4M50 Fuso_230710_130613

INDEX
EQUIPMENT TYPE CODES LIST ...................................................... 00-2
POWER TRAIN LIST ...................................... ................................. 00-3
HOW TO READ THIS MANUAL ........................................................ 00-4
CHASSIS NUMBER, ENGINE NUMBER,

POWER TRAIN LABEL ................................................................... 00-10
VEHICLE IDENTIFICATION NUMBER ........................................... 00-11
PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12
JACKING UP THE VEHICLE .......................................................... 00-24
DIAGNOSIS CODES
1. Connecting Multi-Use Tester ..................................................... 00-26
2. Accessing / Erasing Diagnosis Codes
<Common Rail, Exhaust Gas Recirculation, Pre-heater> ........... 00-30
<Automatic Transmission> ................................................... 00-32
<Anti-lock Brake System> ................................................... 00-34
TABLE OF STANDARD TIGHTENING TORQUES.......................... 00-36
00-1
EQUIPMENT TYPE CODES LIST
Component Name plate marking Code description
Engine
4M50-T 4 M 5 0 T
Turbocharged
Order of development within same series
Order of development among different series
Diesel engine
No. of cylinders (4)
Clutch
C5W33 C 5 W 33
Disc OD
Facing material (W: Woven)
Load carrying capacity of truck class (tonnage)
on which the clutch is primarily used
Initial letter of the clutch
Transmission
M036S5W M 036 S 5 W
Variation (W: With directly-mounted transfer)

Forward speeds
Type of mesh (S: Synchromesh)
Initial letter of the transmission
Propeller shaft
P3 P 3

Initial letter of the propeller shaft
Front axle
F200T F 200 T
Vehicle type (T: Truck)

Initial letter of the front axle
Rear axle
R033T R 03 3 T
Vehicle type (T: Truck)

Initial letter of the rear axle
Reduction and differential
D033H D 03 3 H
Tooth profile (H: Hypoid gear)

Initial letter of the reduction & differential
00-2
POWER TRAIN TABLE 00
Reduction &
Vehicle model Engine Clutch Transmission Propeller shaft Rear axle
differential
FE83DDZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
FE83DEZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
FE83DGZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
Torque
FE83DDZSLSUB 4M50-T8 M036A6 P3 R033T D033H
converter
Torque
FE83DEZSLSUB 4M50-T8 M036A6 P3 R033T D033H
converter
Torque
FE83DGZSLSUB 4M50-T8 M036A6 P3 R033T D033H
converter
FE84DDZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
FE84DEZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
FE84DGZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
FE84DHZSLSUA 4M50-T7 C5W33 M036S5 P3 R033T D033H
Torque
converter
Torque
converter
Torque
converter
Torque
FE84DHZSLSUB 4M50-T8 M036A6 P3 R033T D033H
converter
Torque
FE84DHWSLSUB 4M50-T8 M036A6 P3 R033T D033H
converter
FE85DDZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H
FE85DEZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H
FE85DGZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H
FE85DHZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H
FE85DJZSLSUC 4M50-T8 C5W33 M036S6 P3 R035T D035H
Torque
converter
Torque
converter
Torque
converter
Torque
FE85DHZSLSUB 4M50-T8 M036A6 P3 R035T D035H
converter
Torque
FE85DJZSLSUB 4M50-T8 M036A6 P3 R035T D035H
converter
Front: P2 Front: D1H
FG84DC6SLSUA 4M50-T7 C5W33 M036S5W R033T
Rear: P3 Rear: D033H
Front: P2 Front: D1H
FG84DE6SLSUA 4M50-T7 C5W33 M036S5W R033T
Rear: P3 Rear: D033H
00-3
HOW TO READ THIS MANUAL
This manual consists of the following parts:
Specifications
Structure and Operation
Troubleshooting
On-vehicle Inspection and Adjustment
Service procedures
On-vehicle Inspection and Adjustment

Procedures for inspection and adjustment of individual parts and assemblies as mounted on the vehicle are de-
scribed including specific items to check and adjust. Specified or otherwise, inspection should be performed for
looseness, play, backlash, crack, damage, etc.
Service procedure
Procedures for servicing components and parts off the vehicle are described centering on key points in their re-
moval, installation, disassembly, reassembly, inspection, etc.
Inspection
Check items subject to acceptance or otherwise on the basis of service standards are all given.
Some routine visual checks and cleaning of some reused parts are not described but must be always included in
actual service work.
Caution
This service manual contains important cautionary instructions and supplementary information under the following
four headings which identify the nature of the instructions and information:
DANGER Precautions that should be taken in handing potentially dangerous substances such
as battery fluid and coolant additives.
WARNING Precautionary instructions, which, if not observed, could result in serious injury or
death.
CAUTION Precautionary instructions, which, if not observed, could result in damage to or de-
struction of equipment or parts.
Suggestions or supplementary information for more efficient use of equipment or a

NOTE better understandings.
Terms and Units

Front and rear
The forward running direction of the vehicle is the front and the reversing direction is the rear.
Left and right

Left hand side and right hand side, when facing the forward running direction of the vehicle, are respectively left and
right.
Standard value
Standard value dimensions in designs indicating: the design dimensions of individual parts, the standard clearance
between two parts when assembled, and the standard value for an assembly part, as the case may be.
Limit
When the value of a part exceeds this, it is no longer serviceable in respect of performance and strength and must
be replaced or repaired.
00-4
00
Tightening torque
Values are directly specified for out-of-standard tightening torques for bolts and nuts.
Where there is no specified figure for tightening torque, follow the table covering standard tightening torques.
(Values for standard tightening torques are based on thread size and material.)
When the item is to be tightened in a wet state, wet is indicated. Where there is no indication, read it as dry.
Units
Tightening torques and other parameters are given in SI* units with imperial unit and metric units added in brackets
{ }.
*SI: Le Syst me International d Unit s
Example: 390 N m {290 ft.lbs, 40 kgf m}
Metric unit
Imperial unit
SI unit
Unit SI unit {imperial unit, metric unit} Conversion factor

Force N {lbs, kgf} 9.80665 N {2.2046 lbs, 1 kgf}
Moment of force N m {ft.lbs, kgf m} 9.80665 N m {7.2329 ft.lbs, 1 kgf m}
Positive pressure kPa {psi, kgf/cm2} 98.0665 kPa {14.22 psi, 1 kgf/cm2}
Pressure
Vacuum pressure kPa {in.Hg, mmHg} 0.133322 kPa {0.03937 in.Hg, 1 mmHg}
Volume J {BTU, kcal} 4186.05 J {3.96825BTU, 1 kcal}
Heat quantity W {BTU/h, kcal/h} 1.16279W {3.96825BTU/h, 1 kcal/h}
Example: 30 mm {1.18 in.}
Imperial unit
SI unit
Unit SI unit {imperial unit} Conversion factor

