed? Go to Step 28 Go to Step 3
28 —

System Voltage • The ECM detects that the 12 volts reference circuit
voltage more than 19 volts.
Circuit Description
The ECM provides 12 volts reference voltage to the
mass air flow (MAF) sensor. Battery voltage is supplied • The ECM illuminates the MIL when the diagnostic
in ECM through the dropping resistor, and it is runs and fails. Refer to DTC Type Definitions for
converted into 12 volt. The ECM monitors the voltage Action Taken When the DTC Sets - Type A.
on the 12 volts reference circuit. If the ECM detects the • The ECM limits fuel injection quantity.
voltage is excessively low or high, this DTC will set. • The ECM inhibits cruise control.
• DTC P060B is not set. • Refer to DTC Type Definitions for Condition for
• The battery voltage is between 18 to 32 volts. Clearing the MIL/ DTC - Type A.
Diagnostic Aids
Condition for Setting the DTC • If an intermittent condition is suspected, refer to
Either of following condition is met: Intermittent Conditions in this section.
• The ECM detects that the 12 volts reference circuit
voltage is less than 7 volts. Connector End View Reference: Engine Controls

Go to Diagnostic
3 connector. —

2. Leave the MAF sensor harness connector
disconnected.
4 3. Disconnect the dropping resistor harness —
connector.

Measure the resistance across the dropping
5 resistor. 45 to 55 Ω
feed circuit (pin 1 of FB53) and a known good
ground.
6 18.0 volts

Connect a DMM between the voltage supply circuit
7 (pin 2 of FB53) and a known good ground. 13.0 volts
ignition voltage feed circuit between the ECM Main
8 (15A) fuse and the dropping resistor (pin 1 of —
FB53). Check the ECM Main (15A) fuse first.

resistor (pin 2 of FB53) for an open circuit or

resistor (pin 2 of FB53) for the following
conditions:

(pin 1 of J14, FB128 or FB196) for the
11 —
• A short to the low reference

dropping resistor (pins 1 and 2 of FB53).
12 —
Go to Diagnostic
1. Inspect for corrosion at the harness connector
of the MAF sensor (pin 1 of J14, FB128 or
FB196).
13 —


Replace the dropping resistor.
15 —


Records.

19 —

System Voltage High Action Taken When the DTC Sets
The ECM monitors the ignition voltage on the ignition Definitions for Action Taken When the DTC Sets -
feed terminal to make sure that the voltage stays within Type C.
the proper range. If the ECM detects an excessively
high ignition voltage, this DTC will set. Condition for Clearing the DTC
Condition for Running the DTC Clearing the SVS Lamp/ DTC - Type C.
• A charging system problem may set this DTC.
• The ECM detects that the ignition voltage feed
circuit is more than 32 volts for 30 minutes.

Was the vehicle recently a battery charger placed
2 —
on the battery? Go to Step 7 Go to Step 3
3. Observe the Ignition Voltage parameter with
3 32.0 volts
the scan tool.
value? Aids Go to Step 4
Test the charging system. Refer to Charging
4 System in Section 1E Engine Electrical. — Go to Diagnostic
Did you find a charging system problem? Go to Step 5 Aids
Repair the charging system. Refer to Charging
5 System in Section 1E Engine Electrical. —
2. Clear the DTCs with the scan tool.
6 4. Start the engine and let idle. 32.0 volts
5. Observe the Ignition Voltage parameter with a
scan tool.
Does the scan tool parameter less than the

7 —

Brake Switch Circuit Action Taken When the DTC Sets
The brake switches are installed to the brake pedal Definitions for Action Taken When the DTC Sets -
bracket. Two brake switches are installed and both are Type C.
turned to ON when the brake pedal is depressed. The
power supply voltage is supplied to the brake switches Condition for Clearing the DTC
via the stoplight relay, stoplight relay diode and brake • Refer to DTC Type Definitions for Condition for
switch diode. When the brake switch turns to ON, each Clearing the SVS Lamp/ DTC - Type C.
ground circuit is completed and the signal is input to the
engine control module (ECM). The ECM sets the DTC Diagnostic Aids
when the number of signal inputs of brake switches 1
and 2 do not match to each other.
• The battery voltage is more than 20 volts. Connector End Views or ECM Connector End Views

The ECM detects the brake switch 1 signal and brake
switch 2 signal correlation error for 32 times.

2 —
the brake pedal.

3 —

connector.
4 FU159). —
scan tool.


scan tool.

6 —
Block 2 (pin 13 of FU134) and the brake
switch 1 (pin 1 of FU159) for an open circuit or

switch 1 (pin 2 of FU159) and the ground
terminal (FU54) for an open circuit or high
8 resistance. —

Block 2 (pin 4 of FL67) and the ECM (pin 54 of
9 —

10 —
the brake pedal.

11 —

connector.
12 FB5). —
scan tool.


scan tool.

14 —
(pin 5 of FB35) and the brake switch 2 (pin 1
of FB5) for an open circuit or high resistance.
15 —

switch 2 (pin 2 of FB5) and the ground
terminal (FB21) for an open circuit or high
16 resistance. —

(pin 6 of FB35) and the ECM (pin 55 of FB24)
17 —


19 5. Observe the Brake Switch 1 and Brake Switch —
2 parameter with a scan tool while fully
depressing and releasing the brake pedal.

pedal is released on each parameter? Go to Step 2 Go to Step 20
20 —

Internal Control Module Memory Check Sum Action Taken When the DTC Sets
Error • The ECM illuminates the MIL when the diagnostic
This diagnostic applies to internal microprocessor • The ECM stops engine running. The engine will
integrity conditions within the ECM. run after the key is cycled when the ignition has
• The ECM detects that the calculated checksum
does not agree with the read only memory (ROM) • Refer to DTC Type Definitions for Condition for
internal registered checksum. Clearing the MIL/ DTC - Type A.



Records.

5 —

Control Module Programming Error • The ECM detects an error in the programmed fuel
injector ID code.
Circuit Description
The electrically erasable & programmable read only
memory (EEPROM) memorizes fuel injector ID code • The ECM illuminates the SVS lamp when the
information. If the ECM detects fuel injector ID codes diagnostic runs and fails. Refer to DTC Type
are not programmed into the ECM or an error in the Definitions for Action Taken When the DTC Sets -
programmed fuel injector ID codes, this DTC will set. Type C.
Notice: Clear the DTC with a scan tool after
programming the fuel injector ID code.
• The ECM detects that the fuel injector ID code is
not programmed.


1. Verify the correct fuel injector ID codes are
entered into the ECM with a scan tool. Refer
to ECM Replacement. If the fuel injector ID
codes are correctly entered, clear the DTC
3 with a scan tool. —


Records.


6 —

DTC P0604, P0606 or P060B (Flash Code 153, 51 or 36)
Internal Control Module RAM Error • The ECM detects a malfunction in its internal A/D
converter. (DTC P060B)
ECM Processor
Internal Control Module A/D Processing Action Taken When the DTC Sets
This diagnostic applies to internal microprocessor • The ECM limits fuel injection quantity.
• The battery voltage is more than 16 volts. (DTC • The ECM stops engine running. The engine will
P0604 and P0606) run after the key is cycled when the ignition has
• The ignition switch is ON. (DTC P0604 and P0606) (DTC P0604)
• The ECM detects a malfunction in its internal • Refer to DTC Type Definitions for Condition for
random access memory (RAM). (DTC P0604) Clearing the MIL/ DTC - Type A.
• The ECM detects a malfunction in its internal main
central processing unit (CPU) or sub integrated
circuit (IC). (DTC P0606)
Circuit/ System Testing DTC P0604, P0606 or P060B (Flash Code 153, 51 or 36)



Records.

5 —

Immobilizer not programmed Action Taken When the DTC Sets
The electronically erasable & programmable read only When the DTC Sets - Type D.
memory (EEPROM) memorizes immobilizer security
information for communication with the immobilizer Condition for Clearing the DTC
control unit (ICU) and enabling the engine to start. If the • Refer to DTC Type Definitions for Condition for
ECM detects immobilizer security information are not Clearing the DTC - Type D.
programmed into the ECM, this DTC will set.
Diagnostic Aids
• Non-programmed ECM sets this DTC.
• The ECM detects that the immobilizer security
information is not programmed.

Go to Diagnostic
Did you complete the programming? Go to Step 4 —

Records.

5 —

Throttle Actuator Control Range/ Performance Action Taken When the DTC Sets
The ECM controls the intake throttle valve opening Action Taken When the DTC Sets - Type A.
based on the engine running condition and by • The ECM inhibits EGR valve control.
controlling the intake throttle motor. The intake throttle
valve position is detected by the position sensor, and Condition for Clearing the DTC
relayed to the ECM. If the ECM detects a variance • Refer to DTC Type Definitions for Condition for
between the actual intake throttle valve position and Clearing the MIL/ DTC - Type A.
desired intake throttle valve position while the intake
throttle motor is commanded ON, this DTC will set. Diagnostic Aids
set. • A sticking or intermittently sticking intake throttle
valve may set this DTC.
• A sticking intake throttle valve at full closed
• The ignition switch is ON. position will cause engine starting problem.
• The desired intake throttle valve position is stable.
• The intake throttle motor is commanded ON. Connector End View Reference: Engine Controls
• The ECM detects that the difference between the
actual and the desired intake throttle position is
more than 40% for longer than 5 seconds.

Go to Applicable
Increase and Decrease while observing the
3 Intake Throttle Position. ± 5%

within the specified value quick enough (compare Go to Diagnostic
with a similar unit if available)? Aids Go to Step 4

materials


connector.
2, 4, 5 and 6 of E46).
5 connections and corrosion on each intake —
throttle valve circuit at the harness connector
of the ECM (pins 85, 95, 104, 109 and 112 of
E26).
each circuit.
necessary.

104 and 112 of E26) and the intake throttle
valve (pins 1 and 2 of E46) for the following
conditions:
6 —
• A short to the intake throttle position
sensor circuit(s)


Records.


Records.

11 —

1 voltage is less than 4.5 volts.
The ECM provides 5 volts reference voltage through 1 voltage is more than 5.5 volts.
• PTO throttle sensor • The ECM illuminates the MIL when the diagnostic
• Idle up sensor Action Taken When the DTC Sets - Type A.
through the reference circuit 1 to the cruise control • The ECM blinks the exhaust brake indicator lamp
switch on the combination switch. The 5 volts reference when the diagnostic runs and fails.
circuits are bussed together outside the ECM. • The ECM limits fuel injection quantity.
Therefore, a short circuit condition on one sensor 5 • The ECM inhibits exhaust brake control.
volts reference circuit may affect the entire 5 volts • The ECM inhibits cruise control.
reference circuit 1. The ECM monitors the voltage on
the 5 volts reference circuit 1. If the ECM detects the Condition for Clearing the DTC
voltage is excessively low or high, this DTC will set.
• DTC P060B is not set. Diagnostic Aids


Go to Diagnostic
connector.
ground.
4 4.5 volts

5 (APP) sensor harness connector. 4.5volts

Notice: If no PTO throttle sensor is installed, skip
to Step 7.
6 3. Disconnect the PTO throttle sensor harness 4.5 volts
connector.

7 —
• Idle up sensor (pin 3 of FL33)

voltage.
8 • Idle up sensor (pin 3 of FL33) —
ECM (pin 65 of FB24) and the combination
switch (pin 5 of FL19) for a short to battery or
ignition voltage.

Replace the idle up sensor. Refer to Idle Up Sensor
9 in Section 1I Engine Speed Control System. —
Pedal Position Sensor in Section 1I Engine Speed

11 —


Records.

14 —

Malfunction Indicator Lamp (MIL) Control • The ECM detects a low voltage condition on the
Circuit MIL control circuit when the lamp is commanded
OFF.
Circuit Description • The ECM detects a high voltage condition on the
MIL control circuit when the lamp is commanded
The malfunction indicator lamp (MIL) is located on the
ON.
instrument panel (IP) cluster. The MIL informs the
driver that an emission system fault has occurred and
that the engine control system requires service.
The ECM monitors the MIL control circuit for conditions • The ECM illuminates the MIL when the diagnostic
that are incorrect for the commanded state of the MIL. runs and fails. Refer to DTC Type Definitions for
For example, a failure condition exists if the ECM Action Taken When the DTC Sets - Type A.
detects low voltage when the MIL is commanded OFF,
or high voltage when the MIL is commanded ON. If the Condition for Clearing the DTC
ECM detects an improper voltage level on the control • Refer to DTC Type Definitions for Condition for
circuit, this DTC will set. Clearing the MIL/ DTC - Type A.


Go to Diagnostic
3 block. —


Is the MIL OFF? Go to Step 6 Go to Step 12


voltage to the MIL.
6 3. Measure the voltage from the MIL control 1 volt
circuit in the ECM harness connector (pin 6 of
FB24) to a known good ground.

Is the MIL illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 FU97). —

11 —

13 (pin 31 of FU97). —



15 Driver Info. —



18 —

2 or 5 voltage is less than 4.5 volts.
The ECM provides 5 volts reference voltage through 2 or 5 voltage is more than 5.5 volts.
• Barometric pressure (BARO) sensor • The ECM illuminates MIL when the diagnostic runs
• Intake air temperature (IAT) sensor Taken When the DTC Sets - Type A.
through the reference circuit 5 to the following sensors: • The ECM blinks the exhaust brake indicator lamp
when the diagnostic runs and fails.
• Camshaft position (CMP) sensor
• EGR position sensor
The 5 volts reference circuits 2 and 5 are independent • The ECM inhibits EGR control.
of each other outside of the ECM, but are bussed • The ECM inhibits exhaust brake control.
together inside the ECM. Therefore, a short circuit • The ECM inhibits cruise control.
condition on one sensor 5 volts reference circuit may
affect the entire 5 volts reference circuit 2 and 5. The Condition for Clearing the DTC
ECM monitors the voltage on the 5 volts reference • Refer to DTC Type Definitions for Condition for
circuit 2 and 5. If the ECM detects the voltage is Clearing the MIL/ DTC - Type A.
excessively low or high, this DTC will set.
Diagnostic Aids
• DTC P060B is not set. Intermittent Conditions in this section.
• The ignition switch is ON. Notice: If this DTC is set, the engine cranks but does
not start.

Go to Diagnostic
3. Connect a DMM between the CMP sensor 5
3 volts reference circuit (pin 3 of E48) and a 5.5 volts
known good ground.
4 4.5 volts

harness connector.
3. Disconnect the fuel rail pressure (FRP) sensor
5 harness connector. 4.5 volts

harness connector.
6 3. Disconnect the EGR valve harness connector. 4.5 volts

harness connector.
3. Disconnect the barometric pressure (BARO)

harness connector.

9 —


voltage.
10 —
voltage.

14 —


Records.

18 —

ECM Power Relay Control Circuit Open or Condition for Setting the DTC
High • The ECM detects a low voltage condition on the
ECM main relay voltage feed circuit for 3 seconds
Circuit Description when the relay is commanded ON. (DTC P0685)
The ECM main relay is energized to feed the battery • The ECM detects that the ECM has been ON
voltage to the ECM through the relay switch side when when the ECM main relay is commanded OFF.
the ECM receives an ignition voltage switch ON signal. (DTC P0687)
When the ignition switch is OFF, the ECM main relay is
de-energized after a certain length of time passed. Action Taken When the DTC Sets
If the ECM detects a low voltage condition on the ECM • The ECM illuminates the SVS lamp when the
main relay voltage feed circuit when the relay is diagnostic runs and fails. Refer to DTC Type
commanded ON, DTC P0685 will set. Definitions for Action Taken When the DTC Sets -
If the ECM detects the ECM has been ON when the Type C.
relay is commanded OFF, DTC P0687 will set.
• The battery voltage is between 18 to 32 volts. Clearing the SVS Lamp/ DTC - Type C.
(DTC P0685)
• The ignition switch is ON. (DTC P0685) Diagnostic Aids
• The ignition switch is OFF. (DTC P0687) • If an intermittent condition is suspected, refer to


Go to Diagnostic

1. Inspect for an intermittent, for poor tightening
and corrosion at the chassis ground terminal
(FB20).
2. Repair the tightening or clean the corrosion as
necessary.
3. Inspect the ECM (40A) slow blow fuse for an
4 open. —
4. Replace the ECM (40A) slow blow fuse if
open. If it continues to open, repair the short to
ground on one of the circuits that is fed by the
ECM (40A) slow blow fuse.


connector of the ECM (pins 2, 5, 21 and 40 of
FB24).
each relay circuit.
• Between pins 2 and 5 of FB24 and pin 2
5 of X18 —
• Between pins 21 and 40 of FB24 and pin
3 of X18
• Between ECM (40A) slow blow fuse and
pin 1 of X18
• Between pin 5 of X18 and chassis
ground (FB20)
necessary.

6 —


9 —

Go to Diagnostic



feed circuits between the ECM (pins 2 and 5 of

supply circuits between the ECM (pins 21 and 40 of

7 —

9 —

Sensor Reference Voltage 3 Circuit • The ignition switch is ON.

The ECM provides 5 volts reference voltage through Either of following condition is met:
the reference circuit 3 to the following sensors: • The ECM detects that the 5 volts reference circuit
• Exhaust differential pressure sensor 3 or 4 voltage is less than 4.5 volts.
• Exhaust temperature sensor 1 • The ECM detects that the 5 volts reference circuit
• Exhaust temperature sensor 2 3 or 4 voltage is more than 5.5 volts.
through the reference circuit 4 to the following sensors: Action Taken When the DTC Sets
• Crankshaft position (CKP) sensor • The ECM illuminates the MIL when the diagnostic
• Boost pressure sensor
• Intake throttle position sensor
• Engine coolant temperature (ECT) sensor
• Fuel temperature (FT) sensor
The 5 volts reference circuits 3 and 4 are independent
of each other outside of the ECM, but are bussed • The ECM inhibits cruise control.
together inside the ECM. Therefore, a short circuit
condition on one sensor 5 volts reference circuit may Condition for Clearing the DTC
affect the entire 5 volts reference circuit 3 and 4. The • Refer to DTC Type Definitions for Condition for
ECM monitors the voltage on the 5 volts reference Clearing the MIL/ DTC - Type A.
circuit 3 and 4. If the ECM detects the voltage is
excessively low or high, this DTC will set. Diagnostic Aids

Go to Diagnostic
harness connector.
ground.
4 4.5 volts




a short to ground or short to the low reference
circuit.
8 the low reference circuit: —
E46)

9 voltage. —
E46)




Records.

16 —

Transmission Control System Emissions • The ECM blinks the exhaust brake indicator lamp
Related Malfunction when the diagnostic runs and fails.
Circuit Description
The transmission control module (TCM) requests to
illuminate the malfunction indicator lamp (MIL) to the • Refer to DTC Type Definitions for Condition for
ECM via the controller area network (CAN) Clearing the MIL/ DTC - Type A.
communication bus when the TCM sets a MIL request
DTC(s). If the ECM detects the MIL illumination request Diagnostic Aids
signal, this DTC will set. • Under normal conditions if the TCM sets a DTC
that requests the MIL to be illuminated, P0700 will
Condition for Running the DTC set.
• The ignition switch is ON. Test Description
The number below refers to the step number on the
Condition for Setting the DTC Circuit/ System Testing.
• The ECM detects that the MIL illumination is 2. If the TCM has DTCs set that are requesting MIL
requested by the TCM. illumination, diagnose that DTC first.
3, 5. If the TCM has DTCs set, clear the DTCs in the
Action Taken When the DTC Sets TCM first.

2 3. Start the engine. — Go to Applicable
4. Monitor the DTC Information with a scan tool. DTC in Section 5A
Transmission
Are there any TCM DTCs set? Control System Go to Step 3
Records.



Records.

6 —

Fuel Rail Pressure Too Low Condition for Clearing the DTC
Description Clearing the DTC - Type B.
pressure sections: a suction side between the fuel tank Diagnostic Aids
and the fuel supply pump and a high-pressure side • An intermittently sticking FRP regulator may have
between the fuel supply pump and the fuel injectors. allowed the fuel pressure to become low enough to
Fuel is drawn from the fuel tank via a feed pump and set this DTC.
then pumped into the fuel rail by two plungers, all of • Normal Fuel Rail Pressure readings on the scan
which are internal to the fuel supply pump. This high tool with the engine running in neutral at idle is
pressure is regulated by the ECM using the fuel rail around 30 to 35 MPa (4,350 to 5,080 psi) after
pressure (FRP) regulator dependant upon values from warm up.
detects that the fuel rail pressure is certain pressure • A skewed FRP sensor value can set this DTC. The
lower than the desired pressure, this DTC will set. FRP Sensor on the scan tool should read 0.9 to
Condition for Running the DTC OFF after the engine has stopped running for a
minimum of 1 minute.
• DTCs P0087, P0091, P0092, P0192, P0193,
P0201 - P0204, P060B, P0651, P1261, P1262, Notice: This DTC most likely indicates a loss of fuel
P2146 and P2149 are not set. pressure by a fuel leak from the high pressure side.
• The battery voltage is between 18 to 32 volts. Inspect the high pressure side fuel leakage between
• The ignition switch is ON. the fuel supply pump and fuel injector first.
• The FRP regulator commanded fuel flow is more might be allowed to go into the fuel system. With air in
than a threshold. the fuel system, smooth flow of fuel into the supply
Condition for Setting the DTC bleeding of fuel system after refilling.
is more than 50 MPa (7,200 psi) below the desired Test Description
pressure for longer than 5 seconds. The numbers below refers to the step number on the
Action Taken When the DTC Sets 5. This step checks for a fuel restriction by determining
• The ECM illuminates the MIL on the second if a high vacuum is being pulled on the fuel system
consecutive driving cycle when the diagnostic runs during normal operation.
and fails. Refer to DTC Type Definitions for Action 6. This step checks for an air leak on the suction side of
Taken When the DTC Sets - Type B. the fuel system by determining if a vacuum can be
• The ECM inhibits EGR control. pulled when a fuel line is plugged.

2 —


3 0.9 to 1.0 volt


4 —
may occur.
rail.



line.


line and plug it.
6 1600 RPM.) 8 inHg


kinked.
condition.



2. Unclamp or unplug the fuel line from the
previous step and reconnect the fuel line (if
disconnected).
3. Start the engine and allow it to run for at least
1 minute.
9 —
tool.

connector.
of E47).
113 of E26).
necessary.

connector.
of E49).
11 —
101 of E26).
necessary.


programmed.

to the ECM.



Notice: There is a possibility that the pressure
limiter valve stuck open or operating pressure has
fallen.
16 Replace the pressure limiter valve. Refer to —

Pressure Limiter (Common Rail) in Section 1D
Engine Fuel.

Records.

18 —

Injector Positive Voltage Control Circuit Group • The ECM detects its internal common 2 fuel
1 or 2 injector charge up circuit is open circuit. (DTC
P1262)
Circuit Description
The charge up circuit in the ECM steps up the voltage
for fuel injectors and is divided into two banks, common • The ECM illuminates the MIL when the diagnostic
1 and 2. The common 1 covers fuel injectors in runs and fails. Refer to DTC Type Definitions for
cylinders #1 and #4, and the common 2 covers fuel Action Taken When the DTC Sets - Type A.
injectors in cylinders #2 and #3. If the common 1 or • The ECM limits fuel injection quantity.
common 2 fuel injector charge up circuit in the ECM is • The ECM inhibits pre injection.
an open circuit, DTC P1261 or P1262 will set. • The ECM inhibits EGR control.
• The battery voltage is between 16 to 32 volts. Condition for Clearing the DTC
• The ECM detects its internal common 1 fuel Diagnostic Aids
injector charge up circuit is open circuit. (DTC • If an intermittent condition is suspected, refer to
P1261) Intermittent Conditions in this section.



Records.

5 —

EGR Position Fault Learned Position Error DTC
• The ECM detects that the EGR learned minimum
Circuit Description position is not within a predetermined range when
The ECM controls the EGR valve opening based on the the ignition switch is OFF.
engine running condition and by controlling the EGR
motor. The EGR valve position is detected by the Action Taken When the DTC Sets
position sensor, and relayed to the ECM. • The ECM blinks the MIL when the diagnostic runs
If the ECM detects that the actual EGR position is and fails. Refer to DTC Type Definitions for Action
higher than certain amount, this DTC will set. (Closed Taken When the DTC Sets - Type A.
Position Error DTC) • The ECM limits fuel injection quantity.
If the ECM detects a variance between the learned
closed position and actual closed position, this DTC will
also set. (Learned Position Error DTC) • The ECM inhibits cruise control.
Closed Position Error DTC • Refer to DTC Type Definitions for Condition for
• DTCs P0112, P0113, P0116, P0117, P0118,
P0409, P060B, P0651, P0697, P2227, P2228 and
P2229 are not set.
• The battery voltage is between 16 to 32 volts. scan tool.
• The desired EGR valve position is stable.
Learned Position Error DTC Diagnostic Aids
• DTCs P0404, P0409, P0500, P0502, P0503, • If an intermittent condition is suspected, refer to
P060B, P0651 and P215A are not set. Intermittent Conditions in this section.
Closed Position Error DTC
• The ECM detects that the difference between the Connector End View Reference: Engine Controls
actual and the desired EGR valve position is more Connector End Views or ECM Connector End Views
than 40% for longer than 5 seconds.

Go to Applicable
engine.
conditions:
3 materials —


6, 7 and 8 of E45).
101, 103, 110 and 111 of E26).
each circuit.
necessary.

conditions:
5 —
circuit(s)

Notice: Ignition switch must be cycled before

clear the DTC.
4. Turn ON the ignition and clear the DTCs with
a scan tool.
7 —
Records.

8 —

PM Over Accumulation Action Taken When the DTC Sets
The ECM detects the condition of PM accumulations Action Taken When the DTC Sets - Type A.
from the exhaust differential pressure sensor attached • The ECM limits fuel injection quantity.
to the chassis frame near the diesel particulate defuser • The ECM inhibits cruise control.
amount of PM accumulations or a certain length of Condition for Clearing the DTC
mileage, the automatic regeneration starts. If the
automatic regeneration cannot be completed by some • Refer to DTC Type Definitions for Condition for
reason, the manual regeneration is requested to the Clearing the MIL/ DTC - Type A.
SWITCH" indicator on the instrument panel cluster. If Diagnostic Aids
the DPD filter regeneration interval is more than a • If manual regeneration is frequently requested,
predetermined mileage, this DTC will set. refer to DPD System Manual Regeneration
Frequently chart in symptom diagnostic table.
• DTCs P0500, P0502, P0503 and P215A are not Notice: This DTC is caused by incomplete automatic
set. regeneration has occurred and manual regeneration
urged by the DPD lamp on the IP cluster was
• The ignition switch is ON. disregarded or forgot, which was most likely caused by
Condition for Setting the DTC lamp or "PUSH DPD SWITCH" indicator blinking in the
• The DPD filter regeneration interval is more than past.
520 km.

Regeneration Frequently chart in symptom
diagnostic table.


a scan tool.
knob clockwise.)
to 200°C (392°F).


scan tool.


knob clockwise.)
procedure in
7 —

DPD Insufficient Regeneration • The intake throttle position is more than 22%.
Description
The ECM detects the condition of PM accumulations Condition for Setting the DTC
from the exhaust differential pressure sensor attached • The DPD filter regeneration has been incomplete
to the chassis frame near the diesel particulate defuser purification status continuously.
amount of PM accumulations or a certain length of Action Taken When the DTC Sets
mileage, the automatic regeneration starts. If the • The ECM illuminates the MIL when the diagnostic
automatic regeneration cannot be completed by some runs and fails. Refer to DTC Type Definitions for
reason, the manual regeneration is requested to the Action Taken When the DTC Sets - Type A.
SWITCH" indicator on the instrument panel cluster. • The ECM limits fuel injection quantity.
After the regeneration event is finished, an exhaust • The ECM inhibits cruise control.
differential pressure monitors a purification of the filter.
If the filter regeneration has been incomplete Condition for Clearing the DTC
purification status continuously, this DTC will set. • Refer to DTC Type Definitions for Condition for
• DTCs P0079, P0080, P0116, P0117, P0118, Diagnostic Aids
P0122, P0123, P0201 - P0204, P0335, P0336, • If manual regeneration is frequently requested,
P0404, P0409, P0426, P042B, P042C, P042D, refer to DPD System Manual Regeneration
P0427, P0428, P0500, P0502, P0503, P060B, Frequently chart in symptom diagnostic table.
P0638, P0641, P0651, P1261, P1262, P1404,
• An excessive ash accumulation in the DPD filter
P2146, P2149, P215A, P2227, P2228, P2229,
will cause this DTC to set.
• The mass air flow (MAF) sensor problem will
cause this DTC to set. Refer to DTC P0101 for
• The exhaust gas temperature 1 (in front of filter) is MAF sensor diagnosis and use the Scan Tool Data
more than 100°C (212°F). List or a known good vehicle to determine nominal
• The engine speed is more than 1000 RPM. values.
• The EGR position is less than 95%.



1G Engine Exhaust.
port
pressure sensor
or damaged
2 pipe, gasket, DPD assembly, exhaust —
sensors
• Modified air induction system


3 —
to DPD Control System Check.
Is the intersected range located in C or D? Go to Step 4 Go to Step 5


scan tool.

scan tool.

scan tool.
scan tool.

knob clockwise.)
procedure in
7 —

Immobilizer wrong response Action Taken When the DTC Sets
The ECM communicates with the immobilizer control When the DTC Sets - Type D.
unit (ICU) to execute immobilizer function. The ECM
transmits a specific request signal to the ICU and the Condition for Clearing the DTC
ICU sends back a response signal to the ECM. Both • Refer to DTC Type Definitions for Condition for
communication signals are carried out via a controller Clearing the DTC - Type D.
area network (CAN) communication bus. If the ECM
receives a wrong response signal from the ICU, this Diagnostic Aids
DTC will set.
• The ECM receives a wrong immobilizer response intermittent condition.
signal from the ICU.