mm {in.} 1 mm {0.03937 in.}
Length m {ft.} 1 m {3.2808 ft.}
km {mile} 1 km {0.6214 mile}
kg {lb} 1 kg {2.2046 lb}
Mass
g {oz} 1 g {0.035274 oz}
Temperature
C { F} 1 C {(1 C 1.8 + 32) F}
(in degree Celsius)
km/h {mph} 1 km/h {0.6214 mph}
Velocity
m/s {ft/s} 1 m/s {3.281 ft/s}
L {qts}, L {gal} 1 L {1.05336 qts}, 1 L {0.2642 gal}
Volume
cm3 {cu.in.} 1 cm3 {0.061023 cu.in.}
2 {in2}, m2 {ft2} 1 m2 {1.550 103 in2}, 1 m2 {1.076 10 ft2}
Area m
00-5
Symbol Denotation Application Remarks
Specified values shown in table
Parts not tightened to standard torques
See Table of Standard Tightening Torques for
Tightening torque (standard torques specified where neces-
parts for which no tightening torques are speci-
sary for servicing)
fied.
Locating pin Parts to be positioned for installation
Non-reusable parts Parts not to be reused
Lubricant and/or Parts to be coated with lubricant or sealant Necessary lubricant and/or sealant, quantity re-
sealant for assembly or installation quired, etc. are specified in table.
Parts for which special tools are required for Tool name/shape and part number are shown in
Special tool
service operation table.
Parts associated with those removed/disas-
*a Associated part
sembled for servicing
00-6
00
00-7
How to Use Diagnosis Codes <Electronic Control System (Gr13E, Gr17, Gr23, Gr35E, Gr54)>
TROUBLESHOOTING
1. INSPECTION PROCEDURE
2. CAUTIONS TO OBSERVE WHEN
PERFORMING INSPECTIONS
This section suggests areas to 3. INSPECTIONS DIAGNOSIS BASED ON
inspect for each diagnosis code. DIAGNOSIS CODES
4. MULTI-USE TESTER SERVICE DATA
5. ACTUATOR TESTS PERFORMED USING
MULTI-USE TESTER
6. INSPECTIONS PERFORMED AT
ELECTRONIC CONTROL UNIT CONNECTORS
7. INSPECTION OF ELECTRICAL EQUIPMENT
8. INSTALLED LOCATIONS OF PARTS
9. ELECTRIC CIRCUIT DIAGRAM
They are the diagnosis code and message displayed on Multi-Use Tester. The figure
in the brackets indicates the number of warning lamp flashes, which is the diagnosis
code (this is only applicable to system compatible with Multi-Use Tester-III).
P1463: Exhaust Brake M/V1 (Warning lamp flashes: 93)

Exhaust Brake 3-Way magnetic valve (output side) power-supply circuit
Code generation criteria
shorted out
Resettability Normal signal with starter switch in the ON position
Electronic Control Unit control Auxiliary brake control disabled
Service data 87: Exhaust Brake M/V1
Actuator test AC: Auxiliary Brake M/V1
In-
spec- Electronic control unit
17 : Exhaust Brake 3-Way magnetic valve
tion connector
item
Electrical part #565: Exhaust Brake 3-Way magnetic valve
Wiring diagram Exhaust Brake 3-Way magnetic valve circuit
Refer to Inspection of Electrical

Components.
Refer to Wiring Diagrams.
00-8
00
M E M O
00-9
CHASSIS NUMBER, ENGINE NUMBER, POWER TRAIN LABEL
Chassis and engine numbers are allocated to each vehicle and engine respectively in the order of production.
These numbers are required at vehicle inspection for registration.
Power train label located in the position illustrated indicates the

vehicle model, chassis number and information relevant to the
vehicle s power - train components.
00-10
VEHICLE IDENTIFICATION NUMBER 00
The vehicle identification number is punch-marked on the plate,
which is attached in the position as illustrated.
The vehicle identification number consists of a 17-digit set of al-
phanumeric characters. Each digit represents the following
specifications.
J L 6 A A D 1 S 5 K
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12)
(1) Country J: Japan

(2) Make L: Mitsubishi Fuso
(3) Type 6: Incomplete vehicle
(4) Gross vehicle weight / Brake system
A: 10,001 to 14,000 lbs. / Hydraulic
B: 14,001 to 16,000 lbs. / Hydraulic
C: 16,001 to 19,500 lbs. / Hydraulic
(5) Line A: FE83D
B: FE84D
C: FE85D
(6) Series (Wheel base) D: 2.9 to 3.19 m (9.51 to 10.46 ft.)
E: 3.2 to 3.49 m (10.49 to 11.44 ft.)
(7) Cab chassis type 1: Chassis cab
(8) Engine S: 4.899 L Diesel turbo charged and charge air cooled
(9) Check digit
(10) Model year 5: 2005
(11) Plant K: Kawasaki
(12) Plant sequential number
00-11
PRECAUTIONS FOR MAINTENANCE OPERATION
DANGER
This product contains or emits chemicals known to the State of California to cause cancer and birth de-
fects or other reproductive harm.
Before performing service operations, inquire into the customer s complaints and ascertain the condition by
checking the total distance traveled, the conditions under which the vehicle is operated, and other relevant factors
on the vehicle. And note the necessary information. This information will help you to service the vehicle efficiently.
Check the location of the fault, and identify its cause. Based on your findings, determine whether parts must be re-
moved or disassembled. Then, follow the service procedure given in this manual.
Perform service operations on a level surface. Before starting,

take the following preparatory steps:
To prevent soiling and damage, place covers over the seats,
trim and floor in the cab and over the paintwork of the body.
Prepare all the general and special tools necessary for the job.
WARNING
Special tools must be used wherever specified in this man-
ual. Do not attempt to use other tools since they could
cause injuries and/or vehicle damage.
After manually tilting the cab, be sure to engage the stopper with
the lock lever to secure the cab stay in a rigid state.
Take extreme care when removing/installing heavy items such

as engine, transmission and axle. When lifting heavy items using
a cable etc., observe the following precautions.
Identify the mass of the item being lifted. Use the cable that is
strong enough to support the mass.
00-12
00
If lifting eyes are not provided on the item being lifted, tie a ca-
ble around the item taking into account the item s center of
gravity.
Do not allow anyone to pass or stay under a lifted item which

may possibly fall.
Inspect for oil leakage etc. before washing the vehicle. If the or-
der is reversed, any oil leakage or fault that may exist could go
unnoticed during inspection.
00-13
Prepare replacement parts ready for installation.
Oil seals, packings, O-rings and other rubber parts, gaskets, and
split pins must be replaced with new ones after removal. Use
only genuine MITSUBISHI replacement parts.
When disassembling parts, visually check them for wear, cracks,

damage, deformation, deterioration, rust, corrosion, defective ro-
tation, fatigue, clogging and any other possible defect.
To facilitate correct reassembly of parts, make alignment marks

on them before disassembly and arrange disassembled parts
neatly. Make punch marks and other alignment marks where
they will not detract from parts functionality and appearance.
After removing parts from the vehicle, cover the area to keep it
free of dust.
CAUTION
Be careful not to mix up identical parts, similar parts and
parts that have left/right alignments.
Keep new replacement parts and original (removed) parts
separately.
Apply the specified oil or grease to U-seals, oil seals, dust seals
and bearings before reassembly.
Always use the specified oils and greases when performing in-
spection or replacement. Immediately wipe away any excess oil
or grease with a rag.
00-14
00
Wear safety goggles when using a grinder or welder. Wear
gloves when necessary, and watch out for sharp edges and oth-
er items that might wound your hands.
Before working on the electrical system, disconnect the battery

( ) terminal to prevent short circuits.
CAUTION
Make sure the starter switch and lighting switches are OFF
before disconnecting or connecting battery terminals.
Semiconductor components may otherwise be damaged.
Carefully handle sensors relays, and other items that are sensi-
tive to shock and heat. Do not remove or paint the cover of any
control unit.
When separating connectors, grasp the connectors themselves

rather than the harnesses.
To separate locking connectors, first push them in the direction
of the arrows. To reconnect locking connectors, push them to-
gether until they click.
Before washing the vehicle, cover electrical parts to keep them

dry. (Use plastic sheets or the like.) Keep water away from har-
ness connectors and sensors and immediately wipe off any wa-
ter that gets on them.
00-15
When applying a voltage to a part for inspection purposes,
check that the (+) and ( ) cables are connected properly then
gradually increase the voltage from zero. Do not exceed the
specified voltage.
Remember that control units and sensors do not necessarily op-
erate on the battery voltage.
1. Handling Precautions for Electric Circuits

CAUTION
Do not pierce wire insulation with test probes or alligator
clips when performing electrical inspections. Doing so can,
particularly with the chassis harness, hasten corrosion.
1.1 Inspection of harnesses

(1) Inspections with connectors fitted together
(1.1) Waterproof connectors
Connect an inspection harness and connector A between the
connectors B of the circuit to be inspected. Perform the inspec-
tion by applying a test probe C to the connectors of the inspec-
tion harness. Do not insert the test probe C into the wire-entry
sides of the waterproof connectors since this would damage
their waterproof seals and lead to rust.
(1.2) Non-waterproof connectors

Perform the inspection by inserting a test probe C into the wire-
entry sides of the connectors. An extra-narrow probe is required
for control unit connectors, which are smaller than other types of
connector. Do not force a regular-size probe into control unit
connectors since this would cause damage.
00-16
00
(2) Inspections with connectors separated
(2.1) Inspections on female terminals
Perform the inspection by carefully inserting a test probe into the
terminals. Do not force the test probe into the terminals since
this could deform them and cause poor connections.
(2.2) Inspections on male terminals

Perform the inspection by applying test probes directly to the
pins.
CAUTION
.
Be careful not to short-circuit pins together with the test

probes. With control unit connectors, short-circuiting of
pins can cause damage to the control unit s internal circuit-
ry.
When using a multimeter to check continuity, do not allow the

test probes to touch the wrong terminals.
1.2 Inspection of connectors

(1) Visual inspection
Check that the connectors are fitted together securely.
Check whether wires have been separated from their terminals

due to pulling of the harness.
00-17
Check that male and female terminals fit together tightly.
Check for defective connections caused by loose terminals, by

rust on terminals, or by contamination of terminals by foreign
substances.
(2) Checking for loose terminals

If connector terminal retainers become damaged, male and fe-
male terminals may not mate with each other when the connec-
tor bodies are fitted together. To check for such terminals, gently
pull each wire and see whether any terminals slip out of their
connector housings.
1.3 Inspections when a fuse blows

Remove the fuse, then measure the resistance between ground
and the fuse s load side.
Next, close the switch of each circuit connected to the fuse. If
the resistance measurement between any switch and ground is
zero, there is a short circuit between the switch and the load. If
the resistance measurement is not zero, the circuit is not cur-
rently short-circuited; the fuse probably blew due to a momen-
tary short circuit.
The main causes of short circuits are as follows:

Harnesses trapped between chassis parts
Harness insulation damage due to friction or heat
Moisture in connectors or circuitry
Human error (accidental short-circuiting of components)
00-18
00
1.4 Inspection of chassis ground
A special ground bolt is used to tighten a ground terminal. When
servicing the ground point, be sure to follow the procedures de-
scribed below:
When reinstalling the ground bolt
Tighten the ground bolt to the specified torque.
When relocating the ground point
A special ground bolt must be used. Spot-weld a nut to a
frame and tighten the ground bolt to the specified torque. Be
sure to apply touch-up paint to the welded point.
2. Service Precautions for Alternators

When servicing alternators, observe the following precautions:
Never reverse the polarity of battery connections.
If the polarity of the battery connections was reversed, a large
current would flow from the battery to the alternator, damag-
ing the diodes and regulator.
Never disconnect the battery terminals with the engine running.

Disconnection of the battery terminals during engine operation
would cause a surge voltage, leading to deterioration of the di-
odes and regulator.
Never perform inspections using a high-voltage multimeter.

The use of a high-voltage multimeter could damage the diodes
and regulator.
Keep alternators dry.

Water on alternators can cause internal short circuits and dam-
age.
00-19
Never operate an alternator with the B and L terminals short-cir-
cuited. Operation with the B and L terminals connected together
would damage the diode trio.
Disconnect the battery terminals before quick-charging the bat-

tery with a quick charger.
Unless the battery terminals are disconnected, quick-charging
can damage the diodes and regulator.
00-20
00
3. Intermittent Faults
An intermittent fault typically occurs only under certain operating
conditions. Once these conditions have been identified, the
cause of the intermittent fault can be ascertained easily. First,
ask the customer about the vehicle operating conditions and
weather conditions under which the fault occurs. Also ask about
the frequency with which the fault occurs and about the fault
symptoms. Then, reproduce the fault based on this information.
In accordance with the conditions under which the fault occurs,
determine whether the fault is caused by vibration, heat or other
factors. if vibration is a possible factor, see if the fault can be re-
produced by performing the following checks on individual con-
nectors and other parts:
Gently move connectors up and down and to left and right.
Gently move wiring harnesses up and down and to left and
right.
Gently wiggle sensors and other devices by hand.
Gently wiggle wiring harnesses on suspension systems and
other moving parts.
Connectors and other parts to be checked are those included or

given as likely fault locations in inspection procedures corre-
sponding to diagnosis codes and/or fault symptoms.
00-21
4. Precautions for Arc Welding
When arc welding is performed, current from the welder flows to ground via the vehicle s metal parts. Unless ap-
propriate steps are taken, this current can damage control units, other electrical devices and wiring harnesses.
And, any electrical device near the point on vehicle, to which the negative cable of the welder is connected might
be largely damaged.
Current flows backward as shown below.

4.1 From battery ( ) terminal
To prevent damage to the battery and to electrical devices that are
connected directly to the battery, it is essential to disconnect the
battery s ( ) terminal.
4.2 Procedure
Turn the starter switch to the LOCK position.
Disconnect the battery s ( ) terminal.
Cover all parts of the vehicle that may be damaged by welding

sparks.
Connect the welder s ( ) cable to the vehicle as close as possi-

ble to the area being welded. Do not connect the welder s ( ) ca-
ble to the cab if the frame is being welded, and vice versa.
Set the welding current in accordance with the part being weld-
ed.
00-22
00
M E M O
00-23
JACKING UP THE VEHICLE
<Front of vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Set a bottle jack or garage jack and jack up the front of the vehicle.
3 Support the front of the vehicle frame on jack stands.
WARNING
Chock the wheels firmly to prevent the vehicle from rolling away.
Do not attempt to remove the chocks until the operation is completed.
It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the front of the vehicle frame on rigid racks.
Never attempt to remove any of the bottle jack, garage jack, or jack stands until the operation is complet-
ed.
00-24
00
<Rear of Vehicle>
Jacking up procedure
1 Place chocks against the rear wheels.
2 Set a bottle jack or garage jack and jack up the rear of the vehicle.
3 Support the vehicle frame on jack stands on both sides.
WARNING
Chock the wheels firmly to prevent the vehicle from rolling away.
Do not attempt to remove the chocks until the operation is completed.
It is extremely dangerous to support the vehicle with only bottle jack or garage jack. Be sure to addition-
ally support the vehicle frame on jack stands on both sides.
Never attempt to remove any of the bottle jack, garage jack, or jack stands until the operation is complet-
ed.
00-25
DIAGNOSIS CODES
1. Connecting Multi-Use Tester
The type of Multi-Use Tester to be used varies depending on which system is being inspected. Select and connect
the correct type of Multi-Use Tester to the system being inspected by referring to the following tables.
System compatible with Multi-Use Tester-III