Go to Applicable
Is DTC P0633 or U0167 also set? DTC Go to Step 3


Records.

7 —

Control Module Long Term Memory Condition for Setting the DTC
Performance • The ECM detects that the calculated checksum
does not agree with the electrically erasable &
Circuit Description programmable read only memory (EEPROM)
This diagnostic applies to internal microprocessor internal registered checksum.
Condition for Running the DTC • The ECM illuminates MIL when the diagnostic runs
• The ignition switch is ON. and fails. Refer to DTC Type Definitions for Action
Taken When the DTC Sets - Type A.




Records.

5 —

Service Vehicle Soon Lamp Control Circuit • The ECM detects a low voltage condition on the
SVS lamp control circuit when the lamp is
Circuit Description commanded OFF.
The service vehicle soon (SVS) lamp is located on the • The ECM detects a high voltage condition on the
instrument panel (IP) cluster. The SVS lamp informs SVS lamp control circuit when the lamp is
the driver that a non-emission related fault has commanded ON.
occurred and vehicle service required.
The ECM monitors the SVS lamp control circuit for Action Taken When the DTC Sets
conditions that are incorrect for the commanded state • The ECM will illuminate the SVS lamp. Refer to
of the SVS lamp. For example, a failure condition exists DTC Type Definitions for Action Taken when the
if the ECM detects low voltage when the SVS lamp is DTC Sets - Type C.
commanded OFF, or high voltage when the SVS lamp
is commanded ON. If the ECM detects an improper Condition for Clearing the DTC
voltage level on the control circuit, this DTC will set. • Refer to DTC Type Definitions for Condition for

Go to Diagnostic
3 block. —


5 —
Is the SVS lamp OFF? Go to Step 6 Go to Step 12


voltage to the SVS lamp.
6 3. Measure the voltage from the SVS lamp 1 volt

Is the SVS lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 —

11 —




15 Driver Info. —



18 —

DPD Lamp Control Circuit Condition for Setting the DTC
The diesel particulate defuser (DPD) amber lamp is DPD amber lamp control circuit when the lamp is
located on the instrument panel (IP) cluster. The DPD commanded OFF.
amber lamp informs the driver that an incomplete • The ECM detects a high voltage condition on the
automatic regeneration has occurred and manual DPD amber lamp control circuit when the lamp is
regeneration is required. commanded ON.
The ECM monitors the DPD amber lamp control circuit
for conditions that are incorrect for the commanded Action Taken When the DTC Sets
state of the DPD amber lamp. For example, a failure
condition exists if the ECM detects low voltage when • The ECM will illuminate the SVS lamp. Refer to
the DPD amber lamp is commanded OFF, or high DTC Type Definitions for Action Taken When the
voltage when the DPD amber lamp is commanded ON. DTC Sets - Type C.
If the ECM detects an improper voltage level on the
control circuit, this DTC will set. Condition for Clearing the DTC
If the IP cluster has a multi-information display (MID), • Refer to DTC Type Definitions for Condition for
the DPD amber lamp is not installed. However, a wire Clearing the SVS Lamp/ DTC - Type C.
harness is remaining between the ECM and the IP
cluster, and the ECM will set the DTC if an improper Diagnostic Aids
voltage level on the circuit. • If an intermittent condition is suspected, refer to
Circuit/ System Testing DTC P1669 (Flash Code 75) (without Multi-information Display)

2 —
tool.
Go to Diagnostic
3 block. —


Is the DPD lamp OFF? Go to Step 6 Go to Step 12


voltage to the DPD lamp.
6 3. Measure the voltage from the DPD lamp 1 volt

Is the DPD lamp illuminate? Go to Step 11 Go to Step 8

ground.

9 —

10 FU97). —

11 —

13 (pin 35 of FU97). —



15 Driver Info. —


17 —
tool.

18 —
Circuit/ System Testing DTC P1669 (Flash Code 75) (with Multi-information Display)

2 —
tool.
Go to Diagnostic
3 block. —


5 4. Measure the voltage from the DPD lamp 20 volts
Is the voltage more than the specified value? Go to Step 6 Go to Step 7


1. Disconnect the DMM.
2. Connect a test lamp between the ECM
6 harness connector (pin 9 of FB24) to a known —
good ground.

ground.


• An open circuit
• High resistance

10 —

11 —

12 —

13 Driver Info. —



15 —
tool.

16 —

Particulate Trap Efficiency Below Threshold • The barometric pressure is more than 80 kPa.
• The turbocharger control is under normal
Description condition.
The exhaust differential pressure sensor is attached to • The intake air temperature is between 2 to 50°C
the chassis frame near the diesel particulate defuser (36 to 122°F).
(DPD) assembly. The exhaust differential pressure • The DPD regeneration trip is less than 4,000 km.
changes of the exhaust gas differential pressure Condition for Setting the DTC
• The ECM detects that the exhaust differential
detects that the exhaust differential pressure is certain
pressure is less than a predetermined range of the
pressure low as compared with the calculated exhaust
calculated pressure value for longer than 7
gas flow amount, this DTC will set.
seconds.
• DTCs P0079, P0080, P0102, P0103, P0116,
P0117, P0118, P0122, P0123, P0409, P0427,
P0428, P0477, P0478, P0500, P0502, P0503,
P0560, P060B, P0641, P0651, P0697, P2002,
P215A, P2227, P2228, P2229, P2454, P2455 and • The ECM limits fuel injection quantity.
P2456 are not set.
• The exhaust brake valve is commanded OFF.
• The exhaust throttle valve is inactive. Diagnostic Aids
• The intake throttle valve is inactive. • If an intermittent condition is suspected, refer to
• The mass air flow is more than 60 g/s. Intermittent Conditions in this section.
• The exhaust gas temperature 1 (in front of filter) is • Misrouted, disconnected or plugged exhaust
more than 150°C (302°F). differential pressure hoses or pipes will set this
• The fuel injection quantity is more than 75 mm3/st. DTC.
• The engine coolant temperature is between 50 to Connector End Views or ECM Connector End Views
150°C (122 to 302°F).

2 —
tool.


low exhaust differential pressure.

1G Engine Exhaust.
3 port —
pressure sensor
or damaged
Exhaust.


1G Engine Exhaust.
2. Inspect the DPD filter for damage, cracks or
melt.
3. Inspect the oxygen catalyst for damage or
excessive deposits.
4 —
Important: DPD status in the ECM must be
4. Replace the DPD filter or the oxygen catalyst
as necessary. Refer to Exhaust Pipe in


5 —
FB24).
high resistance.
necessary.


7 a scan tool. —
scan tool. If the DPD filter was replaced at
Step 4, skip to Step 9.

knob clockwise.)
to 200°C (392°F).
Is the Exhaust Differential Pressure parameter

9 —

P2123 will set.
Diagnostic Aids


connector.
ground.

resistance.

• An open circuit
7 —
• High resistance

8 —





12 0.2 volts

13 —

scan tool.
3 —
connector.

connector.


source.

resistance.

9 —




13 4.9 volts

14 —

P2128 will set.
Diagnostic Aids


connector.
ground.

resistance.

• An open circuit
7 —
• High resistance

8 —





12 0.2 volts

13 —

scan tool.
3 —
connector.

connector.


source.

resistance.

9 —




13 4.9 volts

14 —

Pedal Position Sensor 1-2 Voltage Correlation • The APP sensor 1 signal voltage is between 0.2 to
4.9 volts.
Circuit Description • The APP sensor 2 signal voltage is between 0.2 to
The accelerator pedal position (APP) sensor is 4.9 volts.
is made up of two individual sensors within one Condition for Setting the DTC
housing. The APP sensor 1 and APP sensor 2 are hall • The ECM detects that the APP sensor 1 and 2 are
element type sensors, each with the following circuits. more than 45% out of range of each other.
• Low reference circuit Action Taken When the DTC Sets
• Signal circuit • The ECM illuminates the MIL when the diagnostic
The ECM supplies 5 volts to the APP sensor on the 5 runs and fails. Refer to DTC Type Definitions for
volts reference circuit. The ECM also provides a ground Action Taken When the DTC Sets - Type A.
on the low reference circuit. The APP sensor provides • The ECM blinks the exhaust brake indicator lamp
a signal to the ECM on the signal circuits, which is when the diagnostic runs and fails.
relative to the position changes of the accelerator pedal • The ECM inhibits exhaust brake control.
angle. The APP sensor 1 signal voltage is low at rest
and increases as the pedal is depressed. The APP Condition for Clearing the DTC
sensor 2 signal voltage is high at rest and decreases as
the pedal is depressed. If the ECM detects that the
APP sensor 1 signal voltage and the APP sensor 2
signal voltage are out of the correlation, this DTC will
Diagnostic Aids
set.
• DTCs P060B, P0641 and P0651 are not set.

2 —

while observing the DTC Information with a scan
3 tool. —
Go to Diagnostic

(APP) sensor harness connector.
connector of the APP sensor (pins 1, 2, 3, 4, 5
and 6 of FL1).
connector of the ECM (pins 41, 42, 60, 61, 63
and 64 of FB24).
6. Test for high resistance on each sensor circuit.
necessary.

63 and 64 of FB24) and the APP sensor (pins
2 and 5 of FL1) for a short circuit each other.
5 —


with a scan tool.


with a scan tool.

10 —

DTC P2146 or P2149 (Flash Code 158 or 159)
Fuel Injector Group 1 or 2 Supply Voltage Condition for Setting the DTC
Circuit • The ECM detects that the common 1 fuel injector
charge voltage circuit is open circuit, shorted to
Circuit Description ground or shorted to voltage circuit, or cylinder #1
The ECM calculates the optimum fuel injection ON time or #4 fuel injector solenoid coil control circuit is
using data sent from various engine sensors. The shorted to ground. (DTC P2146)
common 1 and 2 fuel injector charge voltage circuits • The ECM detects that the common 2 fuel injector
are high-voltage supply, which drives fuel injectors for charge voltage circuit is open circuit, shorted to
each cylinder in conjunction with the ECM grounding ground or shorted to voltage circuit, or cylinder #2
the fuel injector solenoid control circuit. The common 1 or #3 fuel injector solenoid coil control circuit is
covers fuel injectors in cylinders #1 and #4, and the shorted to ground. (DTC P2149)
common 2 covers fuel injectors in cylinders #2 and #3.
If the common 1 or 2 fuel injector charge voltage circuit Action Taken When the DTC Sets
is open circuit, shorted to ground or shorted to voltage • The ECM illuminates the MIL when the diagnostic
circuit, DTC P2146 or P2149 will set depending upon runs and fails. Refer to DTC Type Definitions for
which bank injector common circuit failed. If the fuel Action Taken When the DTC Sets - Type A.
injector solenoid control circuit is shorted to ground,
this DTC will also set.
Condition for Running the DTC • The ECM inhibits EGR control.
• DTCs P0201 and P0204 are not set. (DTC P2146) • The ECM inhibits cruise control.
• DTCs P0202 and P0203 are not set. (DTC P2149)
Diagnostic Aids


Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #1 or #4
solenoid control circuit (pin 5 or 8 of H76
female side) and a known good ground.

4 ground. —

5 voltage. —

ground.
5 of H76
6 —
8 of H76


8 —

(pin 1 of H76).
necessary.

Mechanical.
terminals.
10 —
(pin 1 of H77).


Measure insulation resistance of the cylinder #1

12 —
programmed.


Records.

16 —

Go to Diagnostic
3 12.0 volts
4. Connect a DMM between the cylinder #2 or #3
solenoid control circuit (pin 6 or 7 of H76
female side) and a known good ground.

4 ground. —

5 voltage. —

ground.
6 of H76
6 —
7 of H76

ECM (pin 116 of E26)and the in-line harness

8 —

(pin 2 of H76).
necessary.

Mechanical.
terminals.
10 —
(pin 2 of H77).


Measure insulation resistance of the cylinder #2

12 —
programmed.


Records.

16 —

Vehicle Speed - Wheel Speed Correlation Condition for Setting the DTC
Circuit Description pulses are not generated for longer than 5
The vehicle speed sensor (VSS) is used by the ECM seconds.
and other modules, which generates a speed signal
from the transmission output shaft rotational speed. Action Taken When the DTC Sets
The sensor has the following circuits. • The ECM illuminates the MIL when the diagnostic
• Ignition voltage feed circuit runs and fails. Refer to DTC Type Definitions for
• Low reference circuit Action Taken When the DTC Sets - Type A.
• VSS signal circuit • The ECM limits fuel injection quantity.
The VSS uses a hall effect element or magnetic • The ECM inhibits pre injection.
resistance element (MRE). It interacts with the • The ECM inhibits cruise control.
magnetic field created by the rotating magnet and
outputs square wave pulse signal. The ECM calculates Condition for Clearing the DTC
the vehicle speed by the VSS.
The ECM receives the wheel speed information from
the electronic hydraulic control unit (EHCU) [ABS
module] via a controller area network (CAN)
Diagnostic Aids
communication bus. If the ECM detects that the wheel
speed from the EHCU is more than 20 km/h but the • If an intermittent condition is suspected, refer to
vehicle speed signal pulses are not generated, this Intermittent Conditions in this section.
DTC will set. • EHCU [ABS module] may output that wheel speed
signal is more than 20 km/h. Refer to Section 4C1
Condition for Running the DTC ABS/ ASR Air Over Hydraulic Type.
• DTCs P0502, P0503 and P060B are not set.
Notice: If this DTC set, the Vehicle Speed
parameter on the scan tool will display 10 km/h.
• The wheel speed is more than 20 km/h. Connector End View Reference: Engine Controls
• The vehicle speed of the EHCU is effective. Connector End Views or ECM Connector End Views

Go to Applicable
2. Observe the speed meter in the instrument
3 panel (IP) cluster. —
Does the speed meter indicate correct vehicle
1. Drive the vehicle. Go to Diagnostic
2. Monitor the DTC Information with a scan tool. System Check -
Does the DTC fail this ignition? Section 4C1 ABS/ Go to Diagnostic
ASR Aids

1. Test the vehicle speed sensor signal circuit
vehicle speed sensor for an open circuit. Refer
to IP Cluster and Warning in Section 9D
5 —
Wiring System.

• Physical damage
damage

connector.

8 Driver Info. —

Records.

10 —

Barometric Pressure Sensor Circuit Range/ • The vehicle is not running.
Performance
Circuit Description • The ECM detects that the BARO is more than 12
The barometric pressure (BARO) sensor is located kPa (1.8 psi) over the boost pressure for longer
behind of the lower cover. The BARO sensor is a than 7 seconds.
transducer that varies voltage according to changes the • The ECM detects that the BARO is more than 10
barometric pressure. Within the ECM, the diagnostic kPa (1.5 psi) below the boost pressure for longer
compares the BARO sensor input to the boost pressure than 7 seconds.
sensor input. If the ECM detects that the inputs are not
within a specified amount of each other, this DTC will Action Taken When the DTC Sets
set. • The ECM illuminates the MIL when the diagnostic
Condition for Running the DTC Action Taken When the DTC Sets - Type B.
• DTCs P0102, P0103, P0116, P0117, P0118,
P0122, P0123, P0237, P0238, P0500, P0502, Condition for Clearing the DTC
P0503, P0560, P060B, P0638, P0651, P0697, • Refer to DTC Type Definitions for Condition for
P215A, P2228 and P2229 are not set. Clearing the MIL/ DTC - Type B.
• The ignition switch is ON. Diagnostic Aids
• The engine speed is less than 625 RPM. • If an intermittent condition is suspected, refer to
• The fuel injection quantity is less than a Intermittent Conditions in this section.
predetermined value.
• The accelerator pedal is not depressed. Connector End Views or ECM Connector End Views

Go to Applicable
2. Compare the Boost Pressure parameter to the
Barometric Pressure parameter with a scan 10 kPa (1.5
3 tool. psi)
Are both parameter within the range specified of Go to Diagnostic
each other? Aids Go to Step 4
Determine the outside barometric pressure from
your location specified in the altitude vs. barometric
4 Pressure. —
Is the Barometric Pressure parameter on the scan

tool close to the outside barometric pressure? Go to Step 5 Go to Step 7

harness connector.
connector of the boost pressure sensor (pins
1, 2 and 3 of E54).
E26).

(pins 91, 95 and 109 of E26) and the boost
pressure sensor (pins 1, 2 and 3 of E54) for

connector.
connector of the BARO sensor (pins 1, 2 and
3 of FL52).
FB24).

1. Test each sensor circuits between the ECM
(pins 60, 61 and 71 of FB24) and the BARO
sensor (pins 1, 2 and 3 of FL52) for high
8 resistance. —

10 —

Records.

12 —

Barometric Pressure Sensor Circuit Low or Condition for Setting the DTC
High • The ECM detects that the BARO sensor signal
The barometric pressure (BARO) sensor is located • The ECM detects that the BARO sensor signal
behind of the lower cover. The BARO sensor is a voltage is more than 4.0 volts for 5 seconds. (DTC
transducer that varies voltage according to changes the P2229)
barometric pressure. The sensor has the following
circuits: Action Taken When the DTC Sets
• BARO sensor signal circuit
The BARO sensor provides a signal to the ECM on the • The ECM uses a BARO substitution of default
signal circuit, which is relative to the pressure changes value.
of the barometric pressure. The ECM should detect a • The ECM inhibits EGR control.
low signal voltage at a low barometric pressure, such
as high altitude place. The ECM should detect high Condition for Clearing the DTC
signal voltage at a high barometric pressure. The ECM • Refer to DTC Type Definitions for Condition for
uses this voltage signal to calibrate the fuel injection Clearing the MIL/ DTC - Type A.
quantity and injection timing for altitude compensation.
If the ECM detects an excessively low or high signal Diagnostic Aids
voltage, DTC P2228 or P2229 will set.
• DTCs P060B and P0651 are not set. Connector End View Reference: Engine Controls


Observe the Barometric Pressure Sensor
3 0.5 volts
Is the Barometric Pressure Sensor parameter less Go to Diagnostic
connector.
ground.

Is the Barometric Pressure Sensor parameter more
Notice: The BARO sensor shares the 5 volts
resistance.

• An open circuit
7 —
• High resistance

8 —


10 —


Records.

13 —

2 4. Observe the Barometric Pressure Sensor 4.0 volts
Is the Barometric Pressure Sensor parameter more Go to Diagnostic

3 —
connector.
4 0.1 volts

connector.
5 0.1 volts


Important: The BARO sensor may be damaged if
source.

Notice: The BARO sensor shares the low
resistance.

9 —


11 —

Records.

14 —

DTC P242F (Flash Code 131)
DPD Restriction Condition for Setting the DTC
• The exhaust differential pressure is more than a
Description predetermined range of the calculated differential
The ECM detects the condition of PM accumulations pressure value for longer than 30 seconds.
from the exhaust differential pressure sensor attached
to the chassis frame near the diesel particulate defuser Action Taken When the DTC Sets
(DPD) assembly. When it is reached to a certain • The ECM illuminates the MIL when the diagnostic
amount of PM accumulations or a certain length of runs and fails. Refer to DTC Type Definitions for
mileage, the automatic regeneration starts. If the Action Taken When the DTC Sets - Type A.
automatic regeneration cannot be completed by some • The ECM limits fuel injection quantity.
reason, the manual regeneration is requested to the
driver by blinking the DPD amber lamp or "PUSH DPD • The ECM inhibits cruise control.
SWITCH" indicator on the instrument panel cluster. If
the ECM detects that the exhaust differential pressure Condition for Clearing the DTC
is more than a predetermined range of the calculated • Refer to DTC Type Definitions for Condition for
value, this DTC will set. Clearing the MIL/ DTC - Type A.

• DTCs P0500, P0502, P0503 and P215A are not • Misrouted, disconnected or plugged exhaust
set. differential pressure hoses or pipes may set this
• The ignition switch is ON. DTC.
• The exhaust gas temperature 1 (in front of filter) is • If manual regeneration is frequently requested,
more than 100°C (212°F). refer to DPD System Manual Regeneration
Frequently chart in symptom diagnostic table.
• The EGR position is less than 95%. Notice: This DTC is caused by incomplete automatic
• The intake throttle position is more than 22%. regeneration has occurred and manual regeneration
• The DPD filter regeneration is inactive. urged by the DPD lamp on the IP cluster was
disregarded or forgot, which was most likely caused by
lamp or "PUSH DPD SWITCH" indicator blinking in the
past.
Circuit/ System Testing DTC P242F (Flash Code 131)

Regeneration Frequently chart in symptom
diagnostic table.


a scan tool.
knob clockwise.)
to 200°C (392°F).


scan tool.


knob clockwise.)
procedure in
7 —

DPD Differential Pressure Sensor Circuit Action Taken When the DTC Sets
Range/ Performance • The ECM illuminates the MIL when the diagnostic
Description Action Taken When the DTC Sets - Type A.
The exhaust differential pressure sensor is attached to • The ECM limits fuel injection quantity.
the chassis frame near the diesel particulate defuser • The ECM inhibits cruise control.
(DPD) assembly. The exhaust differential pressure
sensor is a transducer that varies voltage according to Condition for Clearing the DTC
changes of the exhaust gas differential pressure
detects that the exhaust differential pressure went
excessively high, this DTC will set.
Diagnostic Aids
• DTCs P060B, P0697, P2454, P2455 and P2456
are not set. • Misrouted, disconnected or plugged exhaust
differential pressure hoses or pipes will set this
DTC.
• The exhaust differential pressure is more than 60
kPa.

2 start the engine. —


high exhaust differential pressure.

1G Engine Exhaust.
3 • Any contamination or objects that block —
port
pressure sensor
• Restricted or collapsed exhaust system


4 —
FB24).
high resistance.
necessary.

Important: Clear the DTC and the DPD Status in
the ECM must be reset when the DPD filter is
replaced.
5 Replace the DPD filter. Refer to Exhaust Pipe in —


6 3. Clear the DTC and reset the DPD Status with —

a scan tool.
scan tool.

knob clockwise.)
procedure in
8 —

DPD Differential Pressure Sensor Circuit Low Condition for Setting the DTC
or High • The ECM detects that the exhaust differential
pressure sensor signal voltage is less than 0.2
Circuit Description volts. (DTC P2454)
The exhaust differential pressure sensor is attached to • The ECM detects that the exhaust differential
the chassis frame near the diesel particulate defuser pressure sensor signal voltage is more than 4.9
(DPD) assembly. The exhaust differential pressure volts. (DTC P2455)
changes of the exhaust gas differential pressure Action Taken When the DTC Sets
between in front and in rear of DPD filter. The sensor • The ECM illuminates the MIL when the diagnostic
has the following circuits: runs and fails. Refer to DTC Type Definitions for
• Low reference circuit • The ECM limits fuel injection quantity.
• Exhaust differential pressure sensor signal circuit • The ECM inhibits pre injection.
The exhaust differential pressure sensor provides a • The ECM inhibits cruise control.
signal to the ECM on the signal circuit, which is relative
to the differential pressure changes in front and in rear Condition for Clearing the DTC
of DPD filter. The ECM should detect a low signal
voltage at a low differential pressure, such as small PM
accumulation. The ECM should detect high signal
voltage at high differential pressure, such as large PM
Diagnostic Aids
accumulation. If the ECM detects an excessively low or
high signal voltage, DTC P2454 or P2455 will set. • If an intermittent condition is suspected, refer to


Observe the Exhaust Differential Pressure Sensor
3 0.2 volts
4 circuit (pin 3 of FB66) and a known good 4.5 volts
ground.

6 an open circuit or high resistance. —

• An open circuit
• High resistance

exhaust differential pressure sensor (pins 2
8 and 3 of FB66). —





Records.

13 —

2 4. Observe the Exhaust Differential Pressure 4.9 volts
Sensor parameter with a scan tool.

3 —
4 0.1 volts

parameter less than the specified value? Go to DTC P0697 Go to Step 7
5 0.1 volts


Important: The exhaust differential pressure
sensor may be damaged if the sensor signal circuit
is shorted to a voltage source.
7 following conditions: —


Notice: The exhaust differential pressure sensor
shares the low reference circuit with other sensors.
A fault condition in the low reference circuit may set

exhaust differential pressure sensor (pin 1 of
9 FB66). —





Records.

14 —

DPD Differential Pressure Sensor Learned Condition for Setting the DTC
Position • The ECM detects that the learned exhaust
differential pressure is not within -4.5 to 4.5 kPa.
Circuit Description
The exhaust differential pressure sensor is attached to Action Taken When the DTC Sets
the chassis frame near the diesel particulate defuser • The ECM illuminates the MIL when the diagnostic
(DPD) assembly. The exhaust differential pressure runs and fails. Refer to DTC Type Definitions for
sensor is a transducer that varies voltage according to Action Taken When the DTC Sets - Type A.
changes of the exhaust gas differential pressure • The ECM limits fuel injection quantity.
between in front and in rear of DPD filter.
The ECM learns a variance of the exhaust differential
pressure sensor signal at every ignition cycle after the • The ECM inhibits cruise control.
ignition switch has been ON with the engine OFF for 30
seconds. (The DPD lamps or “AUTO REGEN.”, Condition for Clearing the DTC
“MANUAL REGEN.” indicators on the instrument panel • Refer to DTC Type Definitions for Condition for
cluster indicates this transition by commanded to OFF.) Clearing the MIL/ DTC - Type A.
If the ECM detects that learned exhaust differential
pressure is not within a predetermined range, this DTC Diagnostic Aids
will set. • If an intermittent condition is suspected, refer to
• A skewed exhaust differential pressure sensor
• DTCs P060B, P0697, P2454 and P2455 are not value can set this DTC. The Exhaust Differential
set. Pressure Sensor on the scan tool should read 0.9
• The battery voltage is between 18 to 32 volts. to 1.0 volts with the ignition switch ON and engine
• The ignition switch is ON. OFF.
• The engine is stopped.

Go to Applicable
Is DTC P2454 or P2455 set? DTC Go to Step 3
3 3. Turn ON the ignition for 30 seconds while —
tool.
Go to Diagnostic

FB24).

(pins 67, 79 and 80 of FB24) and the exhaust
differential pressure sensor (pins 1, 2 and 3 of


7 —
tool.

8 —

DPD Regeneration Duration Condition for Setting the DTC
• The DPD filter regeneration event continuously
Description exceeds a predetermined time.
The ECM detects the condition of PM accumulations
from the exhaust differential pressure sensor attached Action Taken When the DTC Sets
to the chassis frame near the diesel particulate defuser • The ECM illuminates the MIL when the diagnostic
(DPD) assembly. When it is reached to a certain runs and fails. Refer to DTC Type Definitions for
amount of PM accumulations or a certain length of Action Taken When the DTC Sets - Type A.
mileage, the automatic regeneration starts. If the • The ECM limits fuel injection quantity.
automatic regeneration cannot be completed by some
reason, the manual regeneration is requested to the • The ECM inhibits cruise control.
driver by blinking the DPD amber lamp or “PUSH DPD
SWITCH” indicator on the instrument panel cluster. Condition for Clearing the DTC
Once the regeneration starts, it must be finished within • Refer to DTC Type Definitions for Condition for
a certain time. If the regeneration event is continuously Clearing the MIL/ DTC - Type A.
over a predetermined time, this DTC will set.
Diagnostic Aids
Condition for Running the DTC • Use the Temperature vs. Resistance table to test
• DTCs P0079, P0080, P0116, P0117, P0118, the exhaust temperature sensor at various
P0122, P0123, P0201 - P0204, P0335, P0336, temperature levels to evaluate the possibility or a
P0404, P0409, P0426, P042B, P042C, P042D, skewed sensor.
P0427, P0428, P0500, P0502, P0503, P060B, • Fuel system problem (e.g. fuel injector damage)
P0638, P0641, P0651, P1261, P1262, P1404, may set this DTC.
P2146, P2149, P215A, P2227, P2228, P2229,
• Deteriorated or damaged oxidation catalyst will set
this DTC.
• If regeneration time is longer than normal, refer to
• The vehicle is running or the PTO control is DPD System Regeneration Long Time chart in
inactive. symptom diagnostic table.
Notice: Under a driving condition that the exhaust
temperature will not be stable during the DPD filter
regeneration event (e.g. frequent stop and start), this
DTC will set.

2 —

P042B, P042C or P042D set? DTC Go to Step 3

Important: There is installation directionality

in the exhaust differential pressure hoses.
Refer to Exhaust Differential Pressure Sensor
port
pressure sensor
or damaged
3 temperature sensor(s) or exhaust —
Exhaust.
sensors
testing.


to DPD Status Table in DPD Control System
Check.
Is the intersected of a range located in C or D? Go to Step 5 Go to Step 6


scan tool.

scan tool.

scan tool.
scan tool.

knob clockwise.)
procedure in
8 —

PTO Sense Circuit Condition for Setting the DTC
• The ECM detects that the PTO throttle sensor
Circuit Description signal voltage is more than 4.8 volts.
The power take off (PTO) throttle sensor (body builder
installed) detects the PTO control throttle angle. The Action Taken When the DTC Sets
ECM receives the PTO control throttle angle from the • The ECM illuminates the SVS lamp when the
throttle sensor and controls the fuel injection quantity diagnostic runs and fails. Refer to DTC Type
(engine speed) during PTO. The PTO throttle sensor Definitions for Action Taken When the DTC Sets -
has the following circuits. Type C.
• 5 volts reference circuit • The ECM disables PTO throttle sensor control.
• PTO throttle sensor signal circuit Condition for Clearing the DTC
The PTO throttle sensor provides a signal to the ECM • Refer to DTC Type Definitions for Condition for
on the signal circuit, which is relative to the position Clearing the SVS Lamp/ DTC - Type C.
changes of the PTO throttle angle. If the ECM detects
an excessively high signal voltage, this DTC will set. Diagnostic Aids
• DTCs P060B and P0641 are not set. • PTO throttle sensor may have an intermittent open
• The battery voltage is between 18 to 32 volts. somewhere in the operating range.