Reference
System Multi-Use Tester to be used
Gr
Common rail 13E
Exhaust gas recirculation 17
Multi-Use Tester-III only
Automatic transmission 23
Pre-heater 54
System compatible with Multi-Use Tester-II

Reference
System Relevant electronic control unit
Gr
Multi-Use Tester-II or
Anti-lock Brake System 35E
Multi-Use Tester-III
1.1 Connecting Multi-Use Tester-III

Special tools
Mark Tool name and shape Part No. Application
FMS-E04-1
(Multi-Use
PC Data transmission to/from V.C.I.
Tester-III ver-
sion)
Data transmission between electronic

V.C.I. MH062927
control unit and PC
Multi-Use Tester-III
Power supply to V.C.I. and communi-
Test Harness B (used MH062929
cation with electronic control unit
for communication)
Multi-Use Tester -III

Multi-Use Tester-III test harness B
Test Harness D MH062951
extension
(used for extension)
00-26
00
Communication between V.C.I. and

USB cable MB991827
PC
Move the starter switch to the LOCK position.

Connect , , and as illustrated.
Connect the Multi-Use Tester-II/III connector with the connector
(16 terminals) on the vehicle.
NOTE
For Multi-Use Tester operations, refer to the Multi-Use
Tester instruction book.
Use to extend the cable if is not long enough such as

when using Multi-Use Tester outside the vehicle.
00-27
DIAGNOSIS CODES
1.2 Connecting Multi-Use Tester-II
Special tools
Multi-Use Tester MB991946 System check
Multi-Use Tester Har-

Power supply to Multi-Use Tester unit
ness
MK327601 and communication with vehicle elec-
(used for communica-
trical equipment
tion)
ROM Pack Electronic control unit inspection/con-

MH062942
(MRT-E11) trol data
Move the starter switch to the LOCK position.

Connect with . Insert .
Connect the connector (16 terminals) with the Multi-Use Tester
II/III connector (16 terminals) in the fuse box.
NOTE
For Multi-Use Tester operations, refer to the Multi-Use
Tester instruction book.
00-28
00
M E M O
00-29
DIAGNOSIS CODES
2. Accessing / Erasing Diagnosis Codes <Common Rail, Exhaust Gas Recircula-
tion, Pre-heater>
2.1 Diagnosis codes
There are two types of diagnosis codes: present codes and past codes.
(1) Present diagnosis codes

When an error occurs after the starter switch has been turned on (when electronic control unit being energized),
the relevant diagnosis code is generated and stored in electronic control unit. This is a present diagnosis code.
(2) Past diagnosis codes

A present diagnosis code becomes a past diagnosis code and is stored in electronic control unit when it is reset,
or when the starter switch is turned OFF and then ON.
2.2 Accessing and erasing diagnosis codes

Diagnosis codes can be accessed or erased either by using Multi-Use Tester-III, or by using vehicle functions
without using Multi-Use Tester-III.
Removing/installing the dedicated fuses will turn the diagnosis and memory clear switches ON/OFF.
NOTE
Be sure to restore the fuse to the original location after accessing and/or erasing diagnosis codes.
(1) Accessing/erasing diagnosis codes using Multi-Use Tester

(1.1) Present diagnosis codes
Turn the starter switch ON.
With the memory clear switch in the fuse box closed and using Multi-Use Tester, access present diagnosis codes
and, if they exist, identify the faults.
(1.2) Past diagnosis codes

Using Multi-Use Tester, access past diagnosis codes and, if they exist, identify the faults.
(1.3) Erasing diagnosis codes

Using Multi-Use Tester, erase diagnosis codes that may have been stored in electronic control unit.
(2) Accessing/erasing diagnosis codes without using Multi-Use Tester

Using the diagnosis and memory clear
switches, display diagnosis codes that
may have been stored in electronic
control unit.
00-30
00
(2.1) Reading diagnosis codes
To read a diagnosis code, observe how may times the warning
lamp flashes and how long each illumination lasts.
The duration of illumination differs between the first and second
digits.
Second digit: 1.2 sec.
First digit: 0.4 sec.
A diagnosis code consists of the flashing of second digit and the
flashing of first digit in that order. If a diagnosis code has 0 in
the second digit, only the first digit will be displayed.
The same diagnosis code will be displayed 3 times in a row be-
fore moving to the display of the next code.
After the last diagnosis code is displayed, the first code will be
displayed again 3 times in a row and then the subsequent
codes. This will be repeated.
When the diagnosis switch is connected, electronic control unit
will immediately stop (terminate) displaying diagnosis codes.

Remove the diagnosis switch.
Diagnosis codes will be displayed (flashing of the warning lamp).
(2.3) Present and past diagnosis codes

After present diagnosis codes are displayed, (with the diagnosis
switch still removed) remove the memory clear switch.
This will cause the warning lamp to start flashing again to indi-
cate present and past diagnosis codes. Observe the codes that
will be displayed, and identify the faults.

All diagnosis codes stored in electronic control unit can be
erased by removing the memory clear switch and then installing
it again.
NOTE
Be careful not to erase diagnosis codes by mistake. They
can easily be erased simply by operating the memory
clear switch only.
If you do not wish to erase diagnosis codes after they
have been displayed, turn the starter switch OFF with the
memory clear switch still removed, and then connect the
memory clear switch.
00-31
DIAGNOSIS CODES
3. Accessing / Erasing Diagnosis Codes <Automatic Transmission>
3.1 Diagnosis codes



Diagnosis codes can be accessed or erased either by using Multi-Use Tester-III, or by using vehicle functions
without using Multi-Use Tester-III.
NOTE

Using Multi-Use Tester, access present diagnosis codes and, if they exist, identify the faults.

Using Multi-Use Tester, access past diagnosis codes and, if they exist, identify the faults.

Using Multi-Use Tester, erase diagnosis codes that may have been stored in electronic control unit.

control unit.
00-32
00
digits.



it again.
NOTE
clear switch only.
00-33
DIAGNOSIS CODES
4. Accessing / Erasing Diagnosis Codes <Anti-lock Brake System>
4.1 Diagnosis codes



Diagnosis codes can be accessed or erased either by using Multi-Use Tester-II or Multi-Use Tester-III, or by using
vehicle functions without using Multi-Use Tester.
NOTE

With the memory clear switch connected in the fuse box, use Multi-Use Tester to access present diagnosis codes
and, if they exist, identify the faults.

With the memory clear switch removed, use Multi-Use Tester to access past diagnosis codes and, if they exist,
identify the faults.

Use Multi-Use Tester to erase diagnosis codes that may have been stored in electronic control unit.

control unit.
00-34
00
digits.



it again.
NOTE
clear switch only.
00-35
TABLE OF STANDARD TIGHTENING TORQUES
Use specified bolts and nuts, tightening them to the torques specified in this section unless otherwise stated.
Threaded portions and bearing surfaces should be dry.
Where the property class differs between the nut and bolt (or stud bolt), use the tightening torque specified in the
table for the bolt.
Hexagon Headed Bolt, Stud Bolt (Unit: N m ft.lbs, kgf m )

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter (Stud) (Stud) (Stud)
M5 2 to 3
{1.5 to 2.2, 0.2 to 0.3}
4 to 6
{3.0 to 4.4, 0.4 to 0.6}
5 to 7
{3.7 to 5.2, 0.5 to 0.7}
M6 4 to 6
{3.0 to 4.4, 0.4 to 0.6}
7 to 10
{5.2 to 7.4, 0.7 to 1.0}
8 to 12
{5.9 to 8.9, 0.8 to 1.2}
M8 9 to 13
{6.6 to 9.6, 0.9 to 1.3}
16 to 24
{12 to 18, 1.7 to 2.5}
19 to 28
{14 to 21, 2.0 to 2.9}
M10 18 to 27
{13 to 20, 1.8 to 2.7}
17 to 25
{13 to 18, 1.8 to 2.6}
34 to 50
{25 to 37, 3.5 to 5.1}
32 to 48
{24 to 35, 3.3 to 4.9}
45 to 60
{33 to 44, 4.5 to 6.0}
37 to 55
{27 to 41, 3.8 to 5.7}
M12 34 to 50
{25 to 37, 3.4 to 5.1}
31 to 45
{23 to 33, 3.1 to 4.6}
70 to 90
{52 to 66, 7.0 to 9.5}
65 to 85
{48 to 63, 6.5 to 8.5}
80 to 105
{59 to 77, 8.5 to 11}
75 to 95
{55 to 70, 7.5 to 10}
M14 60 to 80
{44 to 59, 6.0 to 8.0}
55 to 75
{41 to 55, 5.5 to 7.5}
110 to 150
{81 to 110, 11 to 15}
100 to 140
{74 to 105, 11 to 14}
130 to 170
{96 to 125, 13 to 17}
120 to 160
{89 to 120, 12 to 16}
M16 90 to 120
{66 to 89, 9 to 12}
90 to 110
{66 to 81, 9 to 11}
170 to 220 160 to 210 200 to 260 190 to 240
{125 to 160, 17 to 23} {120 to 155, 16 to 21} {145 to 190, 20 to 27} {140 to 175, 19 to 25}
M18 130 to 170

{96 to 125, 14 to 18}
120 to 150
{89 to 110, 12 to 16}
250 to 330 220 to 290 290 to 380 250 to 340
{185 to 245, 25 to 33} {160 to 215, 23 to 30} {215 to 280, 30 to 39} {185 to 250, 26 to 35}
M20 180 to 240 170 to 220 340 to 460 310 to 410 400 to 530 360 to 480
{130 to 175, 19 to 25} {125 to 160, 17 to 22} {250 to 340, 35 to 47} {230 to 300, 32 to 42} {295 to 390, 41 to 55} {265 to 355, 37 to 49}
M22 250 to 330 230 to 300 460 to 620 420 to 560 540 to 720 490 to 650
M24 320 to 430 290 to 380 600 to 810 540 to 720 700 to 940 620 to 830
Hexagon Headed Flange Bolt (Unit: N m ft.lbs, kgf m )

Strength 4T 7T 8T
Identification
symbol
Nominal
diameter
M6 4 to 6
{3.0 to 4.4, 0.4 to 0.6}
8 to 12
{5.9 to 8.9, 0.8 to 1.2}
10 to 14
{7.4 to 10, 1.0 to 1.4}
M8 10 to 15
{7.4 to 11, 1.0 to 1.5}
19 to 28
{14 to 21, 2.0 to 2.9}
22 to 33
{16 to 24, 2.3 to 3.3}
M10 21 to 31
{15 to 23, 2.1 to 3.1}
20 to 29
{15 to 21, 2.0 to 3.0}
45 to 55
{33 to 41, 4.5 to 5.5}
37 to 54
{27 to 40, 3.8 to 5.6}
50 to 65
{37 to 48, 5.0 to 6.5}
50 to 60
{37 to 44, 5.0 to 6.5}
M12 38 to 56
{28 to 41, 3.8 to 5.5}
35 to 51
{26 to 38, 3.5 to 5.2}
80 to 105
{59 to 77, 8.0 to 10.5}
70 to 95
{52 to 95, 7.5 to 9.5}
90 to 120
{66 to 89, 9 to 12}
85 to 110
{63 to 81, 8.5 to 11}
00-36
00
Hexagon Nuts (Unit: N m ft.lbs, kgf m )
Strength 4T 6T
Identification
symbol
Nominal Standard screw Coarse screw

Standard screw thread Coarse screw thread
diameter thread thread
M5 2 to 3
{1.5 to 2.2, 0.2 to 0.3}
4 to 6
{3.0 to 4.4, 0.4 to 0.6}
M6 4 to 6
{3.0 to 4.4, 0.4 to 0.6}
7 to 10
{5.2 to 7.4, 0.7 to 1.0}
M8 9 to 13
{6.6 to 9.6, 0.9 to 1.3}
16 to 24
{12 to 18, 1.7 to 2.5}
M10 18 to 27
{13 to 20, 1.8 to 2.7}
17 to 25
{13 to 18, 1.8 to 2.6}
34 to 50
{25 to 37, 3.5 to 5.1}
32 to 48
{24 to 35, 3.3 to 4.9}
M12 34 to 50
{25 to 37, 3.4 to 5.1}
31 to 45
{23 to 33, 3.1 to 4.6}
70 to 90
{52 to 66, 7.0 to 9.5}
65 to 85
{48 to 63, 6.5 to 8.5}
M14 60 to 80
{44 to 59, 6.0 to 8.0}
55 to 75
{41 to 55, 5.5 to 7.5}
110 to 150
{81 to 110, 11 to 15}
100 to 140
{74 to 105, 11 to 14}
M16 90 to 120
{66 to 89, 9 to 12}
90 to 110
{66 to 81, 9 to 11}
170 to 220
{125 to 160, 17 to 23}
160 to 210
{120 to 155, 16 to 21}
M18 130 to 170

{96 to 125, 14 to 18}
120 to 150
{89 to 110, 12 to 16}
250 to 330
{185 to 245, 25 to 33}
220 to 290
{160 to 215, 23 to 30}
M20 180 to 240 170 to 220

{130 to 175, 19 to 25} {125 to 160, 17 to 22}
340 to 460
{250 to 340, 35 to 47}
310 to 410
{230 to 300, 32 to 42}
M22 250 to 330 230 to 300

{185 to 245, 25 to 33} {170 to 220, 23 to 30}
460 to 620
{340 to 455, 47 to 63}
420 to 560
{310 to 415, 43 to 57}
M24 320 to 430 290 to 380

{235 to 315, 33 to 44} {215 to 280, 29 to 39}
600 to 810
{440 to 595, 62 to 83}
540 to 720
{400 to 530, 55 to 73}
Hexagon Flange Nuts (Unit: N m ft.lbs, kgf m )