Notice: If no PTO throttle sensor is installed,

2 skip to Step 3. 4.8 volts
value during operating the throttle? Go to Step 3 Aids
3 —
connector.
4 0.1 volts


connector.
5 0.1 volts

Important: The PTO throttle sensor may be
voltage source.
70 of FB24) and the PTO throttle sensor (pin 2
7 of FB129) for the following conditions: —

Notice: The PTO throttle sensor shares the low
8 ECM (pin 41 of FB24) and the PTO throttle —
sensor (pin 1 of FB129) for an open circuit or
high resistance.

PTO throttle sensor (pin 1 of FB129).
9 —


11 —


13 4.8 volts

value during operating the throttle? Go to Step 3 Go to Step 14
14 —

Engine Idle Speed Selector Sensor • The ECM detects that the idle up sensor signal
voltage is less than 0.1 volts for longer than 3
Circuit Description seconds.
The idle up sensor controls the idle speed during warm • The ECM detects that the idle up sensor signal
up and it is installed in the driver’s side instrument voltage is more than 4.9 volts for longer than 3
panel. This sensor is active only when the gear position seconds.
is in the neutral position. When the shift lever is moved
to another position, the signal is ignored. The ECM Action Taken When the DTC Sets
receives the idle up signal from the idle up sensor and • The ECM illuminates the SVS lamp when the
controls the fuel injection quantity. The idle up sensor diagnostic runs and fails. Refer to DTC Type
has following circuits: Definitions for Action Taken When the DTC Sets -
• 5 volts reference circuit Type C.
• Low reference circuit • The ECM disables idle up sensor control.
• Idle up sensor signal circuit
The idle up sensor provides a signal to the ECM on the Condition for Clearing the DTC
signal circuit, which is relative to the position changes • Refer to DTC Type Definitions for Condition for
of the idle up sensor angle. If the ECM detects an Clearing the SVS Lamp/ DTC - Type C.
excessively low or high signal voltage, this DTC will set.
Diagnostic Aids
• The battery voltage is between 18 to 32 volts. • Idle up sensor may have an intermittent open
• The ignition switch is ON. somewhere in the operating range.

4. Fully turn the idle up sensor between lowest
2 0.2 to 4.8 volts
scan tool.
Does the scan tool indicate within the specified Go to Diagnostic

value during turning the sensor? Aids Go to Step 3
3 —
4 0.1 volts
specified value at Step 2? Go to DTC P0641 Go to Step 8
Turn the idle up sensor to lowest position (full
counterclockwise direction).
5 0.1 volts

connector.
ground.
Is the Idle Up Sensor parameter more than the
connector.
8 0.1 volts

connector.
9 0.1 volts

Notice: The idle up sensor shares the 5 volts
resistance.

• An open circuit
12 —
• High resistance


Important: The idle up sensor may be damaged if
source.

Notice: The idle up sensor shares the low
resistance.

Idle up sensor (pins 1, 2 and 3 of FL33).
15 —

ECM (pins 41, 42 and 66 of FB24).

Replace the Idle up sensor. Refer to Idle Up Sensor
17 in Section 1I Engine Speed Control System. —

19 5. Fully turn the idle up sensor between lowest 0.2 to 4.8 volts
scan tool.

value during turning the sensor? Go to Step 20 Go to Step 3

20 —

Control Module Communication Bus Off Action Taken When the DTC Sets
Circuit Description consecutive driving cycle when the diagnostic runs
The ECM, the variable nozzle turbocharger (VNT) and fails. Refer to DTC Type Definitions for Action
control module, the electric hydraulic control unit Taken When the DTC Sets - Type B.
(EHCU), the transmission control module (TCM), the • The ECM blinks the exhaust brake indicator lamp
body control module (BCM) or the data recording when the diagnostic runs and fails.
module (DRM) and instrument panel (IP) cluster • The ECM limits fuel injection quantity.
communicate control and diagnostic information via a
controller area network (CAN) communication bus. The
ECM monitors CAN operational status by expecting a • The ECM inhibits cruise control.
ECM sets CAN Bus OFF status, this DTC will set. Condition for Clearing the DTC
Diagnostic Aids
Condition for Setting the DTC Intermittent Conditions in this section.
• The ECM detects the CAN Bus OFF status. • Parallel resistance of the 120 Ω resistor in the
ECM and the IP cluster should be 60 Ω.


Go to Diagnostic
2. Disconnect the variable nozzle turbocharger
(VNT) control module E9 harness connector.
Is DTC U0110 set, but not DTC U0073? Go to Step 11 Go to Step 4

Notice: If no ABS is installed, skip to Step 5.
2. Reconnect the VNT control module E9
4 3. Disconnect the electric hydraulic control unit —
(EHCU) J7 harness connector.


Notice: If no Smoother transmission is installed,
skip to Step 6.
3. Reconnect the EHCU J7 harness connector if
5 disconnected. —
connector.
Is DTC P0101 set, but not DTC U0073? Go to Step 15 Go to Step 6

Notice: If no multi-information display is installed,
skip to Step 7.
disconnected.
6 4. Reconnect the TCM FU108 harness —
connector if disconnected.
5. Disconnect the body control module (BCM)

disconnected.
4. Reconnect the TCM FU108 harness
7 connector if disconnected. —

2. Reconnect the BCM FL105 or DRM FL101
3. Remove the bezel surrounding the instrument
panel (IP) cluster enough to remove the IP
cluster.
8 —
4. Disconnect the IP cluster FU97 harness
connector.


each control module for the following
conditions:

10 Info. —

11 Induction. —

Replace the EHCU or ABS ECU. Refer to EHCU in
12 Section 4C1 ABS/ ASR. —
programmed.
13 Replace the BCM. Refer to Repair Instructions in —
Section 10B Vehicle Control.

Replace the DRM.
14 —


components or harness connector(s).
Records.

18 —

Lost Communication with TCM Action Taken When the DTC Sets
The ECM and the transmission control module (TCM) Action Taken When the DTC Sets - Type A.
communicate control and diagnostic information via a • The ECM blinks the exhaust brake indicator lamp
controller area network (CAN) communication bus. The when the diagnostic runs and fails.
ECM monitors CAN operational status by expecting a • The ECM inhibits exhaust brake control.
ECM fails to receive an expected message from the Condition for Clearing the DTC
TCM, this DTC will set.
• DTC U0073 is not set. Diagnostic Aids

• The battery voltage is more than 20 volts. • If an intermittent condition is suspected, refer to
• The ECM detects that the CAN Bus messages Connector End Views or ECM Connector End Views
from the TCM are not being received.

Go to Applicable
Is DTC U0073 or U0110 also set? DTC Go to Step 3
Attempt to communicate with the transmission Go to Diagnostic
control module (TCM) via the transmission data System Check -
table. Transmission
3 —
Controls in Section
Does the scan tool communicate with the TCM? 5A Transmission
Go to Step 4 Control System
connector.
4 1.5 to 3.5 volts

5 Step 4) between the TCM (pins 12 and 13 of —
FU108) and the CAN joint connectors.


connector of the TCM (pins 12 and 13 of
6 FU108). —


Records.

9 —

Lost Communication with VNT System Lost Communication DTC
• The ECM detects that the CAN Bus messages
Circuit Description from the VNT control module are not being
The ECM and the variable nozzle turbocharger (VNT) received.
control module communicate control and diagnostic
information via a controller area network (CAN) Action Taken When the DTC Sets
communication bus. The ECM monitors CAN • The ECM illuminates the MIL when the diagnostic
operational status by expecting a constant flow of runs and fails. Refer to DTC Type Definitions for
messages from the VNT control module. If the ECM Action Taken When the DTC Sets - Type A.
fails to send or receive an expected message from the • The ECM limits fuel injection quantity. (Lost
VNT control module, this DTC will set. communication DTC)
• The ECM inhibits cruise control. (Lost
communication DTC)
Error Message DTC
• The battery voltage is between 20 to 32 volts. Condition for Clearing the DTC
Lost Communication DTC Clearing the MIL/ DTC - Type A.
• The battery voltage is more than 20 volts. Diagnostic Aids
Error Message DTC Connector End Views or ECM Connector End Views
• The VNT control module received an error CAN
Bus messages from the ECM.

Go to Applicable
Is DTC U0073 or P0045 also set? DTC Go to Step 3
2. Disconnect the variable nozzle turbocharger
(VNT) control module E9 harness connector.
3 1.5 to 3.5 volts

4 Step 3) between the VNT control module (pins 15 —
and 16 of E9) and weld splice.


Connect a test lamp between the ignition voltage
feed circuit to the VNT control module (pin 13 of
5 E9) and a known good ground. —

Connect a test lamp across the ignition voltage
feed circuit and ground circuit (pins 13 and 14 of
6 E9). —

the ECM Main (15A) fuse and the VNT control
7 module (pin 13 of E9). Check the ECM Main (15A) —
fuse first.

the VNT control module (pin 14 of E9) and the
8 ground terminal (E20). Clean or tighten ground as —
necessary.

connector of the VNT control module (pins 13,
9 14, 15 and 16 of E9). —

10 Induction. —

Records.

12 —

Lost Communication With Vehicle Immobilizer Action Taken When the DTC Sets
Control Module • The ECM will not illuminate the MIL or SVS lamp.
Refer to DTC Type Definitions for Action Taken
Circuit Description When the DTC Sets - Type D.
The ECM communicates with the immobilizer control
unit (ICU) to execute immobilizer function. The ECM Condition for Clearing the DTC
sends a request signal to the ICU. The ECM receives a • Refer to DTC Type Definitions for Condition for
response signal from the ICU. Both communication Clearing the DTC - Type D.
signals are carried out via a controller area network
(CAN) communication bus. If the ECM does not detect Diagnostic Aids
a response signal from the ICU, this DTC will set. • If an intermittent condition is suspected, refer to
• The ECM does not receive a signal from the ICU. intermittent condition.
• Any communication fault with the ICU may set this
DTC.

Attempt to communicate with the immobilizer Go to Diagnostic
control unit (ICU) via the Immobilizer Data table. System Check -
2 — Immobilizer
Does the scan tool communicate with the ICU? Controls in Section
Go to Step 3 9I Security and Lock

5 —

6 —

EGR Control System Check
Description EGR Control Operation
The EGR system recirculates a part of exhaust gas • The engine coolant temperature (ECT) is between
back into the intake manifold, which results in reducing 70 to 100°C (158 to 212°F).
NOx emissions. The EGR control system uses an • The intake air temperature (IAT) is more than -
electronic control system to ensure both driveability 30°C (-22°F).
and low emission. A control current from the ECM
• The barometric pressure (BARO) is more than 90
operates a motor to control the lift amount of EGR
kPa (13 psi).
valve. Also, an EGR position sensor is provided at the
rear of the motor to feed actual valve lift amount back to
the ECM for more precision control.
determined and the valve is driven accordingly.
Circuit/ System Testing EGR Control System Check

2 4. Monitor the DTC Information with a scan tool. —
Are any DTCs set in which the "Action Taken When

the DTC Sets" under that particular code states, Go to Applicable
"The ECM inhibits EGR control"? DTC Go to Step 3

damaged
• EGR gas leakage any of the EGR
passage between the exhaust manifold
and intake manifold
EGR valve
system
3 system —
• Skewed engine coolant temperature
(ECT) sensor. Refer to Temperature vs.
Resistance table to test the ECT sensor
at various temperature levels to evaluate
the possibility of a skewed sensor.
• Skewed barometric pressure (BARO)
sensor. Determine the outside barometric
pressure from you location specified in
the altitude vs. barometric pressure table.
Refer to Altitude vs. Barometric
Pressure.
2. Repair the condition as necessary.

parking brake.
2. Start the engine and warm up (arrow engine
[167°F]).
4 W.O.T (accelerator pedal full travel) many ± 5%
times while observing the Desired EGR
Position and EGR Position parameter with a
scan tool.

tool several times.
5 and Decrease while observing the EGR ± 5%
Position.

specified value quick enough? Go to Step 6 Go to Step 7

6 Increase and Decrease while observing the ± 5%
Intake Throttle Position.

within the specified value quick enough? System OK Go to Step 9
engine.
conditions:
7 materials —
• Bent valve shaft

6, 7 and 8 of E45).
101 103, 110 and 111 of E26).
necessary.

materials



connector.
2, 4, 5 and 6 of E46).
connector of the ECM (pins 85, 95, 104, 109
and 112 of E26).
necessary.


Glow Control System Check
Description • In pre glow phase, the glow relay energizes
The glow control system consists of the ECM, the glow between 1 second to approximately 20 seconds
relay, the glow plug lamp and glow plugs. The glow depending upon the engine coolant temperature. It
control system is operated when the engine coolant energizes 1 second at 10°C (50°F) or more.
temperature is low, which allows easier engine starting. • In after glow phase, the glow relay energizes
The ECM commands the glow relay ON for a certain between 1 second to approximately 20 seconds
length of time at ignition switch is ON with engine OFF. depending upon the engine coolant temperature. It
In after glow phase, the glow plugs remain energized energizes 1 second at 10°C (50°F) or more.
for a certain period with engine run.
Glow Control Operation Connector End Views or ECM Connector End Views
• The glow plug lamp illuminates between 0.5
seconds to approximately 10 seconds depending
upon the engine coolant temperature. It illuminates
0.5 seconds at 10°C (50°F) or more.
Circuit/ System Testing Glow Control System Check

Go to Applicable
Is DTC P0117, P0118, P0380 or P0381 set? DTC Go to Step 3
2. Make sure the metal bus bar that connects
switched battery voltage supply terminal (E31)
and all glow plugs is secured tightly.
bar (glow plug power supply E31 terminal) and
3 a known good ground. —
tool.
test lamp.

2. Remove the metal bus bar from the glow
plugs.
3. Measure resistance of each glow plug
between the glow plug terminals and a known
4 good ground. Make sure to record all 1Ω
measurements and take them quickly as to
not allow engine temperature changes
between measurements.
Are the resistances within the specified value each

other? System OK Go to Step 15

replace with a known good relay.
tool.
test lamp.

Inspect the Glow (60A) slow blow fuse in the
6 chassis side fuse & relay box. —
Is the Glow (60A) slow blow fuse open? Go to Step 7 Go to Step 8
Replace the Glow (60A) slow blow fuse. If the slow
blow fuse continues to open, repair the short to
7 ground on a circuit fed by the slow blow fuse or —
check for a shorted attached component.

3. Connect a test lamp between the battery
8 —
voltage feed circuit of the relay (pin 1 of X19)

1. Connect a test lamp between the voltage
supply circuit of glow plugs (pin 2 of X19) and
a known good ground.
9 —

the Glow (60A) slow blow fuse and the glow relay
10 (pin 1 of X19). —

the glow relay (pin 2 of X19) and the glow plugs
11 (E31 terminal). —

Important: The glow plugs may be burnt out if the
battery voltage supply circuit is shorted to a voltage
source.
12 Repair the short to battery or ignition voltage —
between the glow relay (pin 2 of X19) and the glow
plugs (E31 terminal).

13 connection on each glow relay terminal. —


14 —
Replace the appropriate glow plug.
15 —
components, relay, fuse or harness
connector(s).
tool.
test lamp.


Exhaust Brake Control System Check
Description • The vehicle speed is higher than predetermined
The exhaust brake control system consists of the ECM, range.
the intake throttle valve, the exhaust brake valve, the
exhaust brake solenoid valve and the exhaust brake Test Description
switch. The ECM commands the intake throttle valve The number below refers to the step number on the
and the exhaust brake solenoid valve to close each Circuit/ System Table.
valve based on vehicle running conditions and exhaust 4. Use the scan tool to observe the Accelerator Pedal
brake switch input signal. Position. The Accelerator Pedal Position parameter
should change linearly from 0 to 100% according to the
Exhaust Brake Control Operation accelerator pedal operation.
• The exhaust brake switch is ON. 8. If the Exhaust Brake Solenoid Command parameter
indicates OFF, use the scan tool to observe the Vehicle
Speed, Accelerator Pedal Position and Clutch Pedal
• The accelerator pedal is not depressed. Switch parameters which allows the exhaust brake
• The gearshift clutch is not disengaged (Smoother). control. Refer to engine control wirings and Scan Tool
• The clutch pedal is not depressed (manual Data List for diagnosis.
transmission).

2 —
3. Apply the exhaust brake switch ON and OFF.
Does the exhaust brake indicator lamp turn ON and

OFF with each switch transition? Go to Step 3 Go to 2 of 2 Step 1
1. Drive the vehicle in order to gain exhaust
brake ON time long enough.
2. Apply the exhaust brake switch ON.
3. Release the accelerator pedal.
3 —
Does exhaust brake apply enough (if the vehicle
speed is reduced by applying the exhaust brake but
engine valve noise is heard, intake throttle valve
may not be closed enough)? Go to Step 4 Go to Step 7
1. Reenter the exhaust brake control. Observe the
2. Apply the accelerator pedal while in exhaust Accelerator Pedal
brake control. Position parameter
4 —
for accelerator pedal
Does the exhaust brake control cancel? position sensor
Notice: If no Smoother is installed, skip to Step 6. Go to Diagnostic
1. Reenter the exhaust brake control. System Check -
5 2. Operate the selector lever while in exhaust — Transmission
brake control. Controls in Section
5A Transmission
Does the exhaust brake control cancel? System OK Control System
2. Apply the clutch pedal while in exhaust brake
6 control. —
Does the exhaust brake control cancel? System OK Go to Step 9


7 —

the DTC Sets” under that particular code states, Go to Applicable
“The ECM inhibits exhaust brake control”? DTC Go to Step 8
2. Trigger the Snapshot function in order to
capture and store engine parameters while in
exhaust brake control.
8 3. Review the Exhaust Brake Valve Command —
parameter. The ECM is not
allowing exhaust
Does the Exhaust Brake Valve Command brake control. Refer
parameter indicate ON when the exhaust brake to Exhaust Brake
may operate enough? Go to Step 18 Control Operation
3. Observe the Clutch Pedal Switch parameter
with a scan tool while fully depressing and
9 —
releasing the clutch pedal.
Does the scan tool indicate Applied when the clutch

pedal is applied and Released when the clutch
1. Check to ensure the clutch pedal switch is
adjusted correctly. The plunger should be all
the way in when the pedal is released, yet
should not impede with the clutch pedal full
10 —
upward travel.
2. Adjust the clutch pedal switch as necessary.

2. Disconnect the clutch pedal switch harness
connector.
11 —
voltage feed circuit (pin 1 of FU179) and a
known good ground.

Observe the Clutch Pedal Switch parameter with a
12 between pins 1 and 2 of FU179. —
Does the scan tool indicate Released when the
circuit is jumpered and Applied when the circuit is
not jumpered? Go to Step 15 Go to Step 14
13 (pin 1 of FU179). —


• An open circuit
• High resistance

15 —


Replace clutch pedal switch. Refer to Clutch
17 Control in Section 5E Clutch. —
1. Perform the Exhaust Brake Control with a Problem is relating
scan tool. to solenoid valve,
2. Command the solenoid ON and OFF. solenoid valve
wiring or exhaust
Does the solenoid valve click with each command? brake valve stuck.
Or faulty air
18 —
pressure lines.
Refer to applicable
diagnostic chart in
Section 1G Engine
Exhaust or engine
control wirings. Go to Step 19
harness connector.
19 —
voltage feed circuit (pin 1 of FB41) and a
known good ground.

1. Connect a test lamp across the exhaust brake
solenoid valve harness connector (pins 1 and
2 of FB41).
20 scan tool. —
3. Command the solenoid ON and OFF.

Does the test lamp remain illuminate with each
21 —

the ECM Main (15A) fuse and the solenoid valve
22 (pin 1 of FB41). —

FB41) for the following conditions:
• An open circuit
• High resistance

24 —

25 —


27 —


3. Apply the exhaust brake switch ON and OFF
1 while observing the Exhaust Brake Switch —


Does the exhaust brake indicator lamp always ON
2 —
with each switch transition? Go to Step 10 Go to Step 11
connector (FL73).
3 circuit of combination switch harness (pin 13 —
of FL73) and a known good ground.

Observe the Exhaust Brake Switch parameter with
4 between pins 13 and 15 of FL73. —
5 (pin 13 of FL73). Check the Engine Controller (10A) —
fuse first.

45 of FB24) and the switch (pin 15 of FL73) for
• An open circuit
• High resistance

switch (pins 13 and 15 of FL73).
7 —

8 —

9 —
Is the exhaust brake indicator lamp OFF? Go to Step 19 Go to Step 16


voltage to the exhaust brake indicator lamp.
11 1 volt
5. Measure the voltage from the exhaust brake
indicator lamp control circuit in the ECM
harness connector (pin 7 of FB24) to a known
good ground.

Is the exhaust brake indicator lamp illuminate? Go to Step 15 Go to Step 13

13 —

connection at the harness connector of the IP
cluster (pin 13 of FU98).
14 —

15 —

17 (pin 13 of FU98). —

18 Driver Info. —


Did you complete the action? Go to 1 of 2 Step 2 —

Cruise Control System Check
Description 5. Function of "TAP UP"
The cruise control system consists of the ECM, the If the resume/ accel. switch is tapped (momentarily
cruise control main switch, set/ coast switch, resume/ turned) while the cruise control system is operating, the
accel. switch and cancel switch. The cruise control vehicle speed is increased 1 km/h at a time.
keeps the vehicle speed at a driver's set speed. When 6. Function of "TAP DOWN"
the cruise control main switch is pressed ON, signal is If the set/ coast switch is tapped (momentarily turned)
provided to the ECM and the cruise control main while the cruise control system is operating, the vehicle
indicator lamp on the instrument panel cluster will light speed is decreased 1 km/h.
up. When the cruise set/ coast switch is turned to SET 7. Function of Temporary Acceleration
(-), the switch signal is provided to the ECM and the If the accelerator pedal is depressed while the cruise
vehicle speed is set. The vehicle speed is increased or control system is operating, the vehicle speed is
decreased if the set/ coast switch or the resume/ accel. increased.
switch is turned to RES (+) or SET (-). When the cruise 8. Function of Temporary Cancellation
cancel switch is applied, the switch signal is provided to The cruise control is canceled temporarily if any of the
the ECM and the cruise control system is inactive. following condition is met:
• The cruise cancel switch is applied.
Condition for Running the Cruise Control • The brake pedal is depressed.
• The vehicle speed is between approximately 40 to • The selector lever is operated.
100 km/h. (Speed limiter setting 100 km/h) • The exhaust brake is applied.
• The cruise control main switch is ON. • The actual vehicle speed becomes less than
1. Function of "SET" approximately 40 km/h.
If the set/ coast switch is turned to SET (-) and released
• The actual vehicle speed is more than 40 km/h
while condition for running the cruise control are
below the set speed.
satisfied, the ECM memorize and maintain the vehicle
By applying the resume/ accel. switch, the vehicle
speed at that time.
speed is returned to the vehicle speed memorized by
2. Function of "COAST"
the ECM (resume function) if within the condition for
If the set/ coast switch is turned to SET (-) while the
running the cruise control are satisfied.
cruise control system is operating, the vehicle speed is
9. Function of Complete Cancellation
decreased. Then, when the set/ coast switch is
The cruise control is canceled completely if any of the
released, the vehicle will maintain the vehicle speed at
that time.
3. Function of "RESUME" • The cruise control main switch is OFF.
If the resume/ accel. switch is turned to RES (+) while • The ignition switch is OFF.
the cruise control system is operating and the ECM • The DTCs relating to the cruise control system
memorizes the vehicle speed, the vehicle speed is inhibits are set.
returned to the vehicle speed memorized by the ECM.
4. Function of "ACCEL" Connector End View Reference: Engine Controls
If the resume/ accel. switch is turned to RES (+) while Connector End Views or ECM Connector End Views
the cruise control system is operating, the vehicle
speed is increased. Then, when the resume/ accel.
switch is released, the vehicle will maintain the vehicle
speed at that time.

Circuit/ System Testing Cruise Control System Check

1. Drive the vehicle at 50 km/h on a flat level
road.
2. Press and release the cruise control main
switch.
3. Turn and release the cruise set/ coast switch.
4. Verify the 50 km/h vehicle speed is
2 maintained. —
5. Tap (momentarily turn) the cruise set/ coast

switch 10 times.
Did the vehicle maintain the set speed of 50 km/h,

and then decreased by 1 km/h each time the switch
was tapped (momentarily turned to SET [-])? Go to Step 3 Go to Step 7
Tap (momentarily turn) the cruise resume/ switch
10 times.
3 Does the vehicle speed increase 1 km/h each time —
the switch was tapped (momentarily turned to RES
[+])? Go to Step 4 Go to Step 10
Are the cruise control main and set lamps in the IP Refer to Cab and
cluster illuminated while in cruise control? Chassis Electrical
4 — Section for IP
cluster circuits
Press and release the cruise cancel switch.
5 —
Does the cruise control cancel? Go to Step 6 Go to Step 11
1. Reenter the cruise control. ECM does not
2. Depress and release the brake pedal. support brake
switch parameters
Does the cruise control cancel? on the scan tool.
Use transmission
data display and
6 — refer to Cab and
Chassis Electrical
Section or
Transmission
Control Section for
brake switch circuits
System OK diagnosis
7 —
the DTC Sets” under that particular code states, Refer to Applicable
“The ECM inhibits cruise control”? DTC Go to Step 8
scan tool.
8 —
time the switch is pressed? Go to Step 9 Go to Step 12

Observe the Cruise Set/ Coast Switch parameter
with a scan tool. Retest the cruise
control. Refer to
9 Does the scan tool indicate ON when the switch is — Condition for
turned to SET (-) and OFF when the switch is Running the Cruise
released? Control Go to Step 17
Observe the Cruise Resume/ Acceleration Switch
10 Does the scan tool indicate ON when the switch is —
turned to RES (+) and OFF when the switch is Go to Intermittent
released? Conditions Go to Step 17
a scan tool.
11 —
Does the scan tool indicate ON when the switch is Go to Intermittent
pressed and OFF when the switch is released? Conditions Go to Step 17
2. Disconnect the cruise control main switch
harness connector. (Remove the switch from
the IP bezel as necessary)
12 —
voltage feed circuit of the cruise control main
switch (pin 3 of FU208) and a known good
ground.

jumper wire across the cruise control main switch
13 harness connector between pins 3 and 4 of FU208. —

time the circuit is jumpered? Go to Step 16 Go to Step 15
the Engine Controller (10A) fuse and the cruise
14 control main switch (pin 3 of FU208). —

25 of FB24) and the cruise control main switch
(pin 4 of FU208) for an open circuit or high
15 resistance. —

cruise control main switch (pins 3 and 4 of
16 FU208). —


connector (FL19). (Remove the steering cowl
cover)
17 3. Connect a DMM between the cruise control 4.5 volts
switch signal circuit (pin 5 of FL19) and a
known good ground.
jumper wire across the combination switch harness
connector between the cruise control switch signal
18 circuit and low reference circuit (pins 4 and 5 of —
FL19).