Strength 4T
Identification
symbol
Nominal Standard screw Coarse screw

diameter thread thread
M6 4 to 6
{3.0 to 4.4, 0.4 to 0.6}
M8 10 to 15
{7.4 to 11, 1.0 to 1.5}
M10 21 to 31
{15 to 23, 2.1 to 3.1}
20 to 29
{15 to 21, 2.0 to 3.0}
M12 38 to 56
{28 to 41, 3.8 to 5.6}
35 to 51
{26 to 38, 3.5 to 5.2}
00-37
TABLE OF STANDARD TIGHTENING TORQUES
Tightening Torque for General-Purpose Flare Nut (Unit: N m ft.lbs, kgf m )
4.76 mm 6.35 mm 8 mm 10 mm 12 mm 15 mm
Pipe diameter
{0.19 in.} {0.25 in.} {0.31 in.} {0.39 in.} {0.47 in.} {0.59 in.}
Tightening torque 17 {13, 1.7} 25 {18, 2.6} 39 {29, 4.0} 59 {44, 6.0} 88 {65, 9.0} 98 {72, 10}
Tightening Torque for General-Purpose Air Piping Nylon Tube (DIN Type)
(Unit: N m ft.lbs, kgf m )
Nominal diameter 6 1 mm 10 1.25 mm 12 1.5 mm 15 1.5 mm
wall thickness {0.24 0.039 in.} {0.39 0.049 in.} {0.47 0.059 in.} {0.59 0.059 in.}
+6 +4.4 +0.6 +10 +7.4 +1.0 +10 +7.4 +1.0 +5 +3.7 +0.5
Tightening torque 20 0 {15 0 2.0 0 } 34 0 {25 0 3.5 0 } 49 0 {36 0 5.0 0 } 54 0 {40 0 5.5 0 }
Tightening Torque for General-Purpose Air Piping Nylon Tube (SAE Type)
(Unit: N m ft.lbs, kgf m )
Nominal diameter 1/4 in. 3/8 in. 1/2 in. 5/8 in.
+4 +3.0 +0.4 +5 +3.7 +0.5 +5 +3.7 +0.5 +5 +3.7 +0.5
Tightening torque 13 0 {9.6 0 1.3 0 } 29 0 {21 0 3.0 0 } 49 0 {36 0 5.0 0 } 64 0 {47 0 6.5 0 }
00-38
INDEX
HOW TO READ THE MAINTENANCE SCHEDULE TABLES .......... 01-2
MAINTENANCE SCHEDULE TABLES .............................................. 01-4
MAINTENANCE OPERATIONS ........................................................ 01-8
LUBRICATION TABLES .................................................................. 01-14
LUBRICATION ................................................................................. 01-16
01-1
HOW TO READ THE MAINTENANCE SCHEDULE TABLES
Example Table:
(1) This column contains the maintenance and inspection items.

(2) The periods between inspection and service are based on the assumption that the vehicle will be driven approx-
imately 60,000 kilometers (36,000 miles) per year.
Inspections which must be made are indicated by an or by the appropriate period between servicing.
(3) This column provides a simplified explanation of the operational procedures involved for each inspection or
maintenance item.
(4) The Gr. No. refers to the group number in this Service Manual. For visual checks and simple inspections, see
the sections labelled Working Procedures .
01-2
01
M E M O
01-3
MAINTENANCE SCHEDULE TABLES
: Exhaust emission items.
: Noise control items.
Time of inspection and maintenance
Inspection interval
New vehicle at 4,000 km/

Pre-operational checks
Every 250,000 km/

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Item Working procedures
Gr
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
ENGINE 6,000 miles
Fuel, oil, or coolant Check engine for fuel, oil and Gr11, 12,
leaks from engine coolant leaks. 13A, 14
Engine Check the engine for smooth start- Gr11, 13,
conditions ing and quiet running. 15, 17, 54
Manifold bolts and Check inlet exhaust manifold bolts
Gr15
nuts torque and nuts for looseness.
Check and ad-
Check valve clearance with thick-
just valve clear- Gr11
ness gauge.
ance
Oil filter replace- Every 10,000 km/6,000 miles or
Replace oil filters. Gr12
ment 12 months
Fuel filter re- Every 20,000 km/12,000 miles or
Replace fuel filter. Gr13A
placement 12 months
Every 20,000 km/12,000 miles or Inspect the fuel tank, cap and
Fuel line Gr13A
12 months lines for damage causing leakage.
Belts tension Every 10,000 km/6,000 miles or Inspect belts for crack, wear and
Gr14
and damage 12 months tension.
Check radiator and pressure cap
for sealing performance and
mounting condition.
Inspect hoses for looseness, dete-
Cooling system rioration, damage causing leak- Gr14
age.
Remove dust and foreign matter
deposit from radiator and inter-
cooler front.
Coolant level and
Check coolant level and if level is
leaks from cooling Gr14
low, check for coolant leaks.
system
Coolant replace-
Every 24 months Replace coolant. Gr14
ment
Turbocharger
Check turbocharger rotor play. Gr15
rotor play
Clean air cleaner element by
Air cleaner element Every 5,000 km/3,000 miles Gr15
blowing clean compressed air.
Air cleaner el-
Replace air cleaner element. Gr15
ement replacement
Inspect the exhaust system for
Exhaust
damage, corrosion and loose con- Gr15
system
nection causing leakage.
POWER TRAIN
Clutch pedal and Check the pedal for free play.
Gr21
clutch disc wear Check clutch disc wear.
01-4
01
Inspection interval

Every 250,000 km/

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Gr
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Propeller shaft
flange torque and Check flange yoke bolts for loose-
Gr25
universal joint ness and universal joint for play.
looseness
Check center bearing if trace of
Propeller shaft grease flowing out is evident.
Gr25
center bearing Check center bearing for wear,
damage and play.
FRONT AND REAR AXLE
Wheel hub
Check wheel hub bearing for play. Gr26, 27
bearing
Wheel hub bear- When wheel hub bearing grease
ing hub seals re- is replaced, also replace the Gr26, 27
placement wheel hub bearing hub seals.
Check disc wheel for corrosion,
deformation and cracks.
Measure inflation pressure with
tire gauge.
Check tire tread and side wall for
cracks and damage.
Measure tire tread groove depth See later
Wheel and tire
to make sure it is deep enough. section.
Check tire tread for uneven wear,
stepped wear and other abnormal
wear.
Rotate tires if there is a difference
in the amount of wear on each
tire.
Check wheel nuts for looseness.
Retightening wheel Check at the first 50 to 100 km/30 See later
nuts to 60 miles after changing a section.
wheel.
SUSPENSION SYSTEM
Suspension Check for broken springs and tilt
Gr33, 34
springs of vehicle body toward either side.
Check U-bolt nuts for looseness.
Retightening Check at the first 1 000 km/600
Gr33, 34
U-bolts miles after removing and retight-
ening U-bolt nuts.
BRAKING SYSTEM
Service brake ped- Check brake pedal play and
Gr35A
al stroke.
Depress the brake pedal and
Brake performance check that the brakes work effec- Gr35A
tively and evenly on all wheels.
Disc brake pad and Check disc brake pad and disc for
Gr35A
disc damage and wear.
01-5
MAINTENANCE SCHEDULE TABLES
Inspection interval

Every 250,000 km/

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Gr
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Check lining for wear through in-
Brake lining
spection hole.
Gr35A
Disassemble and check drum for
Brake drum
wear, crack and damage.
Parking brake lever
Check parking brake lever stroke. Gr36
stroke
Inspect brake lines and hoses
Looseness, play looseness, play and damage.
and damage of Inspect wheel cylinder and brake Gr35A
brake system parts master cylinder for looseness,
play and damage.
STEERING SYSTEM
Turn steering wheel right and left
Steering wheel to measure play at steering wheel
Gr37
play rim. Measure while engine is run-
ning.
Check that the steering wheel
does not vibrate or pull to one side
Steering wheel op- and that it is not unduly heavy.
Gr37
eration Also make sure that the steering
wheel returns to its neutral posi-
tion smoothly.
Check steering system for loose-
ness, steering wheel play and op-
Steering system erating condition. Inspect for oil Gr37
leaks, booster and oil pump func-
tion.
CAB
Make sure that warm air blows
Defroster Gr55
properly onto the windshield.
Seated in the driver s seat, adjust
the angles for clear views of the
Rearview mirrors Gr51
sides and rear. Make sure the mir-
rors are clean.
Check the license plate and re-
License plate and
flectors for loose installation, dam-
reflector condition
age, and dirt.
Push down the lock knob and veri-
fy that the door does not open
Door locks Gr43
even when the inner handle is op-
erated.
Confirm that the seat belt buckles
Seat belts function correctly when fastening Gr52
and unfastening.
ELECTRICAL SYSTEM
Press the horn button to check
Horn operation Gr54
that the horn is working properly.
01-6
01
Inspection interval