1. Test the cruise control switch signal circuit
between the ECM (pin65 of FB24) and the
combination switch (pin 5 of FL19) for the
• An open circuit
• High resistance

Notice: The cruise control switch shares the low
20 ECM (pin 41 of FB24) and the combination —
switch (pin 4 of FL19) for an open circuit or
high resistance.

combination switch (pins 4 and 5 of FL19).
21 —


Repair or replace the cruise main switch.
23 —

24 —


Diesel Particulate Defuser (DPD) Control System Check
Description Range A: Normal range
The ECM detects the condition of PM accumulations Range B: DPD amber lamp or “PUSH DPD SWITCH”
from the exhaust differential pressure sensor attached indicator blinks but manual regeneration is possible.
to the chassis frame near the diesel particulate defuser Range C: Exhaust differential pressure is excessive
(DPD) assembly or from mileage. The exhaust high range and manual regeneration is inhibited.
differential pressure sensor is a transducer that varies Range D: Distance status is abnormal range and
voltage according to changes of the exhaust gas manual regeneration is inhibited.
differential pressure between in front and in rear of
filter. When it is reached to a certain amount of PM Test Description
accumulations or a certain length of mileage, the The number below refers to the step number on the
automatic regeneration starts. If the automatic Circuit/ System Table.
regeneration cannot be completed by some reason, the 6. 8. 9. If the regeneration is not started, any DTCs may
manual regeneration is requested to the driver by be set which inhibits regeneration control. If no DTC is
blinking the DPD amber lamp or “PUSH DPD SWITCH” set, use the scan tool to observe the Vehicle Speed,
indicator on the instrument panel cluster. Once the Accelerator Pedal Position, Neutral Switch, Idle Up
regeneration starts, it must be finished within a certain Sensor and PTO Switch parameters which allows the
time. After regeneration is finished, a purification of the DPD regeneration control. Refer to engine control
filter is judged by monitoring an exhaust differential wirings and Scan Tool Data List for diagnosis.
pressure. If an excessive PM accumulation has been
detected, the regeneration will not start since Connector End View Reference: Engine Controls
uncontrolled burning might be happened during Connector End Views or ECM Connector End Views
regeneration event.
The DPD Status Table is used to determine type of the
DPD filter regeneration procedure by comparing the
DPD Accumulation Status parameter and the DPD
Distance Status parameter. To use this table, observe
both parameters with a scan tool, and plot both
readings on the DPD status table. The intersected
range indicates A, B, C or D. (e.g. DPD Accumulation
Status is 3 and DPD Distance Status is 1. The range is
located in B)
5 C
4
B
3
D
2
1 A
0 1 2 3 4
DPD Distance Status
LNW76ESH003501
Circuit/ System Testing Diesel Particulate Defuser (DPD) Control System Check


cluster is operational. Go to P1669 for
2. Turn ON the ignition for 30 seconds, with the Turn OFF the DPD amber lamp
engine OFF. DO NOT start the engine. ignition for 30 circuit diagnosis or
2 —
seconds to relearn GO to IP cluster
Does the DPD amber lamp or “AUTO REGEN.”, exhaust differential diagnosis in Section
“MANUAL REGEN.” indicators turn ON, and then pressure sensor. 9E Instrumentation/
turn OFF? Go to Step 3 Driver Info.
1. Inspect engine oil level. Make sure the oil
amount is within a range.
3 —
4. Observe the DPD Regeneration Switch



1G Engine Exhaust.
port
pressure sensor
or damaged
4 —
Exhaust.
sensors
• Modified air induction


Start the engine and let idle for 30 seconds.
5 Does the DPD amber lamp or “PUSH DPD —
SWITCH” indicator blink? Go to Step 6 Go to Step 7
Perform the DPD manual regeneration by pressing ECM is not allowing
the DPD regeneration switch. the DPD
regeneration
6 Does the regeneration start? —
control. Refer to
Go to Step 10 DTC List

Observe the DPD Accumulation Status and DPD
Distance Status with a scan tool, and plot both
7 readings on the DPD status table. —
Is the intersected range located in A or B? Go to Step 8 Go to Step 9

Important: Reset the DPD Status before ECM is not allowing
regeneration with a scan tool. the DPD
Perform the DPD Normal Regeneration with a scan regeneration
8 —
Important: Reset the DPD Status before
regeneration with a scan tool.
Important: Engine Oil must be replaced after DPD ECM is not allowing
slow regeneration is completed. the DPD
9 — regeneration
Perform the DPD Slow Regeneration with a scan
10 Does the regeneration complete? — Go to Step 11 Go to Step 13
knob clockwise.)
procedure in
Is the Exhaust Differential Pressure parameter Refer to DTC P2002
more than the specified value? for excessive low
12 1.0 kPa
exhaust differential
System OK pressure diagnosis
Notice: If the scan tool displays a message
"Regeneration is impossible", go to applicable
DTC.
1G Engine Exhaust. Inspect the following
conditions:
• DPD filter for damage, cranks or melt
• Oxidation catalyst for damage, cranks
melt or excessive deposits
13 • Deteriorated oxidation catalyst —
testing.
3. Inspect the fuel system problem. Refer to Fuel
System Check chart and appropriate


2. Remove the bezel surrounding the IP cluster
enough to disconnect the DPD regeneration
switch.
3. Disconnect the DPD regeneration switch
15 harness connector. —
circuit of the DPD regeneration switch harness

Observe the DPD Regeneration Switch parameter
with a scan tool while momentarily jumping 3-amp
fused jumper wire across the switch harness
16 connector between pins 1 and 2 of FU142. —
17 (pin 1 of FU142). Check the Engine Controller —
(10A) fuse first.

• An open circuit
• High resistance

19 —

1. Inspect for an intermittent, for a poor
20 —

Repair or replace the DPD regeneration switch.
21 —


components, fuse or harness connector(s).
23 3. Observe the DPD Regeneration Switch —

Symptoms - Engine Controls

Symptoms - Engine Controls Reform or replace connector terminals in the problem
circuit in order to ensure proper contact tension.
Important Preliminary Inspections Before Starting
Remove the terminal from the connector body in order
Perform Diagnostic System Check - Engine Controls to inspect for poor terminal wire connection.
before using the symptom tables, and verify that all of Road test the vehicle with the DMM connected to the
the following are true: suspected circuit. An abnormal reading that occurs
• The ECM and malfunction indicator lamp (MIL)/ when the malfunction occurs is a good indication that
service vehicle soon (SVS) lamp are operating there is a malfunction in the circuit being monitored.
correctly. Use the scan tool in order to help detect intermittent
• The scan tool data is within the normal operating conditions. Useful features of the Tech 2 scan tool
range. Refer to Scan Tool Data List in this section. include the following:
• Verify the customer concern and locate the correct • Trigger the Snapshot feature in order to capture
symptom in the table of contents. Inspect the items and store engine parameters when the malfunction
indicated under that symptom. occurs. Review this stored information in order to
see the specific running conditions that caused the
Visual and Physical Inspection malfunction.
Several of the symptom procedures ask for careful • Freeze Frame/ Failure Record can also aid in
visual and physical inspection. This step is extremely locating an intermittent condition. Review and
important. The visual and physical inspection can lead capture the information in the Freeze Frame/
to correcting a problem without further inspections, and Failure Record associated with the intermittent
can save valuable time. Ensure that: DTC being diagnosed. Drive the vehicle within the
conditions that were present when the DTC
• The ECM grounds are clean, tight, and in their originally set.
proper location.
• Use the Plot Function on the scan tool in order to
• The air hoses are not split or kinked, and properly plot selected data parameters. Review this stored
connected. Inspect thoroughly for any type of leak information to aid in locating an intermittent
or restriction. problem. Refer to scan tool Users Guide for more
• The air intake ducts are not collapsed or damaged. information.
• The exhaust pipes are not collapsed or damaged. Use the data recording module (DRM) or body control
• The engine harness wiring and terminals are module (BCM) data recording function in order to help
properly connected and are not pinched or cut. detect intermittent conditions. The DRM or the BCM
has ability to store engine log data when an event of
Intermittent DTC. Maximum three log data can be stored in the
DRM or the BCM memory. If more than maximum
number of storage is set, oldest log data is overwritten.
Important: Inspect for improper installation of electrical However, if same DTC is set within eight hours that
components if an intermittent condition exists. Inspect DTC is not stored in the DRM or the BCM memory.
for aftermarket add-on electrical equipment devices, The manual trigger function is to store the log data by
lights, and cellular phones. Verify that no aftermarket an arbitrary operation of the driver when an event of
equipment is connected to the controller area network wrong vehicle performance that is instead of an event
(CAN) or other serial data circuit. of DTC. If the driver presses and releases the manual
trigger switch once, that time becomes a trigger and
Important: The problem may or may not turn ON the one log data before and behind the trigger is stored in
MIL/ SVS lamp or store a DTC. Faulty electrical the DRM or the BCM memory. When there is a space in
connections or wiring cause most intermittent the DRM or the BCM memory, log data is stored in that
problems. Perform a careful visual and physical space. However, when more than maximum number of
inspection of the suspect connectors for the following storage is set, oldest log data is overwritten.
conditions:
• Improperly mated connector halves Important: If the intermittent condition exists as a start
• Terminals that are not seated and then stall, test for DTCs relating to the vehicle theft
• Terminals that are damaged or improperly formed deterrent system. Test for improper installation of
electrical options such as lights, cellular phones, etc.
Important: Any of the following may cause an
intermittent MIL/ SVS lamp with no stored DTC:
• The ECM grounds are loose or dirty. Refer to
engine control wirings.

• The MIL/ SVS lamp circuit intermittently shorted to
ground
• Electrical system interference caused by a
malfunctioning relay, ECM driven solenoid, or
switch. The electrical component can cause a
sharp electrical surge. Normally, the problem will
occur when the malfunctioning component is
operating.
• There are any open diodes.
Important: The following symptom tables contain

groups of possible causes for each symptom. The
order of these procedures is not important. If the scan
tool readings do not indicate the problems, then
proceed in a logical order, easiest to check or most
likely to cause first. In order to determine if a specific
vehicle is using a particular system or component, refer
to engine control wirings for an application.
Important: Use the following tables when diagnosing a

symptom complaint:
• Intermittent Conditions
• Hard Start
• Rough, Unstable, or Incorrect Idle and Stalling
• High Idle Speed
• Cuts Out
• Surges
• Lack of Power, Sluggishness or Sponginess
• DPD System Manual Regeneration Frequently

Intermittent Conditions
Checks Action
Definition:
The problem is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom cannot currently be duplicated, if the problem is not DTC related.
Preliminary Checks • Refer to Symptoms - Engine Controls before starting.
Harness/ Connector Many intermittent open or shorted circuits are affected by harness/ connector
movement that is caused by vibration, engine torque, bumps/ rough pavement, etc.
Test for this type of condition by performing the applicable procedure from the following
list:
• Move related connectors and wiring while monitoring the appropriate scan tool data.
• Move related connectors and wiring with the component commanded ON, and OFF,
with the scan tool. Observe the component operation.
• With the engine running, move related connectors and wiring while monitoring
engine operation.
If harness or connector movement affects the data displayed, component/ system
operation, or engine operation, inspect and repair the harness/ connections as
necessary.
Electrical Connections or Wiring Poor electrical connections, terminal tension or wiring problems cause most
intermittent. To perform the following inspections:
• Poor mating of the connector halves, or terminals improperly seated in the
connector body.
• Improperly formed or damaged terminals. Test for poor terminal tension.
• Poor terminal to wire connections including terminals crimped over insulation. This
requires removing the terminal from the connector body.
• Corrosion/ water intrusion. Pierced or damaged insulation can allow moisture to
enter the wiring. The conductor can corrode inside the insulation, with little visible
evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wires that are broken inside the insulation.
• Harness for pinched, cut or rubbed through wiring.
• Ensure that the wiring does not come in contact with hot exhaust components.
Control Module Power and Grounds Poor power or ground connections can cause widely varying symptoms.
Component Power and Grounds • Test all control module power supply circuits. Many vehicles have multiple circuits
supplying power to the control module. Other components in the system may have
separate power supply circuits that may also need to be tested. Inspect connections
at the module/ component connectors, fuses, and any intermediate connections
between the power source and the module/ component. A test lamp or a DMM may
indicate that voltage is present, but neither tests the ability of the circuit to carry
sufficient current. Ensure that the circuit can carry the current necessary to operate
the component.
• Test all control module ground and system ground circuits. The control module may
have multiple ground circuits. Other components in the system may have separate
grounds that may also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the component and
in splice packs, where applicable. Ensure that the circuit can carry the current
necessary to operate the component.
Checks Action
Temperature Sensitivity • An intermittent condition may occur when a component/ connection reaches normal
operating temperature. The condition may occur only when the component/
connection is cold, or only when the component/ connection is hot.
• Freeze Frame, Failure Records or Snapshot Data may help with this type of
intermittent conditions, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the
following:
- High ambient temperatures.
- Underhood/ engine generated heat.
- Circuit generated heat due to a poor connection, or high electrical load.
- Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
- Low ambient temperatures-In extremely low temperatures, ice may form in a
connection or component. Test for water intrusion.
- The condition only occurs on a cold start.
- The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern
that is temperature related.
Electromagnetic Interference (EMI) Some electrical components/ circuits are sensitive to EMI or other types of electrical
and Electrical Noise noise. Inspect the following conditions:
• A misrouted harness that is too close to high voltage/ high current devices such as
injection components, motors, generator etc. These components may induce
electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or the ECM driven
solenoid or switch. These conditions can cause a sharp electrical surge. Normally,
the problem will occur when the malfunctioning component is operating.
• Improper installation of non-factory or aftermarket add on accessories such as
lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell
phones, etc. These accessories may lead to an emission related failure while in
use, but do not fail when the accessories are not in use.
• Test for any open diodes. Some relays may contain a clamping diode.
• Test the generator for a bad rectifier bridge that may be allowing AC noise into the
electrical system.
Incorrect ECM Programming • There are only a few situations where reprogramming a ECM is appropriate:
- An ECM from another vehicle is installed.
- Revised software/ calibration files have been released for this vehicle.
Important: DO NOT reprogram the ECM with the SAME software/ calibration files that
are already present in the ECM. This is not an effective repair for any type of driveability
problem.
• Verify that the ECM contains the correct software/ calibration. If incorrect
programming is found, reprogram the ECM with the most current software/
calibration.
Duplicating Failure Conditions • If none of the previous tests are successful, attempt to duplicate and/ or capture the
failure conditions.
• Freeze Frame/ Failure Records data, where applicable, contains the conditions that
were present when the DTC set.
- Review and record Freeze Frame/ Failure Records data.
- Operate the vehicle under the same conditions that were noted in Freeze
Frame/ Failure Records data, as closely as possible. The vehicle must also be
operating within the Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being diagnosed.
• An alternate method is to drive the vehicle with the DMM connected to a suspected
circuit. An abnormal reading on the DMM when the problem occurs, may help you
locate the problem.
Checks Action
Scan Tool Snapshot The scan tool can be set up to take a Snapshot of the parameters available via serial
data. The Snapshot function records live data over a period of time. The recorded data
can be played back and analyzed. The scan tool can also graph parameters singly or in
combinations of parameters for comparison. The Snapshot can be triggered manually
at the time the symptom is noticed, or set up in advance to trigger when a DTC sets.
An abnormal value captured in the recorded data may point to a system or component
that needs to be investigated further.
Refer to scan tool Users Guide for more information.
DRM or BCM Memory Use data stored in the DRM or the BCM memory or use manual trigger function. The
DRM or the BCM has ability to store engine log data when an event of DTC. The
manual trigger function is to store the log data by an arbitrary operation of the driver
when an event of wrong vehicle performance that is instead of an event of DTC. If the
driver presses and releases the manual trigger switch once, that time becomes a
trigger and one log data before and behind the trigger is stored in the DRM or the BCM
memory.

Hard Start
Checks Action
Definition:
The engine cranks OK, but does not start for a long time. The engine does eventually run, or may start but immediately dies.
• Ensure the driver is using the correct starting procedure.

Checks Action
Mechanical.
Electrical System Checks Inspect the engine electrical for the following conditions. Refer to Section 1E Engine
Electrical.
• Glow plug control system operation. Refer to Glow Control System Check in this
section.
• Slow cranking speed.
• Weakened batteries.

Rough, Unstable, or Incorrect Idle and Stalling
Checks Action
Definition:
Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle speed may vary in RPM. Either condition
may be severe enough to stall the engine.
should always be within 30 to 35 MPa (4,350 to 5,080 psi) after warm up.

Checks Action
Mechanical.
• Faulty engine mounts.
• Faulty crank pulley.
• Faulty generator & A/C compressor.
• Generator output voltage.
• EGR system operating correctly. Refer to EGR Control System Check in this
section.
• A/C operation.

High Idle Speed
Checks Action
Definition:
Engine idle speed is higher than normal in regardless of engine coolant temperature or DPD system regeneration.
• Use the scan tool to compare the engine speed and tachometer on the instrument
panel (IP) cluster.
• Inspect the engine oil level.
should always be within 30 to 35 MPa (4,350 to 5,080 psi) after warm up.
• Observe the Idle Up Sensor. Idle Up Sensor parameter should read less than 0.6
volts at full counterclockwise. If not, check for high resistance in the low reference
circuit or skewed sensor.
• Observe the PTO Remote Throttle Sensor. PTO Remote Throttle Sensor parameter
should read less than 0.4 volts at lowest position. If not, check for high resistance in
the low reference circuit or skewed sensor.
Engine Fuel.
• Fuel injectors. Remove the injectors and visually inspect. (Injector tip(s) may be
damaged)

Cuts Out
Checks Action
Definition:
A constant jerking that follows the engine speed, usually more pronounced as the engine load increase. The exhaust has a
steady spitting sound at idle, low speed, or hard acceleration for the fuel starvation that can cause the engine to cut-out.
Preliminary Check • Diagnostic System Check - Engine Controls.

Surges
Checks Action
Definition:
The engine has a power variation under a steady throttle or cruise. The vehicle seems to speed up and slow down with no
change in the accelerator pedal.
• Ensure the driver understands the A/C compressor operation.

Checks Action
this section.
• Inspect the lock up clutch operation. (Smoother only)
• Inspect deformed tire(s) that may cause surges at fixed vehicle speed range.

Lack of Power, Sluggishness or Sponginess
Checks Action
Definition:
The engine delivers less than expected power. There is little or no increase in speed when partially applying the accelerator
pedal.
• Have the tire sizes changed?
Checks Action

Mechanical.
this section.
Engine Cooling.
• Inspect the lock up clutch operation. (Smoother only).

Hesitation, Sag or Stumble
Checks Action
Definition:
The vehicle has a momentary lack of response when pushing down on the accelerator. The condition can occur at any vehicle
speed. The condition is usually most severe when trying to make the vehicle move from a stop. If severe enough, the condition
may cause the engine to stall.

Checks Action

Mechanical.
this section.
Engine Cooling.
• Inspect the lock up clutch operation. (Smoother only)

Abnormal Combustion Noise
Checks Action
Definition:
A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic knocks that change with the throttle
opening.
• Ensure the vehicle has an actual problem.
• Inspect for smoke associated with the combustion noise.
• Inspect the fuel injectors. Remove the injectors and visually inspect.
Mechanical.
• Inspect for any excessive oil entering combustion chamber.
Additional Checks • Inspect other possible causes that can make similar noise such as loose component
parts, bracket, mount and weak clutch damper spring.

Poor Fuel Economy
Checks Action
Definition:
Fuel economy, as measured by actual road tests and several tanks of fuel, is noticeably lower than expected. Also, the
economy is noticeably lower than it was on this vehicle at one time, as previously shown by actual road tests.
Preliminary Checks • Remove the air cleaner and check for dirt, or for air ducts being plugged or
• Inspect the driving habits of the owner.
• Is the A/C ON full time, defroster mode ON?
• Are the tires at the correct pressure?
• Are the tire sizes changed?
• Is the acceleration too much, too often?
• Inspect dive belt tension.
• Inspect for a proper transmission shift pattern and down shift operation (Smoother
only).
• Suggest to the owner to fill the fuel tank and recheck the fuel economy.
Engine Fuel.
• Fuel type and quality.
• Check fuel leak.
Cooling System Checks Inspect the cooling system for the following conditions. Refer to Cooling System in
• Engine thermostat for always being open or for the wrong heat range.
• Engine cooling fan for always being ON.
Checks Action
Mechanical.

Excessive Smoke (Black Smoke)
Checks Action
Definition:
Black smoke under load, idle or start up hot or cold.

Engine Fuel.
Checks Action
Mechanical.
• Inspect for poor cylinder compression.
Additional Checks • EGR system operating correctly. Refer to EGR Control System Check in this
section.
• Excessive blow-by gasses.

Excessive Smoke (White Smoke)
Checks Action
Definition:
White smoke under load, idle or start up hot or cold.
• A worn or damaged turbocharger turbine wheel, shaft or compressor wheel. Oil leak
from turbocharger. Refer to Turbocharger Assembly in Section 1J Induction.
Exhaust System Checks If an excessive white smoke is present while DPD filter regeneration event, a
deteriorated or damaged oxidation catalyst is suspected.
Checks Action
Mechanical.
• Thermostat working (open stuck).
Electrical System Checks • Glow plug control (preheating) system operation. Refer to Glow Control System
Check in this section.

DPD System Manual Regeneration Frequently
Checks Action
Definition:
The manual regeneration is frequently requested to the driver by blinking the DPD amber lamp. Or, it is frequently requested as
compared with before. (The automatic regeneration cannot be completed frequently.)
• If an excessive black smoke is present, refer to Excessive Smoke (Black Smoke)
chart in symptom diagnostic table.
Inspect the driving habits/ conditions of the owner for the following conditions. Suggest
to the owner to use the selectable regeneration as necessary:
In normal operation;
• Is the driving at long downhill?
• Is a small cargo delivery truck or a garbage truck?
• Is the PTO operating time too long?
In regeneration;
• Is the PTO operating too often and/ or for a long time?


• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust System
port.
Checks Action

DPD System Regeneration Long Time
Checks Action
Definition:
The regeneration time longer than an expected time. Or, it takes longer than before.
• Is the engine warm up control misunderstood as the DPD regeneration?
Inspect the driving habits/ conditions of the owner for the following conditions:
In regeneration;
• Has the manual regeneration started from cold engine?
• Is the PTO operating too often and/ or for a long time?
• Is the ambient temperature excessively high?


• Dislocated or inclined exhaust differential pressure sensor. Refer to Exhaust System
port.
Cooling System Checks Inspect the cooling system for an overheating conditions. Refer to Cooling System in
• Engine coolant leakage.
• Cooling fan belt slippage.
• Cooling fan clutch working.
• Thermostat working.
• Water pump working.
• Radiator clogging.
• Modified cooling system which is less cooling capacity.
Checks Action
Additional Checks • Inspect for an engine overheat condition. Refer to Cooling System in Section 1C
Engine Cooling.
Repair Instructions
Engine Control Module (ECM) Replace-
ment
Description
The following A to G steps provide an overview
procedure to replace and reprogram an ECM. Each A -
G steps is explained further in this section.
1 SAMPLE
A. Upload the fuel injector ID codes from the old 2 64 FB 00
4HK1
00 0A 00 04 F4 F0 00 01 94
ECM. 64 0B 08 10 2B 28 1E 26 17 16 31 7C
3 64
64
CB
21
1A
17
00 2F
16 2B
3C
3A
29
2D
3DFF
4A 14
27
25
5A
65
F0
66
B. Reset the immobilizer security information in
the old ECM. 4
C. Replace the old ECM with the new ECM.
D. Program the immobilizer security information
into the new ECM. 5
E. Program the latest software and calibrations
into the new ECM using the Service
Programming System (SPS). LNW81ASH000101
F. Program the uploaded fuel injector ID codes Legend
and program the vehicle identification number 1. Cylinder #1 fuel injector ID code
(VIN) into the ECM using a scan tool 2. Cylinder #2 fuel injector ID code
programming function. 3. Cylinder #3 fuel injector ID code
G. Perform the fuel supply pump relearn 4. Cylinder #4 fuel injector ID code
procedure by allowing the engine to idle in Park 5. Injector ID code label
or Neutral until normal operating temperature is
achieved.
Recording from each fuel injector
A. Uploading Fuel Injector ID Code 1. Remove the cylinder head cover. Refer to Fuel
The current fuel injector ID code data can be uploaded Injector Replacement.
with a scan tool. If the old ECM cannot be 2. Record 24 figures of each fuel injector ID plate.
communicated with a scan tool, go to Retrieving the The correct order for the fuel injector ID codes of
Fuel Injector ID Code Data with a Non-communicating the following illustration is as follows:
ECM. 64 DA A5 05 2F 4C 0F 36 FA 17 25 8C
2. Turn ON the ignition, with the engine OFF. 2 1
Programming > Store ECU setting 64DA A505
4. After complete the uploading, turn OFF the scan 2F4C 0F36
tool. FA17 25 00
5. Turn OFF the ignition. 0000 8C
Retrieving the Fuel Injector ID Code Data with a

Non-communicating ECM 3
If a scan tool does not communicate, the fuel injector ID

codes must be recorded from the factory affixed label
on the cylinder head cover or each fuel injector ID
plate.
Recording from the label on cylinder head cover LNW76ESH002601
Notice: Only perform this procedure if the fuel injectors Legend

are not being replaced in the past. 1. Fuel injector ID plate
1. Record all numbers of each cylinder on the label. 2. Fuel injector ID code
3. Fuel injector

B. Resetting Immobilizer Security Information 4. In order to get programming approval, the on-
Reset immobilizer security information in the old ECM. screen displays a message to user. Get
Refer to Resetting and Programming Guidelines in the programming approval from the TIS 2000 using
immobilizer section. If the old ECM cannot be the following procedure:
communicated with a scan tool, go to the next a. Connect a scan tool to the terminal that
procedure. installed TIS 2000 with the latest software and
the hardware key is plugged into port.
C. Removal and Installation b. Turn ON the scan tool and keep at title screen.
Removal Procedure c. Launch the TIS application.
1. Disconnect the negative battery cable. d. Select the Security Access at the main screen.
2. Disconnect the ECM harness connectors. e. Highlight the “Tech 2” on the Diagnostic Tool
3. Loosen the bolts (2). Selection screen and click “Next”.
4. Remove the ECM (1). f. Click “Close” on the Security Access Enabled
screen.
h. Disconnect the scan tool from the terminal.
1
Programming > Program ECU.
8. Verify the VIN on the screen and follow the on
screen messages. If not programmed or incorrect
VIN, input correct VIN.
2
9. Verify the fuel injector ID code on the screen and
follow the on screen messages. If not programmed
or incorrect ID cord, input ID code.
MFW71ASH002601
Installation Procedure
for no DTC's. Refer to Diagnostic System Check -
1. Install the ECM (1). Engine Controls if needed.
2. Tighten the bolts (2).
3. Reconnect the ECM harness connectors. G. Supply Pump Relearn
4. Reconnect the negative battery cable. 1. Install a scan tool.
D. Programming Immobilizer Security Information temperature reads 65°C (149°F) or higher while
Program immobilizer security information into the ECM. observing the Fuel Supply Pump Status parameter
Refer to Resetting and Programming Guidelines in the with a scan tool. The scan tool parameter changes
immobilizer section. status Not Learned > Learned.
E. Programming Software and Calibrations

Program latest software/ calibrations if released. Refer
to Service Programming System (SPS) Description and
SPS (Remote Procedure) or SPS (Pass-Thru
Procedure) in this section.
F. Programming Fuel Injector ID Codes and VIN

Programming > Program ECU.

Service Programming System (SPS) De- • The hardware key is plugged into the computer
scription port.
• Vehicle system voltage:
The service programming system (SPS) allows a
technician to program a control module through the - There are no charging system concerns. All
data link connector (DLC). The information transfer charging system concerns must be repaired
circuit that is used at the DLC is the same serial data before programming the ECM.
circuit used by the scan tool for retrieving DTCs, - The battery voltage is greater than 24 volts but
displaying data, clearing DTCs etc. This procedure less than 30 volts. The battery must be fully
offers the ability to install software/ calibrations charged before programming the ECM.
matched to a particular vehicle. - A battery charger is NOT connected to the
Most control modules have two types of memory. The vehicles battery. Incorrect system voltage or
software/ calibrations reside in the flash memory. The voltage fluctuations from a battery charger may
two types of memory are listed below: cause programming failure or ECM damage.
• Electrically Erasable Programmable Read Only - Turn OFF or disable any system that may put a
Memory (EEPROM) load on the vehicles battery. Turn OFF or
This type of memory allows selected portions of disable systems such as:
memory to be programmed while other portions
◊ Heating, ventilation, and air conditioning
remain unchanged.
(HVAC) systems
Certain learned values reside in the EEPROM,
such as: ◊ Headlights
- The vehicle identification number (VIN) ◊ Room lights
- The software/ calibrations identification ◊ Accessory equipment
numbers • The ignition switch is in the proper position. The
- The control module security information scan tool prompts you to turn ON the ignition, with
the engine OFF. DO NOT change the position of
• Flash Read Only Memory-Flash Memory
the ignition switch during the programming
Flash memory has increased memory storage
procedure unless instructed to do so.
capacity. During programming, all information
within this type of memory is erased, and then • All tool connections are secure:
replaced with entirely new information. - The RS-232 cable
- The connection at the DLC
Service Programming Methods
- The voltage supply circuits
The two methods of programming a ECM are listed • DO NOT disturb the tool harnesses while
below: programming. If an interruption occurs during the
• Remote Programming programming procedure, programming failure or
• Pass Thru Programming ECM damage may occur.
For information on programming an ECM using one of • If you are performing the Pass-Thru programming
the methods listed above, refer to Service procedure using a notebook computer without the
Programming System (SPS) (Remote Procedure) or power cord, ensure that the internal battery is fully
Service Programming System (SPS) (Pass-Thru charged.
Procedure).
Before Programming a Control Module Service Programming System (SPS) (Re-

Important: DO NOT program an existing ECM with the mote Procedure)
identical software/ calibration file. This procedure is not Notice: Some module will not accept SPS remote
a short cut to correct the driveability concern. This is an procedure using 10MB PCMCIA card. In such case,
ineffective repair. An ECM should only be programmed use 32MB PCMCIA card or SPS pass-thru procedure.
when the following occurs: The Remote SPS method is a three-step process that
• When a service procedure instructs you to replace involves the following procedures:
the ECM. 1. Connecting the scan tool to the vehicle and
• An updated software/ calibrations is released. obtaining the information from the ECM.
Ensure that the following conditions are met before 2. Connecting the scan tool to the terminal and
programming an ECM: downloading a new calibration file from the
• The scan tool PCMCIA card is programmed with terminal into the scan tool memory.
the latest software. 3. Reconnecting the scan tool to the vehicle and
• The TIS 2000 is installed with the latest software. uploading the new calibration file into the ECM.