Every 250,000 km/

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/
Every 90,000 km/

Gr
150,000 miles
12,000 miles
18,000 miles
24,000 miles
30,000 miles
54,000 miles
2,500 miles
6,000 miles
Confirm that the windshield wash-
Windshield wash-
er fluid level is above the bottom
er fluid level
of the inspection window.
Windshield wiper Check the washer for proper fluid
and washer opera- spray direction and the wipers for Gr51, 54
tion normal action.
Make sure that each lamp lights
Lighting system up or flashes properly. Check Gr54
lamp lenses for dirt and damage.
Gauge, warning/in- Check that gauges, warning
dicator lamp opera- lamps and indicators are working Gr54
tion properly.
01-7
MAINTENANCE OPERATIONS
Tire
Service standards (Unit: mm {in.})

Location Maintenance item Standard value Limit Remedy
Depth of tire tread grooves 1.6 {0.063} Replace
Tightening torque (Unit: N m {ft.lbs, kgf m})

Mark Parts to be tightened Tightening torque Remarks
Wheel nut 490 49 {360 36, 50 5}
Air pressure
Tire air pressure should be checked before the vehicle is driven,
while the tires are still cool.
Item Air pressure
Tire size
Vehicle model kPa {psi, kgf/cm2}
LT215/85R16-10PR
FE83, FE84 550 {80, 5.5}
(Load range E)
215/75R17.5 124/123L
FE85 690 {100, 7.0}
(Load range F)
LT235/85R16-10PR
FG 550 {80, 5.5}
(Load range E)
CAUTION
Make certain that there is no difference in the air pressure
between the inner and outer rear tires.
Make certain you use valve caps on the air valves.
It is not necessary to increase the air pressure for high-
speed driving.
Checking tread depth

Check all around the tire treads to make sure that the depth of
the tread grooves is above the wear limit.
If the tread grooves are not deep enough, slip sign appears at
the position of the mark, where the tread groove has worn
away.
WARNING
If the depth of the tread grooves is not adequate, the tires
will slip on wet roads and present a hazard. Such tires are
also extremely dangerous because they are more suscepti-
ble to hydroplaning when the vehicle is running at high
speeds in the rain. Such tires must be replaced with new
ones as soon as possible.
01-8
01
Checking for cracks, damage, and objects embedded in the
treads
Check the tire treads and walls for cracks and damage.
Check tire treads for uneven wear or other abnormal wear.
Check if metal objects or nails have penetrated the tires.
Check for stones embedded between double tires.
WARNING
Badly damaged or worn tires are extremely dangerous, be-
cause they can be punctured more easily when the vehicle
is running, they must be replaced with new ones as soon as
possible.
Removing tires
Loosen wheel nuts slightly. The wheel nuts for right tires have
right-hand threads R , and the wheel nuts for left tires have left-
hand threads L .
WARNING
Make certain that wheel nut wrench is fully engaged, all the
way to the back of nuts. If it is not, it could slip.
CAUTION
Only loosen wheel nuts slightly. Do not remove them.
Jack up the vehicle carefully, until the tire is slightly off the
ground.
Remove wheel nuts, then remove the tire.
When working on the double tires at the rear of the vehicle, first
remove the outside tire, then lower the vehicle and loosen the
nuts on the inside tire. After doing this, jack the vehicle back up
and remove the tire.
01-9
Mounting tires
To prevent wheel nuts and hub bolt from becoming loose and to
prevent mounted parts (tire assemblies and hub) from being dam-
aged, remove rust, dust, additional coatings of paint, and foreign
particles from the following areas:
A: Hub bolt thread area

B: Wheel mounting surface of hub
C: Wheel alignment area of hub
D: Disc wheel mating surface
E: Disc wheel nut mounting surface
F: Wheel nut thread area
G: Wheel nut spherical area
Install the dual rear tires as follows:

After mounting inner tire and fully tightening inner wheel nuts,
jack the vehicle up and mount on outer tire, then tighten outer
wheel nuts.
Even if only outside tire is to be changed, do not mount it until
inner wheel nuts have been fastened at the specified torque.
Slide the air valves on the inside and outside tires down when
mounting the tires.
WARNING
If the threads are scored, or the disc wheel is deformed or
cracked, change bolts, nuts and disc. Driving the truck be-
fore correcting such problems can cause the tire in ques-
tion to come loose, which could be the source of major
accidents.
CAUTION
Check hub bolt threads carefully for damage before putting
the tire on.
Place the tapered end of wheel nuts towards the disc wheel and
fasten temporarily. Center so that there is no eccentricity be-
tween bolts and the disc wheel bolt holes.
Lower the vehicle.
01-10
01
Tighten the nuts in the order as illustrated, tightening each nut
two or three times. To finish, tighten each nut at the specified
torque.
WARNING
Always use the specified torque when tightening the wheel
nuts. If the wheel nuts are not tightened properly, the
wheels could come loose while the vehicle is being driven,
which could result in life threatening accidents or the truck
being disabled.
Do not coat the threads with grease when tightening the
nuts. This could result in over-tightening force, which could
be dangerous.
CAUTION
Over-tightening the wheel nuts can damage them.
Checking the wheel nuts for looseness

The wheel nuts should be checked for looseness every 10000 km
(6000 miles). All nuts should be tightened at the specified torque.
Check the double rear tires for looseness as follows:
(1) Loosen outer wheel nuts.

(2) Tighten inner wheel nuts at specified torque.
(3) Tighten outer wheel nuts at specified torque.
CAUTION
If outer wheel nuts are tightened without first being loos-
ened, it might not be possible to tighten them at the speci-
fied torque.
01-11
Tire rotation
Tires wear differently, according to the location where they are
mounted. To make this wear uniform and prolong the life of your
tires, they should be rotated every 10000 km (6000 miles) in the ro-
tation order shown below:
When the tread patterns for all tires are identical:
When the tread patterns are different for the front and rear tires:
CAUTION
Always adjust air pressure after running-in new tires.
When using tires of different tread patterns, use rib-type
patterns for the front tires and traction type patterns for the
rear tires.
Avoid using both radial and biased tires on the same vehi-
cle.
01-12
01
M E M O
01-13
LUBRICATION TABLES
: Exhaust emission items.
Inspection interval