Performing the Remote Procedure f. Verify the VIN on the Validate Vehicle
1. Connect a scan tool to the vehicle and obtain the Identification Number (VIN) screen, then click
ECM information using the following procedure: "Next".
Notice: Ensure the ECM is installed in the vehicle Notice: If the ECM is replaced to new one, VIN
and the battery is fully charged before does not displayed. Input correct VIN reading
programming. from stamped VIN or affixed VIN plate on the
vehicle. If the ECM from another vehicle is
a. Install a scan tool.
installed, input correct VIN by same way.
b. Turn ON the ignition, with the engine OFF.
g. Highlight Engine on the Select System Type
c. Select Service Programming System (SPS) > screen, then click "Next", if on-screen
Request Info. instruction displayed.
d. If there is already stored in the scan tool, the h. Complete the following information based on
existing data is displayed on the screen. The the service ID plate on the Validate Vehicle
scan tool asks user to keep existing data "Keep Data screen until "Next" is highlighted, then
Data" or "Continue" to request new vehicle click "Next".
information from the ECM. If there is no data in
• Model
the scan tool, it will immediately start vehicle
identification. • Model year
e. Select the vehicle description by following the • Engine type
on-screen instructions based on stamped VIN • Model designator
or affixed VIN plate on the vehicle. • Destination code
f. During obtaining information, the scan tool is • Transmission type
receiving information from all modules at the i. Verify your selection on the Summary screen.
same time. But only ECM information is
displayed on the screen. Notice: Refer to Service Bulletin and
g. Turn OFF all accessories and press "Okay". Description column before service
h. Verify that the correct VIN is displayed on the programming is performed if the bulletins are
scan tool. If the VIN is incorrect or no VIN, listed along with the calibration files.
record the correct VIN. Notice: Select Cancel if you receive a message
2. Turn OFF the ignition. stating that the calibration selected is already
the current calibration in the ECM and
reprogramming with the same download is not
vehicle.
allowed.
4. Transfer the data from the terminal to the scan tool
j. Click "Reprog".
k. The Transfer Data screen will appear until the
Notice: The TIS supports service programming progress bar reaches 100%.
with the Tech 2 scan tool only. 5. Close the application and return to the TIS
a. Connect the scan tool to the terminal. application selection screen after the download is
complete.
b. Launch the TIS application.
c. Select the Service Programming System at the
terminal.
main screen.
7. Transfer the data from the scan tool to the ECM
d. Highlight the following information on the Select
Diagnostic Tool and Programming Process
screen, then click "Next": a. Install a scan tool.
• Select Diagnostic Tool - Tech 2 b. Turn ON the ignition, with the engine OFF.
• Select Programming Process - Identify c. Select Service Programming System (SPS) >
whether an existing ECM is being Program ECU.
reprogrammed or an ECM is being replaced d. Turn OFF all accessories and press "Continue".
with a new one e. Programming in Process will appear until the
• Select ECU Location - Vehicle progress bar reaches 100%.
e. Verify the connections on the Preparing for
Communication screen, then click "Next". Notice: Some warning lamp may turn ON or
blink while programming the ECM since
communication between the ECM and other
modules are interrupted. Clear DTC in any
module after programming.

f. Press "Continue" and exit the program after the 9. Verify your selection on the Summary screen.
scan tool displays "Programming Was
Successful". Notice: Refer to Service Bulletin and Description
8. Turn OFF the ignition. column before service programming is performed if
the bulletins are listed along with the calibration
files.
vehicle.
Notice: Select Cancel if you receive a message
stating that the calibration selected is already the
Service Programming System (SPS) (Pass- current calibration in the ECM and reprogramming
Thru Procedure) with the same download is not allowed.
10. Click "Reprog".
Pass-Thru programming allows the scan tool to remain
connected to the terminal and to the vehicle throughout 11. The Transfer Data screen will appear until the
the programming process. The vehicle must be in close progress bar reaches 100%.
proximity to the terminal while using Pass-Thru. Some warning lamp may turn ON or blink while
programming the ECM since communication
1. Launch the TIS application.
between the ECM and other modules are
2. Select the Service Programming System at the interrupted. Clear DTC in any module after
main screen. programming.
3. Highlight the following information on the Select 12. Close the application and return to the TIS
Diagnostic Tool and Programming Process screen, application selection screen after the download is
then click "Next": complete.
• Select Diagnostic Tool-Select Pass - Thru 13. Turn OFF the ignition.
• Select Programming Process - Identify whether 14. Turn OFF the scan tool and disconnect from the
as existing ECM is being reprogrammed or an vehicle.
ECM is being replaced with a new one.
• Select ECU Location - Vehicle
4. Complete all vehicle data on the Preparing for
Communication/ Determine Vehicle screen until
"Next" is highlighted, then click "Next".
5. Follow the instruction on the Preparing for
Communication screen, then click "Next".
Notice: In order to reduce the potential for signal

loss, the RS-232 cable should not be more than 25
feet long.
6. Verify the VIN on the Validate Vehicle Identification
Number (VIN) screen, then click "Next".
Notice: If the ECM is replaced to new one, VIN

does not displayed. Input correct VIN reading from
stamped VIN or affixed VIN plate on the vehicle. If
the ECM from another vehicle is installed, input
correct VIN by same way.
7. Highlight Engine on the Select System Type
screen, then click "Next", if on-screen instruction
displayed.
8. Complete the following information based on the
service ID plate on the Validate Vehicle Data
screen until "Next" is highlighted, then click "Next".
• Model
• Model year
• Engine type
• Model designator
• Destination code
• Transmission type
Description and Operation

Engine Control Module (ECM) Description • The exhaust gas recirculation (EGR) system
control
Engine Control Module (ECM) Service Precautions
• The turbocharger system control
• The diesel particulate defuser (DPD) system
control
• The preheating (glow) system control
• The exhaust brake system control
• The immobilizer system control
• On-board diagnostics for engine control
The ECM constantly observes the information from
various sensors. The ECM controls the systems that
affect vehicle performance. The ECM performs the
CAUTION diagnostic function of the system. The ECM can
recognize operational problems, alert the driver
To avoid electric shock; through the malfunction indicator lamp (MIL), and store
Set the key switch to the "OFF" or "LOCK" diagnostic trouble codes (DTCs). DTCs identify the
position before checking or repairing the system faults to aid the technician in making repairs.
computer, wiring or/and connectors.
LNW76ESH000301
Important: The symbol “!” warns you of an electric

shock hazard. To avoid shock and possible serious
injury, DO NOT touch the terminals. When
disconnecting the harness connectors, always turn
OFF the ignition switch or disconnect the battery cable.
-------------------------------------------------------
-----------------------
------------------------------------------------------- -----------------------------------
-----------------------------------
----------------------------
---------------------------
---------------------------
CAUTION
---------------------------------
--------------------------------------------------------
------------------------------ -------------------- ------------------------------------------------------
-------------------------------------------------
MFW84CSH002201
The engine control module (ECM) is designed to

withstand normal current draws associated with vehicle
operation. Avoid overloading any circuit. When testing
for opens and shorts, do not ground or apply voltage to
any of the ECM circuits unless instructed to do so. In
some cases, these circuits should only be tested using
a DMM. The ECM should remain connected to the
ECM harness. The ECM mainly controls the following
items:
• The fuel system control
MG4HKED-WE-1101AU.book
Sensor inputs Fuel injection controls

Intake air temperature (IAT) sensor Fuel rail pressure (FRP) regulator
Mass air flow (MAF) sensor Fuel injector 1
ECM Input & Output
Engine coolant temperature (ECT) sensor Fuel injector 2

Fuel temperature (FT) sensor Fuel injector 3
Barometric pressure (BARO) sensor Fuel injector 4
Boost pressure sensor
Accelerator pedal position (APP) sensor
EGR position sensor Actuator controls
Intake throttle position sensor Intake throttle motor
Crankshaft position (CKP) sensor EGR motor
Camshaft position (CMP) sensor Exhaust brake solenoid
Fuel rail pressure (FRP) sensor Exhaust throttle solenoid
Vehicle speed sensor (VSS) Turbocharger nozzle control solenoid (via VNT
Turbocharger nozzle position sensor (via VNT control module) control module)
Exhaust temperature sensor 2 Relay controls
ECM
355 ページ２０１０年１１月２５日　木曜日　午後１時５８分
Idle up sensor Glow relay

PTO throttle sensor Starter cut relay
ECM main relay
Switch inputs
Ignition switch (ON/ start position) Lamp controls
Clutch switch Malfunction indicator lamp (MIL)
Parking brake switch Service vehicle soon (SVS) lamp
Neutral switch Glow plug lamp
DPD regeneration switch Exhaust brake lamp
Exhaust brake switch DPD lamp
Oil level switch Oil pressure lamp
Cruise control main switch Cruise control main lamp (through CAN)
Cruise control set/ coast switch Cruise control set lamp (through CAN)
Cruise resume/ accel switch
A/C switch Communications
Engine Control System (4HK1)
Controller area network (CAN)
MFWB1AXF000401
1A-355

ECM Voltage Description • If the part has been handled while sliding across
The ECM supplies a buffered voltage to various the seat, while sitting down from a standing
switches and sensors. The ECM can do this because position, or while walking a distance, touch a
resistance in the ECM is so high in value that a test known good ground before installing the part.
lamp may not illuminate when connected to the circuit. • Charge by induction occurs when a person with
An ordinary shop voltmeter may not give an accurate well insulated shoes stands near a highly charged
reading because the voltmeter input impedance is too object and momentarily touches ground. Charges
low. Use a 10-megaohm input impedance DMM, to of the same polarity are drained off leaving the
ensure accurate voltage readings. The input and/ or person highly charged with opposite polarity.
output devices in the ECM include analog-to-digital
converters, signal buffers, counters, and special Malfunction Indicator Lamp (MIL) Operation
drivers. The ECM controls most components with The MIL is located in the instrument panel cluster. The
electronic switches which complete a ground circuit MIL will display the engine symbol when commanded
when turned ON. ON:
Aftermarket Electrical and Vacuum Equipment

Aftermarket or add-on electrical and vacuum
equipment is defined as any equipment which connects
to the vehicle's electrical or vacuum systems that is
installed on a vehicle after the vehicle leaves the
factory. No allowances have been made in the vehicle
design for this type of equipment. No add-on vacuum
equipment should be added to this vehicle. Add-on
electrical equipment must only be connected to the
vehicle's electrical system at the battery power and
ground. Add-on electrical equipment, even when
installed to these guidelines, may still cause the power
train system to malfunction. This may also include
equipment not connected to the vehicle electrical
system such as portable telephones and audios.
Therefore, the first step in diagnosing any power train
fault is to eliminate all aftermarket electrical equipment MFW81ASH000301
from the vehicle. After this is done, if the fault still
exists, the fault may be diagnosed in the normal The MIL indicates that an emission related fault (Type
manner. A or B) has occurred and vehicle service is required.
The following is a list of the modes of operation for the
Electrostatic Discharge Damage MIL:
Electronic components used in the ECM are often • The MIL illuminates when the ignition switch is
designed to carry very low voltage. Electronic turned ON, with the engine OFF. This is a lamp test
components are susceptible to damage caused by to ensure the MIL is able to illuminate.
electrostatic discharge. By comparison, as much as
• The MIL turns OFF after the engine is started if a
4,000 volts may be needed for a person to feel even
diagnostic fault is not present.
the zap of a static discharge. There are several ways
for a person to become statically charged. The most • The MIL remains illuminated after the engine is
common methods of charging are by friction and started if the ECM detects a fault. A DTC is stored
induction. any time the ECM illuminates the MIL due to an
emission related fault.
• An example of charging by friction is a person
sliding across a vehicle seat.
Important: To prevent possible electrostatic discharge
damage, follow these guidelines:
• Do not touch the ECM connector pins or soldered
components on the ECM circuit board.
• Do not open the replacement part package until
the part is ready to be installed.
• Before removing the part from the package,
ground the package to a known good ground on
the vehicle.

Service Vehicle Soon (SVS) Lamp Operation
The service vehicle soon (SVS) lamp is located in the
instrument panel cluster. The SVS lamp will display the
vehicle with wrench symbol when commanded ON:
Ignition switch ON 1 sec. 1 sec. 1 sec.
ON
OFF
15 sec.
1 sec. 1 sec. 1 sec.
LNW91ASH000201
Engine Control Component Description

MFW81ASH000501 Accelerator Pedal Position (APP) Sensor
The SVS lamp indicates that an non-emission related

fault (Type C DTC) has occurred and vehicle service
required. The following is a list of the modes of 1 2
operation for the SVS lamp:
• The SVS lamp illuminates when the ignition switch
is turned ON, with the engine OFF. This is a lamp
test to ensure the SVS lamp is able to illuminate.
• The SVS lamp illuminates for approximately 15
seconds and blinks 3 times when the ignition
switch is turned ON, with the engine OFF. This is a 3
lamp test to the SVS lamp is able to illuminate and
a speed limiter device installation check. (with
speed limiter device)
• The SVS lamp turns OFF after the engine is
started if a diagnostic fault is not present.
• The SVS lamp remains illuminated after the engine
is started if the ECM detects a fault. A DTC is LNW81ASH000801
stored any time the ECM illuminates the SVS lamp Legend
due to a non-emission related fault. 1. Accelerator pedal bracket
3. Accelerator pedal
The APP sensor is mounted on the accelerator pedal

bracket. The sensor is made up of two individual
sensors within one housing. The ECM uses the APP
sensors to determine the amount of acceleration or
deceleration that is desired. The APP sensors are hall
element type sensors. Each APP sensor provides a
different signal to the ECM on the each signal circuit,
which relative to the position changes of the
accelerator pedal angle. The APP sensor 1 signal
voltage is low at rest and increases as the pedal is
depressed. The APP sensor 2 signal voltage is high at
rest and decreases as the pedal is depressed.

Barometric Pressure (BARO) Sensor The boost pressure sensor is located in the air
induction tubing. The boost pressure sensor is a
transducer that varies voltage according to changes in
the air pressure inside the air tubing. The boost
pressure sensor provides a signal to the ECM on the
in the air tubing. The ECM should detect a low signal
voltage at a low boost pressure, such as low engine
load. The ECM should detect high signal voltage at a
high boost pressure, such as high engine load.
1
15°
2
RTW76ESH002401
The BARO sensor is located behind of the lower cover.

The BARO sensor is a transducer that varies voltage
according to changes the barometric pressure. The
BARO sensor provides a signal to the ECM on the
of the barometric pressure. The ECM should detect a
low signal voltage at a low barometric pressure, such 3
signal voltage at a high barometric pressure. The ECM
uses this voltage signal to calibrate the fuel injection LNW76ESH005501
quantity and injection timing for altitude compensation. Legend
1. Camshaft gear
Boost Pressure Sensor 2. Rotating direction
3. Camshaft position (CMP) sensor
The CMP sensor is installed on the cylinder head at the

rear of the camshaft gear. The CMP sensor detects
total of five projections per one engine cycle (four
projections arranged equally every 90° and one
reference projection on the camshaft gear surface).
The CMP sensor is a magnetic resistance element
(MRE) type sensor, which generates a square wave
signal pulse.
LNW76ESH002101

Crankshaft Position (CKP) Sensor The ECT sensor is installed to the thermostat housing.
The ECT sensor is a variable resistor and it measures
the temperature of the engine coolant. When the ECT
A sensor is cold, the sensor resistance is high. When the
engine coolant temperature increases, the sensor
1 1
6°
30°
Section
A
MFWB1ASH000101
Legend
1. Crankshaft position (CKP) sensor
The CKP sensor is located under the fuel supply pump.

There are 56 notches spaced 6° apart and a 30°
section that is open span. This open span portion
2
allows for the detection of top dead center (TDC). The
CKP sensor is a magnetic resistance element (MRE)
type sensor, which generates a square wave signal LNW76ESH001901
pulse. Detecting the open span portion from the CKP
Legend
sensor and one reference projection from the camshaft
position (CMP) sensor, the ECM determines cylinder
#1 compression TDC to ensure they correlate with
each other.
The FT sensor is installed to the fuel supply pump. The
Engine Coolant Temperature (ECT) Sensor FT sensor is a variable resistor and it measures the
temperature of the fuel entering the fuel supply pump.
high. When the fuel temperature increases, the sensor
LNW71ASH002101

Intake Air Temperature (IAT) Sensor The MAF sensor is an air flow meter that measures the
amount of air that enters the engine. It is fitted between
the air cleaner and turbocharger. A small quantity of air
that enters the engine indicates deceleration or idle
speed. A large quantity of air that enters the engine
indicates acceleration or a high load condition. The
MAF sensor assembly consists of a MAF sensor
element and an intake air temperature (IAT) sensor that
are both exposed to the air flow to be measured. The
MAF sensor element measures the partial air mass
through a measurement duct on the sensor housing.
AAW46ESH001401
The IAT sensor is fitted between the air cleaner and

turbocharger. It is internal to the mass air flow (MAF)
sensor. The IAT sensor is a variable resistor and it
measures the temperature of the air entering the
engine. When the IAT sensor is cold, the sensor
Mass Air Flow (MAF) Sensor
AAW46ESH001401

Fuel System Description
Pressure
Pressure sensor
Fuel rail limiter valve
Fuel filter
Supply pump
Injectors
Fuel tank ECM
Various sensors
(accelerator position sensor, coolant temperature,
Camshaft Crankshaft mass air flow, etc.)
position position
sensor sensor
LNW76EMF000601
The common rail system uses a type of accumulator

chamber called the common rail (fuel rail) to store
pressurized fuel, and injectors that contain
electronically controlled solenoid valves to spray the
pressurized fuel in the combustion chambers. The
injection system (injection pressure, injection rate, and
injection timing) is controlled by the ECM, and therefore
the common rail system can be controlled
independently, free from the influence of engine speed
and load. This ensures a stable injection pressure at all
time, particularly in the low engine speed range, so that
black smoke specific to diesel engines generated
during vehicle starting or acceleration can be reduced
dramatically. As a result, exhaust gas emissions are
clear and reduced, and higher output is achieved.
1. High Pressure Control
• Enables high pressure injection from low engine
speed range.
• Optimizes control to minimize particulate matter
and NOx emissions.
2. Injection Timing Control
• Enables finely tuned optimized control in
accordance with running conditions.
3. Injection Rate Control
• Pre injection control that performs a small amount
of injection before main injection.
The common rail system consists primarily of a fuel
supply pump, fuel rail, injectors, and ECM.

Fuel System Component Description
Injector
6
64
00 2
0000
3
5
LNW76EMH000101
Legend
1. Terminal stud
2. Fuel leak off port
3. O-ring
4. Fuel inlet port
5. Injector parts number marking
6. QR plate
Electronic control type injectors controlled by the ECM

are used. Compared with conventional injection
nozzles, a command piston, solenoid valve, etc. are
added.
ID codes displaying various injector characteristic are
laser marked in the plate, and ID codes showing these
in numeric form (30 alphanumeric figures are displayed
and only 24 are used). This system uses fuel injector
flow rate information (ID codes) to optimize injection
quantity control. When an injector is newly installed in a
vehicle, it is necessary to input the ID codes in the
ECM.
QR codes or fuel injector flow rate (ID codes) have
been adopted to enhance the injection quantity
precision of the injectors. The adoption of codes
enables injection quantity dispersion control throughout
all pressure ranges, contributing to improvement in
combustion efficiency and reduction in exhaust gas
emissions.
Return port
Solenoid
Driving current Driving current Driving current
TWV
Outlet orifice From fuel rail

Control chamber
Inlet orifice
Pressure in Pressure in Pressure in

Command piston control chamber control chamber control chamber
Nozzle
Injection rate Injection rate
No injection Injection Injection end
RTW76EMF000601
1) Non-injection state
The two way valve (TWV) closes the outlet orifice by
means of a spring force, when no current is supplied
from the ECM to the solenoid. At this time, the fuel
pressure applied to the nozzle leading end is equal to
the fuel pressure applied to the control chamber
through the inlet orifice. As for the force competition in
this state, the pressure on the command piston upper
surface + nozzle spring force defeat the pressure on
the nozzle leading end, and consequently the nozzle is
pushed downward to close the injection holes.
2) Injection start
The TWV is pulled up to open the outlet orifice, and
thus the fuel leaks toward the return port, when the
current is supplied from the ECM to the solenoid. As a
result, the nozzle is pushed up together with the
command piston by the fuel pressure applied to the
nozzle leading end, and then the nozzle injection holes
open to inject the fuel.
3) Injection end
The TWV lowers to close the outlet orifice, when the
ECM shuts off a current supply to the solenoid. As a
result, the fuel cannot leak from the control chamber,
and thus the fuel pressure in the control chamber rises
abruptly and then the nozzle is pushed down by the
command piston to close the nozzle injection holes,
resulting in the end of fuel injection.

Fuel Supply Pump
Suction pressure
Injector Delivery valve Suction valve Feed pressure
Fuel rail
High pressure
Plunger
Return pressure
Return
FRP regulator
Fuel overflow
Regulation valve
Feed pump
Driveshaft Fuel inlet
Suction
Fuel filter
Fuel tank
Priming pump
LNW81AMF001001
The fuel supply pump is the heart of the common rail Fuel Rail (Common Rail)
type electronic fuel injection system. The fuel supply
pump is installed at the same location as the
conventional injection type pump, which spins at a 1 to
1 ratio of fuel supply pump to crankshaft speed. A fuel
rail pressure (FRP) regulator and fuel temperature
sensor are part of the fuel supply pump assembly.
Fuel is drawn from the fuel tank via the fuel supply
pump by the use of an internal feed pump (trochoid
type). This feed pump pumps fuel into a 2-plunger 1 2
chamber also internal to the fuel supply pump. Fuel into
this chamber is regulated by the FRP regulator solely
controlled by current supplied from the ECM. No
current to the solenoid results in maximum fuel flow
whereas full current to the solenoid produces no fuel
flow. As the engine spins, these two plungers produce
high pressure in the fuel rail. Since the ECM controls
the flow of fuel into this 2-plunger chamber, it therefore
controls the quantity and pressure of the fuel supply to
the fuel rail. This optimizes performance, improves RTW76ESH002001
economy and reduces NOx emissions. Legend


Along with the employment of a common rail type The pressure limiter relieves pressure by opening the
electronic control fuel injection system, the fuel rail is valve if abnormally high pressure is generated. The
provided to store high pressure fuel between supply valve opens when pressure in rail reaches
pump and injectors. A pressure sensor and a pressure approximately 220 MPa (32,000 psi), and closes when
limiter are installed on the fuel rail. The pressure sensor pressure falls to approximately 50 MPa (7,250 psi).
detects the fuel pressure inside the fuel rail and sends Fuel leakage through the pressure limiter re-turns to
its signal to the ECM. Based on this signal, the ECM the fuel tank.
controls the fuel pressure inside the fuel rail via the fuel
rail pressure (FRP) regulator of the supply pump. The Fuel Rail Pressure (FRP) Regulator
pressure limiter opens the valve mechanically to relieve
the pressure when the fuel pressure inside the fuel rail
is excessive.
1
Fuel Rail Pressure (FRP) Sensor
The FRP sensor is installed to the fuel rail and it
detects the fuel pressure in the fuel rail, converts the
pressure into a voltage signal, and sends the signal to
the ECM. The ECM monitors the FRP sensor signal
voltage. Higher fuel rail pressure provides higher signal
voltage while lower pressure provides lower signal
voltage. The ECM calculates actual fuel rail pressure
(fuel pressure) from the voltage signal and uses the
result in fuel injection control and other control tasks.
Pressure Limiter Valve 2
LNW76ESH001901
Legend
1 2 3 4 5
The fuel rail pressure (FRP) regulator [also known as
suction control valve (SCV)] is attached to the fuel
supply pump.
6 7
The ECM controls the duty ratio of the linear type fuel
rail pressure (FRP) regulator (the length of time that the
current is applied to the FRP regulator), in order to
control the quantity of fuel that is supplied to the high-
pressure plungers. Since only the quantity of fuel that is
required for achieving the target rail pressure is drawn
in, the drive load of the supply pump is decreased.
When current flows to the FRP regulator, variable
LNW41ASH001301
electromotive force is created in accordance with the
Legend duty ratio, moving the solenoid plunger to the right side
1. Valve and changing the opening of the fuel passage and thus
2. Valve body regulating the fuel quantity. With the FRP regulator
3. Valve guide OFF, the return spring stretches, completely opening
4. Spring the fuel passage and supplying fuel to the plungers
5. Housing (Full quantity intake and full quantity discharge). By
6. Fuel rail turning the FRP regulator ON/ OFF, fuel is supplied in
7. Fuel return pipe an amount corresponding to the actuation duty ratio,
and fuel is discharged by the plungers.

Fuel Injection System Description Exhaust Gas Recirculation (EGR) System
Fuel Injection Quantity Control Description
This control determines the fuel injection quantity by
adding coolant temperature, fuel temperature, intake 3 4
air temperature, barometric pressure and some switch
inputs information corrections to the basic injection
quantity is calculated by the ECM based on the engine
operating conditions (engine speed, accelerator pedal
pressing amount and boost pressure sensor). More fuel 5
rate indicates if the engine load is increased as the
accelerator pedal is stepped on at constant engine 2
speed.
Combined with high pressure injection of atomized fuel,
this control improves exhaust gas and ensures proper
fuel consumption. Compared with conventional
mechanical governors, an electronic control system
provides higher degree of freedom of fuel injection
quantity control, thereby presenting high accelerator 7 6
response (acceleration feeling and pressing feeling).
1
LNW76ESH003801
Starting Injection Quantity Control
Legend
At the engine starting (after the key switch is turned to 1. ECM
the START position to start the engine, up to return of 2. EGR valve
key switch to the ON position), optimum fuel injection 3. Engine coolant outlet
quantity is controlled based on the information on the 4. Engine coolant inlet
engine speed and coolant temperature. At low 5. EGR cooler
temperature, the fuel injection quantity increases. 6. Intake throttle valve
When the engine started completely, this boosted 7. MAF sensor
quantity mode at the starting is cancelled and normal
running mode is restored.
The EGR system recirculates a part of exhaust gas
Idle Speed Control back into the intake manifold, which results in reducing
nitrogen oxide (NOx) emissions. The EGR control
A control is made so as to achieve stable idling speed
system uses an electronic control system to ensure
at all time regardless of engine secular changes or
both driveability and low emission. A control current
engine condition variations. The ECM sets target idling
from the ECM operates a motor to control the lift
speed and controls the fuel injection quantity according
amount of EGR valve. Also, EGR position sensors are
to the engine conditions (actual engine speed, coolant
provided at the rear of the motor to feed actual valve lift
temperature and engine load) to follow actual engine
amount back to the ECM for more precision control of
speed to the target idling speed so as to ensure stable
the EGR amount.
idling speed.
Idle Vibration Control
A control is made so as to reduce the engine vibration Then, the valve opening is calculated according to the
caused by torque variations between cylinders due to engine speed, and target fuel injection quantity. Based
variations in fuel injection quantity of each cylinder or on this valve opening, the drive duty of the motor is
injector performance. The ECM corrects the injection provided and the valve is driven accordingly.
quantity between cylinders based on the revolution
signals from the crankshaft position (CKP) sensor.
Normal range of correction quantity between cylinders
is within ± 5 mm3.

EGR Valve The intake throttle valve is located on the intake
manifold inlet. The ECM controls the intake throttle
valve opening based on the engine running condition.
The ECM controls the intake throttle valve by
controlling the motor. The motor is controlled based on
pulse width modulation (PWM) signal sent from the
ECM. A duty ratio change 0% to appropriate
percentage is intake throttle valve opening angle
control. To close the valve, duty ratio is increased. To
open the valve, duty ratio becomes small.
The intake throttle valve position is detected by the
position sensor, and relayed to the ECM. The position
sensor provides a signal to the ECM on the signal
circuit, which is relative to the position changes of the
intake throttle valve. The ECM should detect a low
signal voltage at a small opening amount or closed
position. The ECM should detect high signal voltage at
a large opening amount.
LNW76ESH002901
Turbocharger Description
The EGR valve is mounted on the intake manifold. The
ECM controls the EGR valve opening based on the
engine running condition. The ECM controls the EGR
2
valve by controlling the motor. The motor is controlled 3
based on pulse width modulation (PWM) signal sent 5
from the ECM. The EGR valve position is detected by 4
the position sensor, and relayed to the ECM. The
position sensor is made up three individual sensors 1
within one housing. The EGR position sensor 1, 2 and
3 are hall element type sensors. The position sensor 7
provides a low or high signal state to the ECM on the 6
signal circuits, which is relative to the position changes
of the EGR valve.

8
MFWB1ASH000201
Legend
1. Exhaust gas
2. VNT actuator & sensor
3. Turbine wheel
4. Compressor wheel
5. Air cleaner
6. Intercooler
7. Nozzles
LNW76ESH005001

The turbocharger is used to increase the amount of air The position of the turbocharger nozzle is controlled by
that enters the engine cylinders. This allows a the variable nozzle turbocharger (VNT) control module
proportional increase of fuel to be injected into the based on the command from the ECM. When the
cylinders, resulting in higher power output, more engine is low load condition, the turbocharger nozzles
complete combustion, and decreasing temperature of are moved to the open direction (A) and boost pressure
cylinder heads, pistons, valves, and exhaust gas. This becomes low. When the engine is high load condition,
cooling effect helps engine life longer. the VNT control module commands the control
Heat energy and pressures in the exhaust gas are solenoid to close the turbocharger nozzles (B), and
utilized to drive the turbine. Exhaust gas is directed to boost pressure becomes high. The ECM will vary the
the turbine housing, and rotate the turbine wheel. Since target boost pressure dependent upon the
the compressor wheel is attached directly to the turbine requirements of the engine power output.
shaft, the compressor wheel rotates same speed as the The intercooler also helps the performance of the
turbine wheel. Clean air from the air cleaner is drawn engine. Pressurized air from the turbocharger have
into the compressor housing and wheel. The air is higher temperature than intake air, and intercooler
compressed and flow through the intercooler, intake cools the pressurized air. Cooling the intake air
manifold, and go into the cylinders. temperature make the engine efficiency higher and
engine power higher.
A B
2 2
LNW76ELH000201
Legend
1. VNT actuator & sensor
2. Nozzle
3. Turbine wheel

Diesel Particulate Defuser (DPD) System Description
2 1
15
17
14
8 16
6 7 12
5
4
11 13
9 10
LNW81AMF000801
Legend
1. Air cleaner 10. DPD filter
2. Mass air flow (MAF) sensor 11. Exhaust throttle valve
3. Engine assembly 12. Exhaust throttle solenoid valve
4. Exhaust brake valve 13. Exhaust silencer
5. Exhaust brake solenoid valve 14. ECM
6. Exhaust temperature sensor 2 15. Other inputs
7. Exhaust temperature sensor 1 16. DPD regeneration switch
8. Exhaust differential pressure sensor 17. DPD lamps (green and amber)
9. Oxidation catalyst
4
1
2
3
MFW76ESF000201
Legend
2. Exhaust temperature sensor 2 (in front of 5. Exhaust throttle valve
oxidation catalyst) 6. DPD assembly
The DPD is a system that uses an oxidation catalyst to Exhaust Differential Pressure Sensor
clean the exhaust gas, and a filter to collect PM
discharged from the engine. When PM accumulated in
the filter, regeneration is performed. The ECM detects
the condition of PM accumulations from the exhaust
differential pressure sensor or from mileage. When it is
reached to a certain amount of PM accumulations or a
certain length of mileage, the automatic regeneration
starts. If the automatic regeneration cannot be
completed by some reason, the manual regeneration is
requested to the driver by blinking the DPD amber lamp
or “PUSH DPD SWITCH” indicator on the instrument
panel cluster. During regeneration, the temperature
inside the filter is raised, and the accumulated PM is
burned off. In order to adjust to optimized temperature,
the ECM detects exhaust temperature using the
exhaust temperature sensors, and then raises the
temperature by controlling fuel injections, the exhaust
brake valve and exhaust throttle valve to burn off the
accumulated PM. Once the regeneration starts, it must MFW4ADSH002301
be finished within a certain time. After regeneration is

finished, a purification of the filter is judged by The exhaust differential pressure sensor is attached to
monitoring the exhaust differential pressure. the chassis frame near the DPD assembly. The
exhaust differential pressure sensor is a transducer
that varies voltage according to changes of the exhaust
gas differential pressure between in front and in rear of
DPD filter. The exhaust differential pressure sensor
provides a signal to the ECM on the signal circuit,
which is relative to the differential pressure changes in
front and in rear of DPD filter. The ECM should detect a
low signal voltage at a low differential pressure, such
as small PM accumulation. The ECM should detect
high signal voltage at high differential pressure, such as
large PM accumulation.

1 2
3
LNW76ESH003601
MFW4ADSH002401 Legend
1. air inlet
The exhaust temperature sensor 1 and 2 are installed 2. air outlet
to the DPD housing. Both exhaust temperature sensors 3. air exhaust
have thermistor (negative temperature coefficient 4. Solenoid valve
resistor type). The sensor 1 measures the temperature
of the exhaust gas in front of DPD filter and the sensor
The exhaust throttle valve is installed in rear of the DPD
2 measures the temperature of the exhaust gas in front
housing and it composes a part of the exhaust system.
of oxidation catalyst. While the sensor detects that the
The ECM controls the exhaust throttle solenoid valve,
exhaust temperature is low, the sensor resistance is
which supplies power to the exhaust throttle solenoid
high. When the exhaust temperature increases, the
valve based on the DPD system regeneration status.
sensor resistance decreases. With high sensor
The exhaust throttle solenoid valve energizes to apply
air pressure to the exhaust throttle valve.
The exhaust brake valve is installed in front of the DPD
housing and it also composes a part of the exhaust
system. The ECM controls the exhaust brake solenoid
Exhaust Throttle Valve & Exhaust Brake Valve
valve based on the DPD regeneration status or exhaust
brake command signal. The exhaust brake solenoid
valve energizes to apply air pressure to the exhaust
brake valve.
MFW84CSH002301
Legend
1. Exhaust throttle valve & exhaust brake valve

5-8840-2835-0 (J-35616-C)
Connector Test Adapter Kit
Adapter Harness
(With Test Lamp)
5884028350 ADAPTER-H
5-8840-2844-0 (J-44638)
Fuel Pressure/ Vacuum
5-8840-2691-0 Gauge Assembly &
Digital Multimeter (EN-47667) Suction Side
Fuel Pressure/ Vacuum
Gauge Adapter
5884026910 5884028440
Tech2 Kit
AAW0Z0SH015701
THA-10
Tech2 DC24 Volt Adapter 2
ADAPTER2
CAN-di Module
CANDI
C Breaker Box
BREAKER
MG4HKED-WE-1101AU_67013_奥付 10.10.22 4:10 PM ページ 1

First Edition
WORKSHOP MANUAL
(4HK1 model)
0-XXXKI
MG4HKED-WE-1101AU_67013_奥付 10.10.22 4:10 PM ページ 2
2011MY
2011MY

WORKSHOP MANUAL

(4HK1 model)
2011MY
2011MY
WORKSHOP MANUAL
WORKSHOP MANUAL SUSPENSION
SUSPENSION
No.MGSUS-WE-1101AU
MGSUS-WE-1101AU_67016_前書 2010.11.5 3:36 PM ページ 1
Section Sub Section
1C Engine Cooling
1D Engine Fuel
1F Emission Control
1G Engine Exhaust
1J Induction
2B Front Suspension
2C Rear Suspension
3C1 Propeller Shaft
3C2 Front Axle
3C3 Rear Axle
3D Transfer Case
4D Parking Brake
5E Clutch
9C Entertainment
9D Wiring System
9F Body Structure
9G Cab
9H Seats
9L Cab Mounting
MGSUS-WE-1101AU_67016_前書 2010.11.5 3:36 PM ページ 2
MGSUS-WE-1101AU.book 1 ページ２０１１年６月２７日　月曜日　午後４時４１分
Air Suspension Control System 2A1-1
SUSPENSION
Air Suspension Control System
TABLE OF CONTENTS
Air Suspension System . . . . . . . . . . . . . . . . . . . 2A1-2
Description of Function and Operation . . . . . . 2A1-2
Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . 2A1-6
Performing the trouble diagnosis . . . . . . . . . . 2A1-9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-11
Trouble diagnosis using the scan tool . . . . . . 2A1-15
Air suspension control system check . . . . . . 2A1-27
Diagnostic Trouble Code (DTC) List . . . . . . . 2A1-29
DTC 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-30
DTC 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-33
DTC 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-36
DTC 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-37
DTC 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-38
DTC 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-39
DTC 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-44
DTC 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-46
DTC 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-48
DTC 51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-50
DTC 61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-52
DTC 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-53
DTC 71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-54
DTC 72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-57
DTC 81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-60
DTC 82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-62
Failure symptom list . . . . . . . . . . . . . . . . . . . 2A1-64
Air suspension warning light does not
illuminate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-65
Vehicle posture is incorrect . . . . . . . . . . . . . . 2A1-67
Vehicle height adjustments using the remote
controller are not possible . . . . . . . . . . . . . . . 2A1-69
Air tank pressure does not rise . . . . . . . . . . . 2A1-71
CAN communication circuit system check . . 2A1-72
Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-73
Height Sensor . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-74
Components . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-74
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-74
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-75
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-75
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-75
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-75
Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . 2A1-76
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-76
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-76
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-76
Air Suspension Control Unit . . . . . . . . . . . . . . . 2A1-77
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-77
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-77
Magnetic Valve . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-78
Components Location Diagram. . . . . . . . . . . 2A1-78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-78
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-79
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A1-79
2A1-2 Air Suspension Control System
Air Suspension System

Description of Function and Operation Leveling Control
Compared to a leaf suspension, an air suspension A height sensor detects the vehicle height. If the
system uses air-springs to softly absorb impacts, and vehicle height is higher than a specified range from the
controls for the optimum conditions such as the rising set standard vehicle height value in the initial
and lowering of cargo when stopping the vehicle, adjustment, the AIR SUS ECU activates a magnetic
starting, and traveling. valve to adjust the vehicle to the standard height.
Basic Operations When stopped

Each height sensor detects the vehicle height, which
Initial Control
can change when the vehicle is stopped, due to its
When the ignition switch is turned ON, the air cargo, bumps in the road surface, and air pressure and
suspension control unit (AIR SUS ECU) performs the temperatures. If the vehicle height is outside the
following controls. standard range, this quickly adjusts the vehicle to its
1. It turns its own circuits inside the AIR SUS ECU to correct height.
ON. It takes several seconds to determine that the vehicle
2. The air suspension warning light will light for three has changed from a traveling to a stopped state, so
seconds to check the lights. adjustments will not start soon after the vehicle has
stopped.
When not using a vehicle height adjustment remote
control, if the vehicle height is dramatically outside the
standard range, the air suspension warning light in the
IP cluster will light. In such cases, adequately increase
the air pressure in the air tank to return the vehicle
height to its original height. Drive the vehicle after the
air suspension warning light has extinguished.
The AIR SUS ECU performs the following controls

when the vehicle is stopped.
• Compare the target vehicle height value (standard
vehicle height value) and height sensor value. If
within a fixed range, vehicle height control is not
applied. (within 10 mm / 0.39 in )
If there is a difference beyond the fixed range for
the target value, the air supply/exhaust magnetic
value is driven to supply to or exhaust air from the
MFS7Z0SH001401
air suspension to raise or lower the vehicle height
and bring it within the fixed range.
• If the left and right height sensors fails to function,
the magnetic valve control is prohibited.
• If either one of the left or right height sensor fails to
function, the height is controlled by using the
height target and the sensor of the side that is
working normally.
When Driving
Only when vehicle height continuously exceeds the
standard range over a fixed amount of time, the vehicle
height will gradually be adjusted to ensure stability in
vehicle operation.
Remote control
There are three modes available with the Remote
Controller. They are "Normal Mode", "Vehicle Height
Initial Adjustment Mode" and "Adjustment Mode".

1. Normal Mode
This is a remote controlling for handling cargo by
ordinary users.
In the height adjustment (normal mode) by remote
control, the following functions are provided.
• With vehicle height memory function
- Rear axle manual vehicle height up/down
- Memory and call-up of two vehicle heights
2. Vehicle height initial adjustment mode
This is a mode that independently stores the height
of the traveling vehicle and the adjustment range
for the rear left and rear right.
Always setup prior to vehicle delivery.
3. Maintenance Mode
This mode uses the remote controller to operate
each of the bellows independently to supply or
exhaust air. Use this to check the operations of
each function.
Air minimum pressure holding control within the

air spring
Because the bellows has a self-sealing structure that
uses internal pressure, when the vehicle is driving
normally, the internal pressure is controlled to be a
minimum of approximately 30 kPa (0.3 kg/cm2 / 4 psi).
However, that excludes remote control.
Valve operation halt control using air pressure

To ensure air pressure when used by the brakes or
other equipment, and for smooth operation of air
suspension control, use each switch to stop or enable
the follow valve operations.
Automatic vehicle height adjustment when using

the remote controller, manual operation using the
"↑" and "↓" switches
Control is allowed when the air tank pressures is a
minimum of 540kPa (5.5kg/cm2 / 78 psi), and control is
terminated when the air tank pressures is less than
540kPa (5.5kg/cm2 / 78 psi).
Calls up vehicle height using the "M1," "M2," and
"Normal Level" switches when using the remote
controller, and controls all when not using the
remote controller.
Control is started when the air tank pressures is a
minimum of 640kPa (6.5kg/cm2 / 92 psi).
After starting control, if the pressures in the air tank is a
minimum of 540kPa (5.5kg/cm2 / 78 psi), even less
than 640kPa (6.5kg/cm2 / 92 psi), control is continued
until the target pressure is reached.
The pressure is less than 540kPa (5.5kg/cm2 / 78 psi),
control is terminated when the pressure is a minimum
of 640kPa (6.5kg/cm2 / 92psi).
Key OFF control

When the ignition switch is turned OFF, the air
suspension control unit (AIR SUS ECU) performs the
"Stopped vehicle leveling control".

System diagram
Multi-protection
Compressed air tank for Main compressed air tank
valve
air suspension
Air Air
pressure pressure
switch switch
Air
(6.5k) (5.5k)
pressure Height sensor
sensor
Air spring Air spring
Exhaust
Compressed air line

Magnetic valve
Electrical circuit
Air
pressure
sensor
Air spring Air spring
Height sensor
Control unit
Vehicle height adjustment

Starter switch Vehicle speed sensor
remote control switch
Air suspension
Parking brake
warning light
Foot brake Buzzer
MFW82AXF000101

Air hose diagram
Compressed air line

2
1
3
MFW82ALF000201
Legend
1. Air pressure sensor 3. Magnetic valve
2. Air tank for air suspension 4. Multi protection valve

Circuit Diagram
Air suspension control unit (AIR SUS ECU) system
wiring diagram
Battery
24 volts
Battery
D25
Ignition SW; ACC

VCC Power supply Key on / ACC signal
Air pressure A13 D12
Signal Ignition SW; ON
sensor, A2 Ignition signal
rear right Ground D13
A20
Air suspension warning light
D8
A10
Buzzer(external)
D4
Ground Buzzer(internal)
VCC Power supply
A12 D14
Air pressure
Signal
sensor, A1
Power supply
rear left Ground D2
A19 Remote
Clock signal
D18 control
unit
Data
D3 (Internal)
Air suspension control unit
M/V; rear right Power supply

A6 A17
Remote
M/V; rear left control
A5 unit
Data
M/V; rear master A16 (External)
A7
Air pressure switch 6.5K

A18
Data link Air pressure switch 5.5K

D9
connector A8

D17
Memory clear switch(connector)
Speed sensor D16

Speed signal
D1
control unit
Power supply
A15
Signal Height sensor,
A4
rear right
Ground
A22
CAN High
D5
Other ECU, Meter CAN Low
D6
Power supply
A14
Signal Height sensor,
A3
rear left
Ground
A21
MFW82ALF000301

Air suspension control unit (AIR SUS ECU) pin
assignment
AIR SUS ECU external view
Connector D Connector C Connector B Connector A
MFWB2AMF000101
AIR SUS ECU pin assignment
D13 D12 D11 D10 D9 D8 D7 D6 D5 D4 D3 D2 D1 A11 A2 A1

C8 C7 C6 C5 C4 C3 C2 C1 B6 B5 B4 B3 B2 B1 A10 A9 A8 A7 A6 A5 A4 A3
D26 D25 D24 D23 D22 D21 D20 D19 D18 D17 D16 D15 D14 C16 C15 C14 C13 C12 C11 C10 C9 B12 B11 B10 B9 B8 B7 A22 A21 A20 A19 A18 A17 A16 A15 A14 A13 A12
HCS7Z0SF000101
CAUTION:
Neither connector B nor C are used.

Connector A
No. Circuit names No. Circuit names
1 Air pressure sensor rear left signal 12 Air pressure sensor rear left power supply
2 Air pressure sensor rear right signal 13 Air pressure sensor rear right power supply
3 Height sensor rear left signal 14 Height sensor rear left power supply
4 Height sensor rear right signal 15 Height sensor rear right power supply
5 M/V rear left power supply 16 Remote control unit (external) data
6 M/V rear right power supply 17 Remote control unit (external) power supply
7 M/V rear master power supply 18 Air pressure switch (6.5k) signal
8 Air pressure switch (5.5k) signal 19 Air pressure sensor rear left GND
9 — 20 Air pressure sensor rear right GND
10 Buzzer (external) 21 Height sensor rear left GND
11 — 22 Height sensor rear right GND
Connector D
No. Circuit names No. Circuit names
1 Vehicle speed signal 14 GND
2 Remote control unit (internal) power supply 15 —
3 Remote control unit (internal) data 16 Memory clear switch (connector)
4 Buzzer (internal) 17 Diagnostic request switch
5 CAN communication (High) 18 Remote control unit (internal) clock timer signal
6 CAN communication (Low) 19 —
7 — 20 —
8 Air suspension warning light 21 —
9 Data link connector 22 —
10 — 23 —
11 — 24 —
12 Ignition switch "ACC" signal 25 Battery power supply
13 Ignition switch "ON" signal 26 —

Performing the trouble diagnosis • If memory clear cannot delete the diagnostic
trouble code (DTC), be sure to inspect the
Precautions on inspection
malfunction location indicated by the diagnostic
• When you inspect the air suspension system, trouble code (DTC).
always make a record of the detected diagnostic
trouble code (DTC). (Also check whether the
engine and other systems are being inspected at
the same time, with their own diagnostic trouble
code (DTC) output, and make a record if such
codes are detected).
Inspection procedure flowchart
Air suspension system inspection
Starter switch on
- IP cluster failure
Did the air suspension No
- Power supply/ GND circuit failure
warning light switch on - Repair the malfunction
- Circuit (harness) error
for 3s then turn off?
- ECU failure
Yes
Diagnostic switch ON
(connect the jumper wire)
No - IP cluster failure
Did the warning light
- Diagnostic switch circuit failure Repair the malfunction
blink?
- ECU failure
Yes
No A DTC has been detected,

Is a flash code 01
so refer to the table to locate Repair the malfunction
displayed?
the failure.
Yes
DTC deleted
If the air suspension system is
normal but the problem persists,
carry out inspection and repair
of mechanical systems.
Test drive to check the
repair
Test drive to check the repair
End
MFW82ALF000401
Checking DTC • Use a scan tool (use communications mode) to

• Check from the air suspension warning light. clear the DTC.
• Check with a scan tool.(Connect a scan tool)
Clearing DTC
• Use the memory clear switch (connected to the
connector) to clear the DTC.

Displaying the DTC DTC display method (procedure)
DTCs stored in the Air suspension control unit can be • Turn ON the ignition, and check the air suspension
displayed using flashes of the air suspension warning warning light.
light by short-circuiting pins 12 and 4 of the data link If the air suspension warning light is flashing, the
connector (DLC). DTC(s) is set.
• Turn OFF the ignition, and connect the jumper wire
between terminal 12 and terminal 4 or 5 of the
DLC.
• Turn ON the ignition, and read the DTC(s) in
accordance with the blinking status of the air
suspension warning light in the IP cluster.
9 1 When the air suspension control system is normal,
10 2
11 3
code 1 continues to be displayed.
12 4 When many DTCs are set, the air suspension
13 5 warning light sequentially indicates all DTCs from
14 6
the lowest code number.
15 7
16 8 • Find the corresponding meaning of the DTC from
the diagnostic trouble code (DTC) table.
*If a scan tool is connected, you can use it to read
the code.
MFA7Z0SH000201
Example DTC25
t4 t3 t2 t3 t2 t1 t2 t1 t2 t1 t2 t1 t2 t1 t4 t1 = About 0.3 second
t2 = About 0.6 second

Turn ON
Turn OFF
Place of ten Place of one
MFW82ASF000101
Clearing diagnostic trouble codes • Turn OFF the ignition.

Diagnostic codes recorded in the air suspension control If the scan tool is connected, you can delete codes by
unit are not cleared even if the defective areas are operating it.
repaired. Use one of the following methods to clear the
diagnostic codes.
The memory clear switch (connector) is installed inside
the center cover ASM.
• If a short circuit is made to the DLC No.12 pin with
No.4 or No.5 pin, disconnect them.
• Turn ON the ignition.
• Connect the memory clear connector for 3 second
or more after turning the ignition switch ON.
• After connecting the memory clear connector for 1
second or more, disconnect the memory clear
connector.

Adjustment
Air suspension vehicle height initial adjustment
The initial settings to store the normal vehicles position must always be done at the
dealership prior to vehicle delivery. (After mounting the rear body, the vehicle should be
empty.)
Purpose:
Preset the normal vehicle position to absorb weight fluctuations of the body.
For air-suspension vehicles, it is possible to adjust the normal vehicle height position to
any position, but to ensure correct vehicle posture and to limit damage to cargo, it is
necessary to achieve the proper suspension stroke.
Target Values
Adjust the air suspension height to the values in the table.
Vehicle model Height
FRR ,FSR 215mm (8.46in)
Always make adjustments on a level road.
The ignition switch is turned ACC or ON.
The air tank air pressure must be 640kPa{6.5kg/cm 2} or more.
Firmly set the parking brake.
Set the height sensor level to be level.

Caution:
Adjust vehicle height using the remote controller.
The rod length should be adjusted to the standard value. Do not make fine adjustment.
Upper height of the frame is as follows.
Vehicle model Tire Size Upper height (reference values)
FRR 9.5R 17.5 795mm (31.3in)
FSR 245/70R 19.5 785mm (30.9in)
FSR 265/70R 19.5 800mm (31.49in)
Upper height of the frame
Air spring height
MFWB2AXF000101
NOTE:
Initial vehicle frame height adjustment is performed in 2 steps (Standard (mid) position
followed by low position).
1. Equipment
· Set the parking brake.
· Start the engine and allow it to idle.
2. Change to vehicle height initial adjustment mode.

· Wait until the compressed air tank pressure rises.
· Press and release the remote control unit power button to turn the unit on.
The remote control power light (green) on the remote control unit turns on. The
Air suspension warning light (red) on the instrument panel also turns on.
And, is displayed in the multi display in the meter.
· Simultaneously press and hold the stop button STOP

, the up button , and the
down button until the buzzer sounds (approximately 5 seconds). The unit is
now in the initial vehicle frame height adjustment mode.
3. Neutral vehicle height adjustment

· Press and release the M2 button M2
. Press the up button or the down
button to adjust the right-side standard height.
· Press and release the M1 button M1
. Press the up button or the down
button to adjust the left-side standard height.
4. Neutral vehicle height memory

· Simultaneously press and hold the height adjustment button and the stop
button STOP
until the buzzer briefly sounds (approximately 2 seconds). This
records the height in air suspension electronic control unit memory.
If the buzzer continues to sound, an error has occurred. Repeat Steps 4 through.
MFW82AXF000301
5. Low position vehicle height adjustment

· Simultaneously press and release either the M1 or M2 button M1 M2
and the
down button . The air is completely expelled from the air springs on both
sides of the vehicle. Vehicle height is at its lowest position.
6. Low position vehicle height memory

· Simultaneously press and hold the height adjustment button and the stop
button STOP
until the buzzer briefly sounds (approximately 2 seconds). This
records the height in air suspension electronic control unit memory.
If the buzzer continues to sound, an error has occurred. Repeat the entire
procedure.
7. Finish the vehicle height initial adjustment mode

· Press and release the remote control unit power button to turn the unit off.
The green power light on the remote control unit and the air suspension
warning light (red) on the instrument panel turn off.
Vehicle height adjustment power button

(rear axles)
Memory button 2
Memory button 1 Vehicle height reset button
M1 M2 Stop button
UP button
STOP
Down button
MFW82AXF000401
Air supply and exhaust by remote control
This mode allows adjustment of the compressed air in the air springs of each wheel.
It is used to check electrical connections and air line connections.
CAUTION:
If this operation is used to adjust the compressed air in each air spring individually,
the diaphragms of air springs without pressure can become detached, so care is required.
In that case, fill the affected air spring with compressed air in advance.
- Press the power button on the remote control.
STOP M2
- While pressing the Stop button , press memory button 2 and vehicle height reset
button simultaneously for at least 5s.
NOTE:
The buzzer sounds for 1s when the mode switches.
- Release air pressure from the air springs.
The air springs are assigned to the buttons below.
M1 M2
Left Right
Supply Exhaust
Eg.1 To supply compressed air to the right side, press the memory
M2
button 2 to select the right side.
A brief press is sufficient, there is no need to press the buttons for longer.
The memory button 1 need to be pressed after that to select
left side.
Use the and buttons to supply or exhaust air.
- To complete the process, press the power button to turn the power lamp off.
CAUTION:
After completing adjustment, check that all air springs contain compressed air.
MFW82AXF000701

Trouble diagnosis using the scan tool Data Display
Operating Procedure Displays the states recognized and controlled by the air
suspension control unit (AIR SUS ECU) in each item.
1. Connect the scan tool.
The displayed values are the typical values of the scan
2. Turn ON the ignition. tool data list.
3. Switch the power of the scan tool to ON and select The content of displayed items are described in the
"Diagnostic" > "Model Year" > "F Series Truck" > data.
"Chassis" > "Air Suspension". This menu displays the current data.
4. Select the function to be used from the menu The display is synchronized with the vehicle and
screen. machine statuses.
• When a menu of the data display cannot be
Menu list selected:
The following table shows which functions appear and A malfunction has occurred in wiring between the
are displayed with the current scan tool software. AIR SUS ECU and DLC.
• When the display shows abnormal fixed values:
[Example] When displayed data values, such as
F0: Diagnostic Trouble Codes
for engine rpm and the sensors, etc, are
F0: Read DTC Info As Stored By ECU consistently fixed and do not reflect from their
actual state: If you can manually move the
F1: Clears the DTC information
connector or harness and the display is released
F1: Data Display from a fixed state, there is a problem in the
terminal fittings, the pins are out of alignment,
F2: Snapshot
there is a disconnection in the harness that was
F3: Actuator Test moved by hand or there is a short circuit. Repair is
required.
F0: Magnetic Valves
It is necessary to repair the power disconnection in
F0: M/V_RR (Rear Right) the harness you manually moved and the short
circuit.
F1: M/V_RL (Rear Left)
• When * (asterisk) is displayed for the value display;
F1: Lamps There is a problem in the scan tool software.
F0: Height Lamp If * (asterisk) is discovered in even one position in
the data display, it is necessary to upgrade the
F2: Buzzer PCMCIA card.
F0: Buzzer
Snapshot
F1: Buzzer (Outside) To identify the cause of a malfunction, run the snapshot
F4: Programming and review the data.
• Snapshot records the data list menu and plots
F0: Remote Control
graphs.
F1: Write vehicle Type Data • By using this mode, you can regenerate and
record the conditions of customers' complaints to
Menu description discover errors in the data.
By selecting a menu, you can check the DTC and data, • If you use the trigger type specifying method, the
conduct tests and learning. data of the moment when DTC is displayed can be
recorded.
Diagnostic Trouble Codes (DTC) • The recorded data can be replayed with a home
Reading, checking and deleting of DTC is to power supply.
performed.
DTC is the language that the person performing the Actuator Test
diagnosis uses to communicate with the ECU of the Inspect the operations and functions of parts targeted
vehicle. for the test to check whether there are problems.
DTCs can be broadly classified into two categories:
past DTCs and current DTCs. CAUTION:
• Current DTC: Displays a malfunction (failure) from If conditions such as the running state of the vehicle
the current ignition cycle. and engine, water temperature, vehicle speed,
switches and gear position are not met, and DTC is
• Past DTC: Displays a malfunction in the previous
detected, each test may possibly not operate.
or past ignition cycle.
Item Description How to Use

F0: Magnetic Valves When giving ON/OFF If the magnetic valve does not operate when
instructions, check the turned ON, there is an abnormality in the magnetic
operations of the magnetic valve harness or AIR SUS ECU.
valve.
F1: Lamps When giving the ON/OFF If a air suspension warning light does not operate
instructions, check the when turned ON, there is an abnormality in the air
operation of the air suspension suspension warning light, harness or AIR SUS
warning light (lighting/ ECU.
extinguishing).
F2: Buzzer When giving ON/OFF If the buzzer does not sound when turned ON,
instructions, check the there is an abnormality in the buzzer, harness or
operations of the buzzer AIR SUS ECU.
(ringing/not ringing).
Programming 7. When "Plot" appears at the bottom of the screen,

Used in converting information of the vehicle data and select it.
converting AIR SUS ECU. 8. When the item selection screen is displayed, press
"Enter" on the items and choose up to 3 items, and
Creating graphs select "Approve" at the bottom of the screen.
Snapshot data can be used to create a graph. 9. A graph will show up on the screen.
Graph can be used to determine the cause of the
failure. Method to regenerate the graph of the recorded
data
Method to create a graph after displaying data 1. Select "Snapshot Data" on the screen displayed
1. Select "Data Display" from the application menu. when the scan tool is powered "ON".
2. When the vehicle data is displayed, select 2. Confirm that the snapshot data titles are displayed.
"Snapshot" at the bottom of the screen. 3. Select the snapshot data title.
3. Wait for a certain period of time and press "EXIT" 4. Data will be displayed on the screen. Select "Plot"
button. at the bottom of the screen to view a graph.
4. When the screen switches, select "Continue" that 5. When the item selection screen is displayed, press
appears at the bottom of the screen. "Enter" on the items and choose up to 3 items, and
5. When "Plot" appears at the bottom of the screen, select "Approve" at the bottom of the screen.
select it. 6. A graph will show up on the screen.
6. When the item selection screen is displayed, press
"Enter" on the items and choose up to 3 items, and Scan tool data
select "Approve" at the bottom of the screen. The purpose of data list is for checking the status of the
7. A graph will show up on the screen. vehicle and equipment.
Method to create a graph by determining the trigger NOTE:

type • Control values are displayed for vehicle height
1. Select "Data Display" from the application menu. values. To convert to mm increments, it is
necessary to integrate the coefficient (1.69).
2. Select the item displayed on the screen.
• The contents displayed will vary according to the
3. When the snapshot option screen is displayed,
vehicle model.
specify the trigger type and select "Record
Snapshot" at the bottom of the screen.
4. When (Standby) starts blinking at the bottom right
of the screen, select "Trigger" at the bottom of the
screen.
5. Confirm the trigger type.
6. When the screen switches, select "Continue" that
appears at the bottom of the screen.
Data Display Items Units Description How to Use

System Voltage V Displays the voltage being If the difference with the actual
charged to the AIR SUS ECU. A battery voltage is high, it is
difference between the actual possibly due to installation of
battery voltage may sometimes accessories to the circuit,
occur because of loads on the causing an voltage drop. If the
circuits, or minute resistance standard battery voltage is
values in the harness and periodically incorrect, it is
connector terminals. necessary to inspect the circuits,
connectors and their fittings, and
for noise from surrounding
accessory equipment.
To conduct inspections for
voltage drops and noise caused
by the accessory, turn OFF all
accessory switches. You can
discover the accessory by
turning them ON in order.
(Voltage drop/noise)
Vehicle Speed km/h Convert the signals from the If the speed meter and display
vehicle speed sensor at the are different, or the display will
speed sensor control unit. The not change, check the engine
AIR SUS ECU convert to vehicle side data. For example, if the
speed based on the signals for engine side and speed meter are
display. synchronized, it is necessary to
inspect the air suspension side
speed sensor control unit and
circuits between the AIR SUS
ECU and the AIR SUS ECU.
If a problem is found in both the
engine side and the air
suspension side, it is necessary
to inspect the speed sensor
control unit, the engine control
circuit between the AIR SUS
ECU and the common circuits.
Vehicle Speed Signal V Converts the signals from the With the ignition switch ON, and
Input Voltage vehicle speed sensor at the the display continues for 0V, it is
speed sensor control unit and necessary to inspect for
displays that signal. disconnection of the circuits
between the speed sensor
control unit and the AIR SUS
ECU.
If B+ voltage continues, it is
necessary to inspect the B+
short of the same circuit.
Key Switch Open/Closed Indicates the operation of the If there is no change in the
ignition switch. display for the behavior of the
Displays "Closed" when the vehicle, there is a problem in the
ignition switch is ON. circuits or AIR SUS ECU. It is
Displays "Open" when the necessary to inspect the
ignition switch is OFF. switches, circuits and AIR SUS
ECU.

Brake Switch Open/Closed Indicates the operation of the If there is no change in the
brake switch. display for the behavior of the
When the brake pedal is vehicle, there is a problem in the
depressed, "Closed" is circuits or AIR SUS ECU. It is
displayed. necessary to inspect the
When the brake pedal is switches, circuits and AIR SUS
released, "Open" is displayed. ECU.
Parking Switch Open/Closed Indicates the operation of the If there is no change in the
parking switch. display for the behavior of the
parking switch is ON. circuits or AIR SUS ECU. It is
Displays "Open" when the necessary to inspect the
parking switch is OFF. switches, circuits and AIR SUS
ECU.
M/V Power Relay ON/OFF Indicates operations of its own If the display indicates that the
circuits inside the AIR SUS ECU. starter switch is "OFF" even
The internal self-hold circuit though it is "ON", it is necessary
turns ON when the ignition to replace the AIR SUS ECU.
switch ON signal is inputted to
the AIR SUS ECU.
0.5 seconds after the internal
self-hold circuit turns ON, the
magnetic valve is controlled.
M/V Master Rr ON/OFF Indicates the operation status of If the symptom remains even
the rear master magnetic valve. when the rear air supply/exhaust
The magnetic valve is turned ON valve is operating, regardless of
when power is supplied from the whether the display is OFF, it is
AIR SUS ECU A7 pin. necessary to inspect the circuit
GND short.
If the display is ON (between the
AIR SUS ECU A7 pin and
master magnetic valve), this is
supported by diagnosis trouble
codes.
M/V Rr_R ON/OFF Indicates the operation status of If the symptom remains even
the rear right magnetic valve. when the rear right air supply/
The magnetic valve is turned ON exhaust valves are operating,
when power is supplied from the regardless of whether the
AIR SUS ECU A6 pin. display is OFF, it is necessary to
inspect the circuit GND short.
codes.

M/V Rr_L ON/OFF Indicates the operation status of If the symptom remains even
the rear left magnetic valve. when the rear left air supply /
The magnetic valve is turned ON exhaust valves are operating,
when power is supplied from the regardless of whether the
AIR SUS ECU A5 pin. display is OFF, it is necessary to
inspect the circuit GND short.
codes.
Actual RR Height — Displays the current vehicle By comparing to target values, it
height value (rear right) as the is the point to determine whether
control value of the vehicle the problem (vehicle height gap)
height value (rear right) height is on the control side or is
sensor signal voltage value. mechanical in nature.
(Converts to mm increments Following the vehicle stationary
using X 1.69) leveling adjustment, there is no
problem at the control side if the
vehicle height (rear right)
complies within ±10mm (0.39 in)
of the target vehicle height
value. (The vehicle height is
normal.)
Actual RL Height — Displays the current vehicle By comparing to target values, it
height value (rear left) as the is the point to determine whether
control value of the vehicle the problem (vehicle height gap)
height value (rear left) height is on the control side or is
sensor signal voltage value. mechanical in nature.
(Converts to mm increments Following the vehicle stationary
using X 1.69) leveling adjustment, there is no
vehicle height (rear left)
normal.)
RR Height Target — Displays the target value of the By comparing to actual values
vehicle height value (rear right). (rear right), it is the point to
(Normally, middle vehicle height determine whether the problem
is inputted.) (vehicle height gap) is on the
control side or is mechanical in
nature.
Following the vehicle stationary
leveling adjustment, there is no
vehicle height (rear right)
normal.)

RL Height Target — Displays the target value of the By comparing to actual values
vehicle height value (rear left). (rear left), it is the point to
(Normally, middle vehicle height determine whether the problem
is inputted.) (vehicle height gap) is on the
control side or is mechanical in
nature.
Following the vehicle stationary
leveling adjustment, there is no
vehicle height (rear left)
normal.)
RR Height Gap — Displays the gap between target Following the vehicle stationary
(Actual - Target) value and actual value of the leveling adjustment, there is no
vehicle height value (rear right). problem in the vehicle height
control if the display value is
within ±10 mm (0.39 in).
If the display value is beyond
±10mm (0.39 in), it is necessary
to inspect the vehicle height
control and air pressure control.
RL Height Gap — Displays the gap between target Following the vehicle stationary
(Actual - Target) value and actual value of the leveling adjustment, there is no
vehicle height value (rear left). problem in the vehicle height
control if the display value is
within ±10 mm (0.39 in).
If the display value is beyond
±10mm (0.39 in), it is necessary
to inspect the vehicle height
control and air pressure control.
RR Air Pressure kg/cm2 Converts the Rear right air By comparing to target values, it
pressure sensor signal voltage is the point to determine whether
value to kg/cm2 increments to the problem (vehicle height gap)
display the current rear right air is on the control side or is
pressure. mechanical in nature.
There is no problem with the
control side if air is supplied/
exhausted to make the actual
pressure comply with the
targeted pressure value.
(The air pressure control is
normal.)
RL Air Pressure kg/cm2 Converts the Rear left air By comparing to target values, it
pressure sensor signal voltage is the point to determine whether
value to kg/cm2 increments to the problem (vehicle height gap)
display the current Rear left air is on the control side or is
pressure. mechanical in nature.
There is no problem with the
control side if air is supplied/
exhausted to make the actual
pressure comply with the
targeted pressure value.
(The air pressure control is
normal.)

RR Pressure Sensor — Displays the rear right air If the power supply diagnosis is
Power Supply Diagnosis pressure sensor signal voltage fixed at approximately 0 V or
value. approximately 5 V without the
actual value complying with the
target value of the rear right air
pressure, it is necessary to refer
to the diagnostic trouble code
(DTC) 71 to execute a diagnosis.
RL Pressure Sensor — Displays the rear left air If the power supply diagnosis is
Power Supply Diagnosis pressure sensor signal voltage fixed at approximately 0 V or
value. approximately 5 V without the
actual value complying with the
target value of the rear left air
pressure, it is necessary to refer
to the diagnostic trouble code
(DTC) 72 to execute a diagnosis.
Maximum Pressure kg/cm2 Converts all air pressure sensor —
signal voltage values to kg/cm2
increments to display the current
maximum air pressure.
Average Pressure kg/cm2 Converts all air pressure sensor —
signal voltage values to kg/cm2
increments to display the current
average air pressure.
Control Phase — Displays the current control state Checks the control phase and
targets vehicle behavior.
RR Height Learn Value — Displays the rear right maximum Checks the rear right maximum
(HI) vehicle height learning value. vehicle height learning value and
targets vehicle standard values.
RL Height Learn Value — Displays the rear left maximum Checks the rear left maximum
(HI) vehicle height learning value. vehicle height learning value and
RR Height Learn Value — Displays the rear right standard Checks the rear right standard
(MID) vehicle height learning value. vehicle height learning value and
RL Height Learn Value — Displays the rear left standard Checks the rear left standard
(MID) vehicle height learning value. vehicle height learning value and
RR Height Learn Value — Displays the rear right minimum Checks the rear right minimum
(LOW) vehicle height learning value. vehicle height learning value and
RL Height Learn Value — Displays the rear left minimum Checks the rear left minimum
(LOW) vehicle height learning value. vehicle height learning value and
Rr APS 5.5k Open/Closed Displays the action after the air If there is no change in the
(Air Pressure Switch) pressure switch (5.5k). display for the behaviour of the
switch is ON. switch itself, circuits or AIR SUS
Displays "Open" when the switch ECU. It is necessary to inspect
is OFF. the switches, circuits and AIR
SUS ECU.

Rr APS 6.5k Open/Closed Displays the action after the air If there is no change in the
(Air Pressure Switch) pressure switch (6.5k). display for the behaviour of the
switch is ON. switch itself, circuits or AIR SUS
Displays "Open" when the switch ECU. It is necessary to inspect
is OFF. the switches, circuits and AIR
SUS ECU.
Height Lamp ON/OFF Displays the operating condition Regardless of the display
of the air suspension warning showing "ON", if the air
light. suspension warning light is not
The AIR SUS ECU sends an lit, it is necessary to inspect for a
instruction to the IP cluster via malfunction in the IP cluster or a
CAN communication and the IP disconnection in the CAN
cluster drives the air suspension communications circuit.
warning light.
Buzzer (Cabin) ON/OFF Displays the operating condition Regardless of the display
of the buzzer (cabin). showing "ON", if the buzzer does
The AIR SUS ECU sends an not sound, it is necessary to
instruction to the IP cluster via inspect for a malfunction in the
CAN communication and the IP IP cluster or a disconnection in
cluster drives the buzzer. the CAN communications circuit.
Buzzer (Outside) ON/OFF Displays the operating condition Regardless of the display
of the buzzer (outside). showing ON, if the buzzer does
The buzzer sounds when power not sound, it is necessary to
is supplied from the AIR SUS inspect for a melted fuse or a
ECU A10 pin. disconnection in the buzzer
circuit.
Regardless of the display
showing OFF, if the buzzer does
not stop sounding, it is
necessary to inspect for a short
circuit in the circuit power
voltage from the buzzer to the
AIR SUS ECU A10 pin.
Diagnostic Switch Open/Closed Displays the operation of the If there is no change in the
diagnostic switch. display for the connection of the
Displays "Closed" when the diagnostic switch, there is an
switch is ON. Displays "Open" abnormality in the connector,
when the switch is OFF. circuits or AIR SUS ECU. It is
necessary to inspect the
switches, circuits and AIR SUS
ECU.
Memory Clear Switch Open/Closed Indicates the operation of the If there is no change in the
memory clear switch. display for the connection of the
Displays "Closed" when the memory clear switch, there is an
switch is ON. Displays "Open" abnormality in the switch, circuits
when the switch is OFF. or AIR SUS ECU. It is necessary
to inspect the connector circuit
and AIR SUS ECU.
Load History No/Yes Displays the load history. Used to determine whether there
is an accumulated history
equivalent to GVW in the past.

Remote Control Status Operation/ Displays the control condition of Set the parking brake on the
Prohibition the remote controller. stopped vehicle to ON, and turn
the remote controller switch to
ON to switch from prohibit to
operate.
Remote Control Learned Normal/Lowest Displays the vehicle height initial Checks condition of vehicle
Status learning condition. height initial learning.
Displays a normal condition (It can be checked with MID in
when the vehicle height learning the IP cluster.)
value is normal.
AIR SUS ECU determines the
height when the lowest vehicle
height is learned after neutral
height learning at the time of
vehicle height learning.
Remote Control Hysteresis Standard/ Displays the condition of the Check the condition when you
Select Narrow remote controller hysteresis change the remote controller
selection. hysteresis.
Remote Control Standard/ Displays the condition of the Check the condition when you
Permission Conditions Freight remote controller permission change the remote controller
Select container condition selection. permission conditions.
Remote Control Timer OFF/Time Displays the condition of the Check the condition when you
Select remote controller timer selection. change the remote controller
timer.
Store Weight kg Displays the current weight data —
Data;MIMAMORI for MIMAMORI.
EOL Data — Displays the EOL vehicle model Checks the current vehicle
code. model code.
Scan Tool Data Reference Value • The engine is stopped

Vehicle Condition: • Brake pedal not depressed
Data Display Items Units Reference Value

System Voltage V 23
Vehicle Speed km/h 0
Vehicle Speed Signal Input Voltage V 2
Key Switch Open/Closed Closed
Brake Switch Open/Closed Open
Parking Switch Open/Closed Closed
M/V Power Relay ON/OFF ON
M/V Master Rr ON/OFF OFF
M/V Rr_R ON/OFF OFF
M/V Rr_L ON/OFF OFF
Actual RR Height — 126
Actual RL Height — 126
RR Height Target — 128
Data Display Items Units Reference Value

RL Height Target — 128
RR Height Gap (Actual - Target) — -2
RL Height Gap (Actual - Target) — -2
RR Air Pressure kg/cm2 0.5
RL Air Pressure kg/cm2 0.5
RR Pressure Sensor Power Supply Diagnosis — 240
RL Pressure Sensor Power Supply Diagnosis — 240
Maximum Pressure kg/cm2 1.9
Average Pressure kg/cm2 0.5
Control Phase — 0F
RR Height Learn Value (HI) — 184
RL Height Learn Value (HI) — 184
RR Height Learn Value (MID) — 128
RL Height Learn Value (MID) — 128
RR Height Learn Value (LOW) — 104
RL Height Learn Value (LOW) — 104
Rr APS 5.5k (Air Pressure Switch) Open/Closed Open
Rr APS 6.5k (Air Pressure Switch) Open/Closed Open
Height Lamp ON/OFF OFF
Buzzer (Cabin) ON/OFF OFF
Buzzer (Outside) ON/OFF OFF
Diagnostic Switch Open/Closed Open
Memory Clear Switch Open/Closed Open
Load History No/Yes No
Remote Control Status Operation/ Prohibition
Prohibition
Remote Control Learned Status Normal/Lowest Normal
Remote Control Hysteresis Select Standard/ Standard
Narrow
Remote Control Permission Conditions Select Standard/ Standard
Freight
container
Remote Control Timer Select OFF/Time OFF
Store Weight Data;MIMAMORI kg 670
EOL Data — 15

Using the scan tool for air suspension trouble • Deleting DTCs (Diagnostic trouble codes):
diagnosis You can delete DTC information recorded in the
• When the scan tool is connected to the onboard ECU of the air suspension electronic control
diagnosis module (ECU) installed in the vehicle system.
and discovers a problem on the vehicle, it detects • Actuator test
and displays a variety of data indicating the vehicle This sends forced operating or non-operating
operating conditions as service information to signals to the air suspension control system's
repair the vehicle, detects the location of the actuator, lights, regulator and equipment to test the
problem, and assists in self-diagnosis. This quality of the control functions.
manual describes the air suspension of the scan This enables you to determine whether the
tool. This is to assist in the proper and rational system's functions qualifications are correct.
trouble diagnosis, repairing and the checking of
repairs at the vehicle servicing station. Quantitative (Performance) analysis functions of
Mechanical parts are briefly explained. If there are the scan tool (Example)
areas where you need a deeper understanding of • Display of data list:
mechanical parts of the scan tool, read the scan This displays performance data from the vehicle's
tool user's guide. measurement system. (This system measures
• The service station checks and records claims of physical quantities and provides easy-to-use
problems from customers when the defective formats for reading and using those values.)
vehicle is received. Discrepancies between true values and measured
Prior to inspection, the failure should be duplicated values are caused by system check errors (regular
based on the claim, then the cause should be errors), random errors (irregular errors), and fixed
identified, repaired and the repair should then be value errors (fixed display values).
checked. However, there are cases in which it is - Systematic errors (regular errors) are often
difficult to specify the cause of the problem from related to the basic precision of the instruments
customer claims on a broad array of electronically (such as sensors).
controlled vehicles. Trouble diagnosis using the - Random errors (irregular errors) are often
scan tool is an analysis to specify the causes of a related to electrical (charged voltages),
problem from both a qualitative (functional) mechanical or other noise.
analysis and a quantitative (performance) analysis.
- For fixed value errors, there is a disconnection,
It is an extremely rational method to solve
short or malfunction of the unit in the circuit on
problems in an electronic-control system.
the instrument (such as sensors).
• It is necessary for the technician to understand the
quantitative and qualitative analyses functions of General Diagnosis Procedures
the scan tool.
1. Check that the air suspension warning light lights
Qualitative (Functional) analysis functions of the for three seconds when the ignition switch is
scan tool (Example) turned "ON" to test the light. If the air suspension
warning light does not light up, check for the
• DTC (Diagnostic trouble codes) display: following conditions.
Displays the current and past DTCs, and the
• IP cluster not learned
quality and condition of the problem.
Multiple DTCs are displayed simultaneously in • IP cluster malfunction
ascending order or in order of priority which is • Abnormality in AIR SUS ECU power supply/
helpful in analyzing problems with a 5 V power GND circuit
supply or ground-shared circuit. • CAN communication circuit malfunction
For example, if an ECU internal 5 V power supply
• Abnormality in AIR SUS ECU
circuit of a sensor is being shared, and there is a
breakage in the power supply, there will be two 2. Connect the scan tool to the vehicle and start the
DTCs displayed for the 5 V power supply sensor engine. Check the lighting of the air suspension
that is shared. In other words, the cause of the warning light.
problem can be identified from the combination of If the air suspension warning light repeatedly
DTCs. blinks, check the DTC using the scan tool.
• Display of vehicle information: • Points to check
This displays the module part number of each - Meaning of DTC
electronic control system, and identification of - Identification of current and past DTCs
system equipment, etc. This enables you to
- Record of DTC data (trigger point snapshot)
identify the onboard diagnosis (OBD) system.
- History
- Current ignition cycle DTC

3. If the air suspension warning light is not blinking,
check the DTC using the scan tool.
• Points to check
Meaning of DTC
Identification of current and past DTCs
Record of DTC data (trigger point snapshot)
History
Tests not executed after deleting DTCs
Current ignition cycle DTC
4. When DTC is confirmed
Record the DTC and snapshot data, then delete
the DTC.
Then,
Reproduce the failure based on the trigger data
record.
Detect the failure based on the meaning of the
reproduced DTC in the order of power supply,
ground and signals.
• Points to check
Snapshot of data list; traceability of numerical
values; correctness of numerical values;
identification of fixed values
5. When DTC is not confirmed
• Points to check
Other tests; identify whether mechanical or
electrical problem.
Snapshot of data list; traceability of numerical
values; correctness of numerical values;
identification of fixed values
- Systematic errors (regular errors) are often
related to the basic precision of the
instruments (such as sensors).
- Random errors (irregular errors) are often
related electrical (charged voltages),
mechanical or air leak, or other noise.
- For fixed value errors, there is a
disconnection, short or malfunction of the
unit in the circuit on the instrument (such as
sensors).

Air suspension control system check
Description • Inspect the harness connectors for AIR SUS ECU
The air suspension control system check is the starting connection failures, terminal end protrusions,
point for trouble diagnosis. Before using these inappropriate fittings, lock damages, inappropriate
procedures, visually inspect the air suspension control terminal shape or damage, and connection failures
unit (AIR SUS ECU) and ground to check that they are in the terminals and wires.
clean and properly installed, and the connector or • Inspect for harness damage. If there are no
terminal is connected. abnormalities with the harness, shake the
It is also necessary to check at the same time for air connectors and wires relating to AIR SUS ECU
leaks coming from the air hoses. communication using the vibration method and
There must be a minimum of 20 V of input voltage from check the condition of system communications
the battery in order for the AIR SUS ECU to operate using the scan tool.
normally. If there is a change in the display, identify the
If there are parts installed on the AIR SUS ECU power problem by vibrating the part where the problem is
supply circuit that cause a drop in voltage (such as located.
commercially available horns, illumination, audio • If commercial parts such as a horn, illumination,
system or vehicle wireless radios), and the voltage audio system or vehicle wireless radio are
drops under 20 V, the diagnosis control will not operate installed, turn their switches ON to check the
normally, even though the battery voltage is normal. communication of the system and check for a drop
Visually inspect the area to check the power supply of in voltage with the scan tool.
commercial parts. Commercially available parts often generate a
The engine control system must be running normally in great deal of noise. Turn their switches ON and
order for the AIR SUS ECU to operate normally. use the scan tool to check for changes in the data
If problems are found in both the air suspension system list.
and the engine control system, it is necessary to place It is necessary to contact the user when it is
priority in inspecting the engine problem and repairing. necessary to change the commercial part's
installation position, power supply or output.
Diagnostic Aids
Inspect for the following conditions:
Air suspension control system check

1. Turn ON the ignition with engine OFF.
2. Check the lighting of the air suspension
1 warning light. —
Was the air suspension warning light extinguished Go to "Failure
or blinking three seconds after it has lit ? Go to Step 2 symptom list"
2 4. Use the scan tool to display the air suspension —
data.
Was the air suspension data displayed by the scan

tool ? Go to Step 3 Go to Step 5
Use a scan tool to check the diagnostic trouble
3 code (DTC). — Go to Applicable
Was the DTC displayed by the scan tool ? DTC Go to Step 4
1. Use the scan tool to display the air suspension
data.
4 2. Compare the displayed data and typical —
values. Inspect the part that
Go to "Failure had an abnormal
Was the displayed value near to the typical value ? symptom list" value

2. Check the battery voltage.
5 3. If a problem is discovered, recharge or repair 20V or more
the battery.
Was the problem detected ? Check the repair Go to Step 6

1. Check/inspect the following.
• Fuse
• Disconnection in AIR SUS ECU GND
circuit
6 • Disconnection in AIR SUS ECU power —
supply
2. If a problem is discovered, repair it.

1. Check/inspect the disconnection in the
communication circuit of the scan tool.
7 2. If a problem is discovered, repair it. —

Replace the AIR SUS ECU.
8 —
Have the solutions been completed ? Check the repair —

DTC Explanation of DTCs Reference

11 Height sensor error (rear right) DTC 11
12 Height sensor error (rear left) DTC 12
21 CPU error (ECU check sum error or read/write error) DTC 21
22 Vehicle model error (Wrong specification) DTC 22
23 EOL (End of Line) was not carried out on the ECU (data DTC 23
communications error)
25 Vehicle speed sensor system error DTC 25
32 Rear right side, solenoid valve error DTC 32
33 Rear left side, solenoid valve error DTC 33
36 Rear air supply and exhaust solenoid valve error DTC 36
51 Compressed air control time out error DTC 51
61 Air suspension relay circuit open (ECU internal circuit) DTC 61
62 Air suspension relay circuit short (ECU internal circuit) DTC 62
71 Air pressure sensor error (Rear right) DTC 71
72 Air pressure sensor error (Rear left) DTC 72
81 Air leakage (Rear right) DTC 81
82 Air leakage (Rear left) DTC 82

DTC 11
Height sensor error (rear right) Diagnostic Aids
• Height sensors are installed at the vehicle side. A connection failures, terminal end protrusions,
link extending from the rotating shaft is joined to inappropriate fittings, lock damages, inappropriate
the accelerator, and the link uses the up and down terminal shape or damage, and connection failures
movement by the changing vehicle height. in the terminals and wires.
Detects the pseudo-vehicle height based on the • Inspect for harness damage. If there are no
amount of the displacement angle of the abnormalities with the harness, shake the
suspension arm and vehicle. connectors and wires relating to height sensor
• The air suspension control unit (AIR SUS ECU) (rear right)" using the vibration method and check
determines the vehicle height position based on the condition of the "RR actual vehicle height (rear
the change of the sensors' signal voltages. right) using the scan tool.
• DTC11 is set when the AIR SUS ECU detects an If there is a change in the display, identify the
abnormality in the height sensor (rear right) signal problem by vibrating the part where the problem is
voltage. located.
The AIR SUS ECU sets DTC11 when the following When an abnormality occurs in the system, and the
conditions are established. DTC is stored in the AIR SUS ECU, DTC is not deleted
• The ignition switch is at the "ON" position. from the memory even if the defective part is repaired.
Use the following measures to execute a forced
• The height sensor signal voltage (rear right) is deletion from the memory.
max. 0.3 V or min. 4.7 V.
1. Delete the DTC using the scan tool "Clear DTC
• The conditions above are continued for a minimum Information."
of 0.3 seconds.
2. Over one second after the ignition switch is at
Action Taken when the DTC Sets "ON", keep the memory clear switch "ON"
(connector is inserted) continuously for a minimum
• Air suspension warning light: Blinking of 1 second. Thereafter, the DTC is deleted when
• Problem history: Retain the memory clear switch is turned "OFF"
• When there is one malfunctioning location on the (connector is disconnected).
height sensor, the vehicle height and vehicle Both 1 and 2 delete all of the current and past DTCs.
height target on the normal side is used to control,
as normal. Check of Repair
• If the left and right sensors are malfunctioning, After performing air suspensions repairs, it is
prohibit the magnetic valve control. However, only necessary to check that the repair was accurate after
air supply and exhaust are possible with the repairing the vehicle to prevent from making the same
remote controller. It will immediately return to repairs again. To check the DTC11 repairs, check the
prohibit the magnetic valve control when the following conditions.
remote controller is turned OFF. • The battery voltage is more than 20 volts.
• The ignition switch is at the "ON" position.

Was the air suspension control system checked ? Go to Air
1 — suspension control
Go to Step 2 system check
Check for current/past malfunction of that DTC.
2 —
Has DTC malfunctioned in the past ? Go to Step 3 Go to Step 4

1. Record history of past malfunctions.
2. Clear the DTC.
3. Run the vehicle to reproduce the problem
3 —
based on the history and the condition for
setting the DTC.
Go to Diagnostic
Was DTC 11 reproduced ? Go to Step 4 Aids
2. Mount the digital multi-meter (DMM) between
the AIR SUS ECU terminal A4 and GND from
the backside of the air suspension control unit
(AIR SUS ECU) connector.
4 4.7 V
4. Check the DMM display voltage value.
Was the displayed voltage above the standard

value ? Go to Step 6 Go to Step 5
At Step 4, was the displayed voltage value below Go to Diagnostic
5 0.3V
the standard value ? Go to Step 7 Aids
2. Disconnect the height sensor harness
connector.
6 3. Turn ON the ignition. 0.3V
Did the displayed vehicle height change to below

standard value ? Go to Step 8 Go to Step 7
connector.
3. Connect a jumper wire between the height
sensor connector (vehicle side) power supply
7 terminal and the signal terminal. 4.7 V

Inspect for disconnection of the height sensor GND
harness.
2. Disconnect the AIR SUS ECU harness
connector.
8 3. Measure the resistance value between the 2Ω
height sensor connector (vehicle side)
terminal 2 and the AIR SUS ECU connector
(vehicle side) terminal A22.
Was the resistance value below the standard value

? Go to Step 9 Go to Step 11
No problem in AIR SUS ECU or circuit
1. Inspect and repair deformation/adjustment
mis-positioning of the height sensor
9 installation site. —
2. If a problem is detected, repair it.


Replace the height sensor.
10 —
Repair the disconnection of the height sensor GND
11 harness. —
1. Inspect for disconnections/shorts in the height
sensor signal harness and power supply
harness.
12 —

1. Inspect for looseness, protrusion, lock
damage at the AIR SUS ECU connector
terminal.
13 —

14 —

DTC 12
Height sensor error (rear left) Diagnostic Aids
• Height sensors are installed at the vehicle side. A connection failures, terminal end protrusions,
link extending from the rotating shaft is joined to inappropriate fittings, lock damages, inappropriate
the accelerator, and the link uses the up and down terminal shape or damage, and connection failures
movement by the changing vehicle height. in the terminals and wires.
Detects the pseudo-vehicle height based on the • Inspect for harness damage. If there are no
amount of the displacement angle of the abnormalities with the harness, shake the
suspension arm and vehicle. connectors and wires relating to height sensor
• The air suspension control unit (AIR SUS ECU) (rear left) using the vibration method and check the
determines the vehicle height position based on condition of the "RL actual vehicle height (rear
the change of the sensors' signal voltages. left)" using the scan tool.
abnormality in the height sensor (rear left) signal problem by vibrating the part where the problem is
voltage. located.
The AIR SUS ECU sets DTC12 when the following When an abnormality occurs in the system, and the
conditions are established. DTC is stored in the AIR SUS ECU, DTC is not deleted
• The ignition switch is at the "ON" position. from the memory even if the defective part is repaired.
Use the following measures to execute a forced
• The height sensor signal voltage (rear left) is max. deletion from the memory.
0.3 V or min. 4.7 V.
• The conditions above are continued for a minimum Information."
of 0.3 seconds.
Action Taken when the DTC Sets "ON", keep the memory clear switch "ON"
• Air suspension warning light: Blinking of 1 second. Thereafter, the DTC is deleted when
• Problem history: Retain the memory clear switch is turned "OFF"
• When there is one malfunctioning location at the (connector is disconnected).
rear sensor, the vehicle height and vehicle height Both 1 and 2 delete all of the current and past DTCs.
target on the normal side is used to control, as
normal. Check of Repair
• If the left and right sensors are malfunctioning, After performing air suspensions repairs, it is
prohibit the magnetic valve control. However, only necessary to check that the repair was accurate after
air supply and exhaust are possible with the repairing the vehicle to prevent making the same
remote controller. It will immediately return to repairs again.
prohibit the magnetic valve control when the To check the DTC12 repairs, check the following
remote controller is turned OFF. conditions.

2 —

2. Clear the DTC.
3 —
setting the DTC.
Go to Diagnostic
Was DTC12 reproduced ? Go to Step 4 Aids
2. Mount the digital multi-meter (DMM) between
4 4.7 V

5 0.3V
connector.
Did the displayed voltage value change to below

connector.
3. Connect a jumper between the height sensor
connector at the vehicle side power supply
7 terminal and the signal. 4.7 V

Inspect for disconnection of the height sensor GND
harness.
connector.
8 3. Measure the resistance value between the 2Ω
height sensor connector (vehicle side)

1. Inspect and repair deformation/adjustment
mis-positioning of the height sensor
9 installation site. —


Replace the height sensor.
10 —
Repair the disconnection of the height sensor GND
11 harness. —
1. Inspect for disconnections/shorts in the height
sensor signal harness and power supply
harness.
12 —

terminal.
13 —

14 —

DTC 21
CPU error (ECU check sum error or read/write Action Taken when the DTC Sets
error) • Air suspension warning light: Blinking
• Problem history: Retain (if the writing process
Description cannot be performed, it will not be retained.)
An electronically erasable programming read-only • Prohibit control of the magnetic valve.
memory (EEPROM) is used in the air suspension • Prohibit all timeout diagnostics.
control unit (AIR SUS ECU) used on this vehicle.
DTC21 is set when an abnormality occurs in the Diagnostic Aids
EEPROM.
DTC21 will recur even if the defective part is replaced if Inspect for the following conditions:
the cause of the problem in the AIR SUS ECU is not • Inspect the harness connectors for AIR SUS ECU
solved. connection failures, terminal end protrusions,
Before replacing the AIR SUS ECU, it is necessary to inappropriate fittings, lock damages, inappropriate
inspect the B+ short / AIR SUS ECU ground. terminal shape or damage, and connection failures
in the terminals and wires.
Condition for Setting the DTC • Inspect for harness damage. If there are no
The AIR SUS ECU sets DTC21 when the following abnormalities with the harness, shake the
conditions are established. connectors and wires relating to B+ using the
• The battery voltage is more than 20 volts. vibration method and check the condition of
system voltage using the scan tool. If there is a
• The ignition switch is at the "ON" position. change in the display, identify the problem by
• Value written to the AIR SUS ECU and read value vibrating the part where the problem is located.
are different. • Check whether there is any water damage on the
• AIR SUS ECU internal ROM error AIR SUS ECU connector vehicle side, as a cause
of Battery short.

1. Clear the DTC.
2 based on the history and the condition for —
setting the DTC.
Go to Diagnostic
Check for multiple DTC.
1. Check whether other DTC were detected at
the same time as DTC21.
3 2. If another DTC was detected other than —
DTC21, repair of the other DTC should take
priority.

damage on the air suspension control unit
4 —

5 —

DTC 22
Vehicle model error (Wrong specification) • Vehicle model writing setting to AIR SUS ECU is
different.
Description
Action Taken when the DTC Sets
DTC22 is generated when written to a vehicle model
other than the one set for the air suspension control • Air suspension warning light: Blinking
unit (AIR SUS ECU). Repair of DTC22 is not possible in • Problem history: Retain (if the writing process
the market. cannot be performed, it will not be retained.)
• Prohibit control of the magnetic valve
• Vehicle height adjustments carried out by remote
The AIR SUS ECU sets the DTC22 when the following controller operating
conditions are established.
• The battery voltage is more than 20 volts. Diagnostic Aids
• The ignition switch is at the "ON" position. Inspect for the following conditions:
• Check the writing of the vehicle model.

1. Clear the DTC.
setting the DTC.
Go to Diagnostic
1. Check the writing of the vehicle model.
2. If a problem is detected, rewrite it.
3 (Manufacturer) —

Replace the air suspension control unit (AIR SUS
4 ECU). —

DTC 23
EOL (End of Line) was not carried out on the • The battery voltage is more than 20 volts.
ECU (data communications error) • The ignition switch is at the "ON" position.
• Vehicle model has never been written to the AIR
Description SUS ECU.
An electronically erasable programming read-only
memory (EEPROM) is used in the air suspension Action Taken when the DTC Sets
control unit (AIR SUS ECU) used on this vehicle. • Air suspension warning light: Blinking
DTC23 is generated when vehicle model writing has • Problem history: Retain (if the writing process
never been implemented to the AIR SUS ECU by the cannot be performed, it will not be retained.)
EOL.
Repair of DTC23 is not possible in the market. • Control with initial value of AIR SUS ECU.
Condition for Setting the DTC Diagnostic Aids
The AIR SUS ECU sets DTC23 when the following Inspect for the following conditions:
conditions are established. • Check the writing of the EOL.
(Check the EOL data with the scan tool.)

1. Clear the DTC.
setting the DTC.
Go to Diagnostic
1. Check for multiple DTCs.
2. If a problem is detected, write the vehicle
3 model. (Manufacturer) —

4 ECU). —

DTC 25
Vehicle speed sensor system error • Inspect the harness connectors for AIR SUS ECU
connection failures, terminal end protrusions,
Description inappropriate fittings, lock damages, inappropriate
terminal shape or damage, and connection failures
• The speed sensor control unit is used to detect
vehicle speed.
• Inspect for harness damage. If there are no
• The air suspension control unit (AIR SUS ECU)
abnormalities with the harness, shake the
determines vehicle speed based on pulse output
connectors and wires relating to vehicle speed/
signals from the speed sensor control unit or CAN
CAN using the vibration method and check the
signal from the ABS ECU, operates/cancels
vehicle speed and vehicle speed signal input
vehicle height control determines.
voltage using the scan tool.
• DTC25 is set when the AIR SUS ECU detects If there is a change in the display, identify the
following condition. problem by vibrating the part where the problem is
- The AIR SUS ECU detects an error in the located.
vehicle speed signal voltage from the speed • If commercial parts such as a horn, audio system
sensor control unit. or illumination are installed, idle the engine, turn all
- The AIR SUS ECU detects a normal in the commercial parts's switches ON, then check the
vehicle speed signal voltage from the speed vehicle speed and vehicle speed signal input
sensor control unit, no pulse signal and the voltage using the scan tool.
vehicle speed signal a minimum of 20 km/h Contact the user when there is a dramatic effect,
(12.4 MPH). such as a drop in voltage.
- The AIR SUS ECU detects an error in the
vehicle speed signal from the ABS ECU. Condition for Clearing the DTC
When an error occurs in the system, and the DTC is
Condition for Setting the DTC stored in the AIR SUS ECU, the DTC is not deleted
The AIR SUS ECU sets DTC 25 when any of the from the memory even if the malfunctioning part is
following conditions is established. repaired. Use the following measures to execute a
forced deletion from the memory.
• The vehicle speed sensor signal voltage is a
Information."
minimum of 19 V.
2. Over one second after the ignition switch is at ON,
• The vehicle speed sensor signal voltage is a
keep the memory clear switch ON (connector is
maximum of 0.3 V.
inserted) continuously for a minimum of 1 second.
• The vehicle speed sensor signal voltage is a Thereafter, the DTC is deleted when the memory
minimum 0.3 V or a maximum 19 V, no pulse clear switch is turned OFF (connector is
signal and the vehicle running speed is a minimum disconnected).
20 km/h (12.4 MPH) from the ABS ECU. Both 1 and 2 delete all of the current and past DTCs.
• CAN communication error.
• The above conditions last over 7.5 seconds. Check of Repair
After performing air suspensions repairs, it is
Action Taken when the DTC Sets necessary to check that the repair was accurate after
• Air suspension warning light: Blinking repairing the vehicle to prevent making the same
• Problem history: Retain repairs again.
To check the DTC25 repairs, check the following
• Implement control with vehicle speed a minimum conditions.
of 50 km/h (31.1 MPH).
• Prohibit control with remote controller.
• The ignition switch is at the "ON" position, with the
• While running, the start timing of the leveling engine OFF or the vehicle running speed is a
control will become the same as high speed minimum 20 km/h (12.4 MPH).
running
• The above conditions last over 7.5 seconds.
Diagnostic Aids

2 —
2. Clear the DTC.
setting the DTC.
Go to Diagnostic
Check whether the DTC relating to the vehicle
sensors on the engine control side or the wheel
speed sensors on the ABS control side has been
4 sets. — Go to Applicable
DTC in Section 1A
Has the engine control side DTC or the ABS control Engine Control
side DTC been detected ? System or 4C ABS Go to Step 5
connector.
3. Inspect whether there is a short with the
5 battery/GND between the AIR SUS ECU pin —
D1 and the speed sensor control unit.

2. Inspect whether there is a breakage with the
AIR SUS ECU pin D1 and the speed sensor
6 control unit. —

damage at the AIR SUS ECU terminal.
7 2. If a problem is detected, repair it. —


2. Disconnect the harness connector for the
following modules:
• Engine control module (ECM)
• Transmission control module (TCM) (if so
equipped)
• ABS control unit (ABS ECU)
• Body control module (BCM) (with multi
information display)
8 • Data recording module(DRM) (without —
multi information display)
• IP cluster
• Air suspension control unit (AIR SUS
ECU)
each component for a short to ground and
short to voltage.

2. Reconnect the ECM harness connector.
9 and a known good ground. 1.5 to 3.5 volts

Notice: If no smoother is installed, skip to Step 11.
2. Reconnect the TCM harness connector.
10 1.5 to 3.5 volts

2. Reconnect the ABS control unit harness
connector.
11 1.5 to 3.5 volts


2. Reconnect the BCM or DRM harness
connector.


2. Reconnect the IP cluster harness connector.

connections and for corrosion at the harness
connector of the ECM.
14 —

connector of the TCM.
15 —

connector of the ABS ECU.
16 —

connector of the BCM or DRM.
17 —

connector of the IP cluster.
18 —

connector of the AIR SUS ECU.
19 —


20 Replace the ECM. —

21 Replace the TCM. —

Important: Replacement ABS ECU must be
22 Replace the ABS ECU. —

programmed.
23 Replace the BCM or DRM. —

Replace the IP cluster.
24 —
25 —

5. Observe the DTC information with a scan tool.

27 Are there any DTCs that you have not diagnosed? — Go to DTC List System OK

DTC 32
Rear right side, solenoid valve error • Inspect for harness damage. If there are no
Description connectors and wires relating to rear right
magnetic valve using the vibration method and
• The magnetic valve is used in air pressure control.
check the "M/V Rr_R" using the scan tool.
• The air suspension control unit (AIR SUS ECU) If there is a change in the display, identify the
drives the magnetic valve according to conditions, problem by vibrating the part where the problem is
and adjust the vehicle height by controlling air located.
pressure.
• DTC32 is set when the AIR SUS ECU detects an Condition for Clearing the DTC
abnormality in the rear right magnetic valve circuit. When an abnormality occurs in the system, and the
DTC is stored in the AIR SUS ECU, the DTC is not
Condition for Setting the DTC deleted from the memory even if the defective part is
The AIR SUS ECU sets DTC32 when the following repaired. Use the following measures to execute a
conditions are established. forced deletion from the memory.
• The battery voltage is more than 20 volts. 1. Delete the DTC using the scan tool "Clear DTC
• The ignition switch is at the "ON" position. Information."
• Abnormal magnetic valve circuit 2. Over one second after the ignition switch is at ON,
keep the memory clear switch ON (connector is
Action Taken when the DTC Sets inserted) continuously for a minimum of 1 second.
Thereafter, the DTC is deleted when the memory
• Air suspension warning light: Blinking
clear switch is turned OFF (connector is
• Trouble diagnosis; Retain disconnected).
• Prohibit control of the rear right magnetic valve. Both 1 and 2 delete all of the current and past DTCs.
Level only the normal locations. Prohibit all timeout
diagnostics. Check of Repair
Diagnostic Aids necessary to check that the repair was accurate after
• Inspect the harness connectors for AIR SUS ECU repairing the vehicle to prevent from making the same
connection failures, terminal end protrusions, repairs again. To check the DTC32 repairs, check the
inappropriate fittings, lock damages, inappropriate following conditions.
terminal shape or damage, and connection failures • The battery voltage is more than 20 volts.

2 —
2. Clear the DTC.
3 —
setting the DTC.
Go to Diagnostic

connector.
3. Disconnect the magnetic valve harness
connector.
4. Check continuity of the harness between the
4 —
AIR SUS ECU connector (vehicle side)
terminal A6 and magnetic valve connector
(vehicle side) terminal 3.
5. If a problem (disconnection) is discovered,
repair it.

magnetic valve connector (vehicle side)
terminal 2 and body GND.
5 2. If a problem (disconnection/ short) is —
discovered, repair it.

1. Attach the magnetic valve harness connector.
2. Check resistance value between the AIR SUS
ECU connector (vehicle side) terminal A6 and
6 magnetic valve connector terminal 4. 75 - 85Ω
Was the resistance value in the range of specified

values ? Go to Step 9 Go to Step 7
1. Inspect for looseness of the magnetic valve
terminal, protrusion, lock damage, and
disconnection of the harness on the GND side
7 of the valve. —

Replace the magnetic valve.
8 —
terminal.
9 —

10 —

DTC 33
Rear left side, solenoid valve error • Inspect for harness damage. If there are no
Description connectors and wires relating to rear left magnetic
valve using the vibration method and check the "M/
• The magnetic valve is used in air pressure control.
V Rr_L " using the scan tool.
• The air suspension control unit (AIR SUS ECU) If there is a change in the display, identify the
drives the magnetic valve according to conditions, problem by vibrating the part where the problem is
and adjust the vehicle height by controlling air located.
pressure.
• DTC33 is set when the AIR SUS ECU detects an Condition for Clearing the DTC
abnormality in the rear left magnetic valve circuit. 1. Delete the DTC using the scan tool "Clear DTC
Information."
2. Over one second after the ignition switch is at ON,
The AIR SUS ECU sets DTC33 when the following keep the memory clear switch ON (connector is
conditions are established. inserted) continuously for a minimum of 1 second.
• The battery voltage is more than 20 volts. Thereafter, the DTC is deleted when the memory
• The ignition switch is at the "ON" position. clear switch is turned OFF (connector is
disconnected).
• Abnormal magnetic valve circuit
Both 1 and 2 delete all of the current and past DTCs.
Check of Repair
• Trouble diagnosis; Retain necessary to check that the repair was accurate after
• Prohibit control of the rear left magnetic valve. repairing the vehicle to prevent from making the same
Level only the normal locations. Prohibit all timeout repairs again. To check the DTC33 repairs, check the
diagnostics. following conditions.
Diagnostic Aids
• Inspect the harness connectors for AIR SUS ECU
inappropriate fittings, lock damages, inappropriate

2 —
2. Clear the DTC.
3 —
setting the DTC.
Go to Diagnostic

connector.
connector.
4 —
repair it.


6 magnetic valve connector terminal 4. 75 - 85Ω

7 of the valve. —

8 —
terminal.
9 —

10 —

DTC 36
Rear air supply and exhaust solenoid valve • Inspect for harness damage. If there are no
error abnormalities with the harness, shake the
connectors and wires relating to the air supply/
Description exhaust magnetic valve rear master using the
vibration method and check the "M/V Master Rr"
• The magnetic valve is used in air pressure control. using the scan tool. If there is a change in the
• The air suspension control unit (AIR SUS ECU) display, identify the problem by vibrating the part
drives the magnetic valve according to conditions, where the problem is located.
and adjust the vehicle height by controlling air
pressure. Condition for Clearing the DTC
• DTC36 is set when the AIR SUS ECU detects an When an abnormality occurs in the system, and the
abnormality in the rear master magnetic valve DTC is stored in the AIR SUS ECU, the DTC is not
circuit. deleted from the memory even if the defective part is
repaired.
The AIR SUS ECU sets DTC36 when the following Information."
conditions are established. 2. Over one second after the ignition switch is at ON,
• The battery voltage is more than 20 volts. keep the memory clear switch ON (connector is
• The ignition switch is at the "ON" position. inserted) continuously for a minimum of 1 second.
• Abnormal magnetic valve circuit Thereafter, the DTC is deleted when the memory
clear switch is turned OFF (connector is
Action Taken when the DTC Sets disconnected).
• Trouble diagnosis; Retain Check of Repair
• Prohibit control of the rear master magnetic valve After performing air suspensions repairs, it is
and air leak diagnosis. necessary to check that the repair was accurate after
repairing the vehicle to prevent from making the same
Diagnostic Aids repairs again. To check the DTC36 repairs, check the
Inspect for the following conditions: following conditions.
• Inspect the harness connectors for AIR SUS ECU • The battery voltage is more than 20 volts.
connection failures, terminal end protrusions, • The ignition switch is at the "ON" position.

2 —
2. Clear the DTC.
setting the DTC.
Go to Diagnostic

connector.
connector.
4 —
repair it.


6 valve connector terminal 4. 75 - 85Ω

7 of the valve. —

8 —
terminal.
9 —

10 —

DTC 51
Compressed air control time out error • Inspect for pipe damage. If abnormalities cannot
be visually located, shake the part related to the air
Description hose by vibrating it, and check the condition of the
air pressure and magnetic valve operations using
the scan tool. If there is a change in the display,
determines the air pressure based on the change
identify the problem by vibrating the part where the
of the sensors' signal voltages.
problem is located.
• DTC51 is set when the AIR SUS ECU detects an
• Inspect for improper fittings. If you cannot visually
abnormality in the magnetic valve continuous
find the abnormality, apply air gas leak inspection
operating time.
spray (1-8844-7465-0), a spray type soap water, or
apply diluted soap water to the part related to the
air hose to identify the problem by finding bubbles.
• The ignition switch is ON. Condition for Clearing the DTC
• When the following conditions are established and When an abnormality occurs in the system, and the
continue for five minutes. DTC is stored in the AIR SUS ECU, the DTC is not
- The diagnosis port check has been deleted from the memory even if the defective part is
implemented. repaired. Use the following measures to execute a
forced deletion from the memory.
- The remote controller is not operating.
- Left and right air pressure values are less than
Information."
490kPa (5.0 kg/cm2 / 71psi).
- One of the rear magnetic valve is turned ON.
"ON", keep the memory clear switch "ON"
of 1 second. Thereafter, the DTC is deleted when
• Air suspension warning light: Blinking the memory clear switch is turned "OFF"
• Failure history; Don't retain (connector is disconnected).
• Prohibit magnetic valve drive. Both 1 and 2 delete all of the current and past DTCs.
Diagnostic Aids Check of Repair

Inspect for the following conditions: After performing air suspensions repairs, it is
necessary to check that the repair was accurate after
repairing the vehicle to prevent from making the same
repairs again. To check the DTC51 repairs, check the
following conditions.
in the terminals and wires. • The battery voltage is more than 20 volts.
• Inspect for harness damage. If there are no • The ignition switch is ON.
abnormalities with the harness, shake the • When the following conditions are established and
connectors and wires relating to air pressure continue for five minutes.
sensor using the vibration method and check the - The diagnosis port check has been
air pressure using the scan tool. If there is a implemented.
change in the display, identify the problem by - The remote controller is not operating.
vibrating the part where the problem is located.
- Left and right air pressure values are less than
Inspect for the following conditions: 490kPa (5.0 kg/cm2 / 71psi).
• Inspect the pipe and air springs for improper air - One of the rear magnetic valve is turned ON.
hose connections, bent attachments, inappropriate
fittings, pipe damages, inappropriate pipe shapes
or crushed pipes, and improper connections of the
magnetic valve and pipe.


1. Clear the DTC.
setting the DTC.
Go to Diagnostic
1. Check the DTC setting other than DTC51.
2. When DTCs relating to the magnetic valve
and air leaks are set at the same time, repair
3 giving priority to the DTC diagnostic charts of —
the magnetic valve or the air leak. Go to applicable
DTC diagnostic
Was a DTC other than DTC51 set ? chart Go to Step 4
1. Inspect for air leaks from the rear side air
hose, connections and air spring.
2. If you cannot find the problem, apply a thin
layer of soap water to the air hose,
4 connections and air spring to find the problem —
where bubbles are formed.
3. Find the problem and repair it.
Go to Diagnostic
Was the problem detected ? Check the repair Aids

DTC 61
Air suspension relay circuit open (ECU Diagnostic Aids
internal circuit) Inspect for the following conditions:
Description connection failures, terminal end protrusions,
• The air suspension internal self-holding circuit inappropriate fittings, lock damages, inappropriate
drives when the air suspension control unit (AIR terminal shape or damage, and connection failures
SUS ECU) detects the ignition switch is "ON" to in the terminals and wires.
control the power supply at the AIR SUS ECU. • Inspect for harness damage. If there are no
• The AIR SUS ECU drives the air suspension abnormalities with the harness, shake the
internal self-holding circuit based on the ignition connectors and wires relating to the air suspension
switch signal to ensure the power circuit (B+). The self-holding circuit using the vibration method and
power supply is used to supply +5 V sensor power check the condition of system communications
and microcontroller power. using the scan tool.
error (power disconnection) in system power. problem by vibrating the part where the problem is
located.
The AIR SUS ECU sets DTC61 when the following
conditions are established. When an abnormality occurs in the system, and the
deleted from the memory even if the defective part is
• The input voltage from the air suspension internal repaired. Use the following measures to execute a
self-holding circuit is a maximum of 20 V. forced deletion from the memory.
• The above condition continues for more than 0.3 1. Delete the DTC using the scan tool "Clear DTC
seconds. Information."
"ON", keep the memory clear switch "ON"
• Air suspension warning light: Blinking (connector is inserted) continuously for a minimum
• Prohibit magnetic valve drive of 1 second. Thereafter, the DTC is deleted when
• Prohibit all timeout diagnostics the memory clear switch is turned "OFF"
(connector is disconnected).

Go to Step2 system check
2 —
2. Clear the DTC.
3. Reproduce the failure based on the history
and the condition for setting the DTC.
3 —
4. If a DTC other than the DTC61 was set in the
past, re-inspect the diagnosis procedures for
that DTC.
Go to Diagnostic
4 ECU). —

DTC 62
Air suspension relay circuit short (ECU • With the ignition switch in the "ON" position again,
internal circuit) make the air suspension warning light blink
simultaneously to performing normal operations.
Description
Diagnostic Aids
• The air suspension internal self-holding circuit
drives when the air suspension control unit (AIR Inspect for the following conditions:
SUS ECU) detects the ignition switch is "ON" to • Inspect the harness connectors for AIR SUS ECU
supply power in the AIR SUS ECU. connection failures, terminal end protrusions,
• The AIR SUS ECU drives the air suspension inappropriate fittings, lock damages, inappropriate
internal self-holding circuit based on the ignition terminal shape or damage, and connection failures
switch signal to ensure the power circuit (B+). The in the terminals and wires.
power supply is used to supply +5 V sensor power • Inspect for harness damage. If there are no
and microcontroller power. abnormalities with the harness, shake the
• DTC62 is set when the AIR SUS ECU detects an connectors and wires relating to the air suspension
error (short) in system power. self-holding circuit using the vibration method and
check the condition of system communications
Condition for Setting the DTC using the scan tool. If there is a change in the
display, identify the problem by vibrating the part
The AIR SUS ECU sets DTC62 when the following where the problem is located.
conditions are established.
• The air suspension internal self-holding circuit is Condition for Clearing the DTC
OFF for two seconds.
When an abnormality occurs in the system, and the
• The input voltage from the air suspension internal DTC is stored in the AIR SUS ECU, the DTC is not
self-holding circuit is a minimum of 20 V. deleted from the memory even if the defective part is
• The above condition continues for more than 0.3 repaired. Use the following measures to execute a
seconds. forced deletion from the memory.
Action Taken when the DTC Sets Information."
• Air suspension warning light: Blinking after the 2. Over one second after the ignition switch is at
ignition switch is turned "ON" again "ON", keep the memory clear switch "ON"
• Problem history: Retain (connector is inserted) continuously for a minimum
• Prohibit the magnetic valve, warning lights and of 1 second. Thereafter, the DTC is deleted when
buzzer while the ignition switch is "OFF". the memory clear switch is turned "OFF"

2 —
2. Clear the DTC.
3. Reproduce the failure based on the history
and the condition for setting the DTC.
3 —
4. If a DTC other than the DTC62 was set in the
past, re-inspect the diagnosis procedures for
that DTC.
Go to Diagnostic
4 ECU). —

DTC 71
Air pressure sensor error (Rear right) • Inspect for harness damage. If there are no
Description connectors and wires relating to air pressure
sensor (rear right) using the vibration method and
check the "RR Air Pressure" using the scan tool.
If there is a change in the display, identify the
problem by vibrating the part where the problem is
• DTC71 is set when the AIR SUS ECU detects an located.
abnormality in the air pressure sensor (rear right)
signal voltage. Condition for Clearing the DTC
Condition for Setting the DTC When an abnormality occurs in the system, and the
The AIR SUS ECU sets DTC71 when the following deleted from the memory even if the defective part is
conditions are established. repaired. Use the following measures to execute a
• The ignition switch is at the "ON" position. forced deletion from the memory.
• The air pressure sensor signal voltage (rear right) 1. Delete the DTC using the scan tool "Clear DTC
is abnormally high or low. Information."
• The conditions above are continued for a minimum 2. Over one second after the ignition switch is at
of 30 seconds. "ON", keep the memory clear switch "ON"
Action Taken when the DTC Sets of 1 second. Thereafter, the DTC is deleted when
• Problem history: Retain
• Intermittent failure condition;
Prohibit control of all magnetic valves. Check of Repair
Prohibit timeout diagnostics.
• Problem current condition; necessary to check that the repair was accurate after
Prohibit control of the lowest pressure retention of repairing the vehicle to prevent from making the same
the location where the failure occurred repairs again. To check the DTC71 repairs, check the
following conditions.
Diagnostic Aids

2 —
2. Clear the DTC.
3 —
setting the DTC.
Go to Diagnostic

2. Install the digital multi-meter (DMM) between
4 4.6V

5 0.1V
2. Disconnect the air pressure sensor harness
connector.
Did the displayed voltage value change to below

2. Disconnect the air pressure sensor harness
connector.
3. Connect a jumper wire between the terminals
1 and 2 of the air pressure sensor connector
7 (vehicle side). 4.6V

Inspect for disconnections of the air pressure
sensor GND harness.
connector.
8 3. Measure the resistance value between the air 2Ω
pressure sensor connector (vehicle side)

1. Inspect and repair deformation of the air
9 pressure sensor mounting site. —

Replace the air pressure sensor.
10 —
Repair the disconnection of the air pressure sensor
11 GND harness. —

1. Inspect for disconnections/shorts in the air
pressure sensor signal harness and power
supply harness.
12 —

terminal.
13 —

14 —

DTC 72
Air pressure sensor error (Rear left) • Inspect for harness damage. If there are no
Description connectors and wires relating to air pressure
sensor (rear left) using the vibration method and
check the "RL Air Pressure" using the scan tool.
If there is a change in the display, identify the
problem by vibrating the part where the problem is
• DTC72 is set when the AIR SUS ECU detects an located.
abnormality in the air pressure sensor (rear left)
signal voltage. Condition for Clearing the DTC
Condition for Setting the DTC When an abnormality occurs in the system, and the
The AIR SUS ECU sets DTC72 when the following deleted from the memory even if the defective part is
conditions are established. repaired. Use the following measures to execute a
• The ignition switch is at the "ON" position. forced deletion from the memory.
• The air pressure sensor signal voltage (rear right) 1. Delete the DTC using the scan tool "Clear DTC
is abnormally high or low. Information."
• The conditions above are continued for a minimum 2. Over one second after the ignition switch is at
of 30 seconds. "ON", keep the memory clear switch "ON"
Action Taken when the DTC Sets of 1 second. Thereafter, the DTC is deleted when
• Problem history: Retain
• Intermittent Failure Condition;
Prohibit control of all magnetic valves. Check of Repair
Prohibit timeout diagnostics.
• Problem current condition; necessary to check that the repair was accurate after
Prohibit control of the lowest pressure retention of repairing the vehicle to prevent from making the same
the location where the failure occurred repairs again.
To check the DTC72 repairs, check the following
Diagnostic Aids conditions.
Inspect for the following conditions: • The battery voltage is more than 20 volts.
• Inspect the harness connectors for AIR SUS ECU • The ignition switch is at the "ON" position.


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2011MY

WORKSHOP MANUAL GENERAL INFORMATION

General Information 0A-1

0A-2 General Information

General Information 0A-3

Service Parts ID Plate

0A-4 General Information

Option DNB O/S rear view mirror - pillar mounted

B1T Parking brake drum - 10 inch E2N Fuel pipe - steel

B13 Australia equipment E29 Auxiliary steps

B84 Body side molding F59 Front stabilizer

CE4 Head lamp washer GL6 Rear shock absorber

C13 Wiper with intermittent GN1 Rear stabilizer

C2C Transmission oil cooler G86 Limited slip differential - no spin

C3N Final differential lock JBZ Lighting system - Japanese standard

C41 Heater & defroster J91 Trailer brake control

C5T Propeller shaft - P90 type KG2 Generator 24V60A

C60 Manual air conditioning K30 Auto cruise

Manual air conditioning K44 Generator 24V-90A

General Information 0A-5

0A-6 General Information

General Information 0A-7

0A-8 General Information

General Information 0A-9

0A-10 General Information

Vehicle Identification Number (VIN)

1. World manufacturer identifier (WMI) 2. Vehicle model code

General Information 0A-11

4. Wheel base code

5. Model year code

0A-12 General Information

General Information 0A-13

0A-14 General Information

Garage Jack and Safety Stand

Lifting Point Positions - Front side

General Information 0A-15

FRR/FSR models (with air suspension)

FVR model (with air suspension)

0A-16 General Information

General Information 0A-17

Caution for The Maintenance of Electrical Parts

Regarding vehicle washing

0A-18 General Information

HCW90ASH000201 Connector circuit inspection requirements

General Information 0A-19

Inspection requirements for waterproof connector

Connecting connector terminals

0A-20 General Information

General Information 0A-21

3. When wiring the harness by diverting it around

0A-22 General Information

Regarding The Scan Tool

General Information 0A-23

0A-24 General Information

Parts of the Tech 2

1. Soft keys displayed on the screen.

General Information 0A-25

Parts of the Tech 2 24 V adaptor 2

1. Signal change switch • “3” : —

0A-26 General Information

1. Tech 2 connecting cable

7. Turn the ignition "ON", and press the "PWR" key of

General Information 0A-27

Recommended Liquid Gasket

F&G Series EURO 5

F&G Series EURO 5