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/

Items Lubricant specifications Gr
12,000 miles
18,000 miles
24,000 miles
30,000 miles
2,500 miles
6,000 miles
Engine oil contamination and Engine oil
oil level API classification, CD, CD/SF, CE, CE/SF
or CF-4 or JASO classification DH-1
Over 30 C {86 F} SAE 40 Gr12
40 to 5 C {104 to 23 F} SAE 30
Engine oil replacement 15 to 15 C {59 to 5 F} SAE 20W-20
Over 15 C {5 F} SAE 15W-40
Below 0 C {32 F} SAE 10W-30
Manual transmission oil level Engine oil
Vehicle operated continuously at high
speed
API classification CC
SAE 30 or SAE 40 Gr22
Manual transmission oil Gear oil
replacement Every 60,000 km/36,000 miles
API classification
GL-3 SAE 80 (General)
GL-3 SAE 90 (Warm region)
GL-4 SAE 90 (Tropical region)
Automatic transmission fluid
level Mobil ATF3309 manufactured by Gr23
Automatic transmission fluid Exxon Mobil
replacement
Transfer gear oil level Gear oil
<FG Model only> API classification
GL-3 SAE 80 (General) Gr24
Transfer gear oil replacement GL-3 SAE 90 (Warm region)
<FG Model only> GL-4 SAE 90 (Tropical region)
Rear axle housing gear oil level Gear oil
API classification GL-5
Below 40 C {104 F} SAE 90
Over 40 C {104 F} SAE 140
Use SAE 140 when operating vehicle at
high load, such as continuous ascent on Gr27
Rear axle housing gear oil slopes and when the outside temperature
replacement is 10 C {50 F} or more
<Limited slip defferential only>
Limited slip differential oil
API classification
GL-5 SAE 90
Front axle housing gear oil level Gear oil
<FG Model only> API classification GL-5
Below 40 C {104 F} SAE 90
Over 40 C {104 F} SAE 140 Gr26B
Front axle housing gear oil Use SAE 140 when operating vehicle at
replacement <FG Model only> high load, such as continuous ascent on
slopes and when the outside temperature
is 10 C {50 F} or more
Hub bearing grease replace- Wheel bearing grease
ment [NLGI No. 2 (Li soap)] Gr26, 27
Front axle birfield joint grease Wheel bearing grease Gr26B

replacement <FG Model only> [NLGI No. 2 (Li soap)]
Front axle kingpin bearing Wheel bearing grease
grease replacement Gr26B
<FG Model only> [NLGI No. 2 (Li soap)]
Front axle steering knuckle Wheel bearing grease

grease replacement [NLGI No. 2 (Li soap)] Gr26B
<FG Model only>
Brake reservoir tank fluid level Brake fluid
<SAE J1703f or FMVSS No. 116 DOT3> Gr35A
Brake fluid replacement
01-14
01
Inspection interval

Reference
Every 10,000 km/
Every 20,000 km/
Every 30,000 km/
Every 40,000 km/
Every 50,000 km/

Items Lubricant specifications
Gr
12,000 miles
18,000 miles
24,000 miles
30,000 miles
2,500 miles
6,000 miles
Power steering fluid level Automatic transmission fluid
Power steering fluid <DEXRON, DEXRON II or DEXRON III Gr37
replacement type>
Center
bearing Bearing grease [NLGI No. 3 (Li soap)] Gr25
Universal
Lubrication of joint,
slip joint
propeller shaft Wheel bearing grease See later
Double [NLGI No. 2 (Li soap)] section.
Cardan joint
<FG Model
only>
Lubrication of rear suspension See later
spring pin Chassis grease [NLGI No. 1 (Li soap)] section.
Lubrication of kingpins Wheel bearing grease [NLGI No. 2 (Li See later
soap)] section.
Lubrication of door hinge Chassis grease [NLGI No. 1 (Li soap)] Gr43
Lubrication of anchor hook Chassis grease [NLGI No. 1 (Li soap)] Gr42
<except crew cab>
01-15
LUBRICATION
Greasing Various Areas of Chassis
Carefully clean away all dust and dirt from the grease nipples, and use the specified type of grease. The areas to be
greased are shown in the following illustration.
<FE>
1. Rear spring pin front (left and right, 2 points)
2. Rear spring pin rear (left and right, 4 points)
01-16
01
3. Kingpin bearing (left and right, 4 points)
4. Propeller shaft universal joint s-all
5. Propeller shaft slip joint
01-17
LUBRICATION
<FG>
1. Rear spring pin front (left and right, 2 points)
2. Rear spring pin rear (left and right, 4 points)
01-18
01
3. Propeller shaft universal joint s-all
4. Double Cardin joint, propeller shaft slip joint, propeller shaft uni-
versal joint
5. Propeller shaft slip joint
01-19
INDEX
SPECIFICATIONS ................................. 11-2 PISTONS, CONNECTING ROD

AND CYLINDER LINERS .....................11-56
STRUCTURE AND OPERATION
1. Exploded View ................................ 11-3 FLYWHEEL ...........................................11-70
2. Cylinder Head, Cylinder Head Gasket,
Camshaft, and Camshaft Frame ...... 11-4 FRONT CASE .......................................11-74
3. Valve Mechanism ............................. 11-5
4. Connecting Rod ............................... 11-6 TIMING GEARS AND BALANCE
5. Piston ............................................. 11-6 SHAFTS ................................................11-76
6. Timing Gears .................................. 11-7
CRANKSHAFT AND CRANKCASE.....11-84
7. Flywheel .......................................... 11-7
8. Balance Shafts ................................... 11-8 BALANCE SHAFT BUSHINGS ............11-92
9. Crankcase and Main Bearings ........ 11-9
10.Oil Seals ........................................... 11-11
TROUBLESHOOTING ......................... 11-12
ON-VEHICLE INSPECTION AND

ADJUSTMENT
1. Measuring Compression
Pressure ........................................ 11-14
2. Inspection and Adjustment of Valve
Clearances ..................................... 11-16
ENGINE REMOVAL AND INSTALLATION

<TILT CAB>.......................................... 11-18
<FIXED CAB>....................................... 11-26
ROCKER COVER ................................ 11-28
ROCKERS AND CAMSHAFTS ........... 11-30
CYLINDER HEAD AND VALVE

MECHANISM ........................................ 11-42
11-1
SPECIFICATIONS
Item Specifications
Engine model 4M50T7 4M50T8
Type 4-cylinder, in-line, water-cooled, 4-cycle diesel engine
Combustion chamber Direct injection type
Valve mechanism Double overhead camshaft (DOHC)
Maximum output HP / rpm 147 / 2700 175 / 2700
Maximum torque ft.lbf / rpm 347 / 1600 391 / 1600
Bore stroke mm {in.} 114 120 { 4.49 4.72}
Total displacement L {qts} 4.899 {4899}
Compression ratio 17.5
11-2
STRUCTURE AND OPERATION 11
1. Exploded View
11-3
2. Cylinder Head, Cylinder Head Gasket, Camshaft, and Camshaft Frame
The camshaft is supported at its jour-
nals from below by the cylinder head
and retained from above by the cam-
shaft frame.
The upper and lower camshaft bear-
ings are identical, but cannot be inter-
changed when they are reinstalled.
The exhaust camshaft and the intake
camshaft have identical gears but dif-
ferent cams.
The thirteen shortest bolts and four
shorter bolts fasten the camshaft
frame onto the cylinder head.
The two long bolts fasten the camshaft
frame to the front case.
2.1 Cylinder head gasket

Select and use a cylinder head gasket
of a thickness that can accommodate
the piston projection.
The size (thickness) class of the gas-
ket can be identified by the shape of
the notches and size mark cut on the
edge of each gasket.
11-4
11
3. Valve Mechanism
The short rockers and the long rockers are installed differently, as shown in the illustration.
Each valve has an inner valve spring and an outer valve spring.
11-5
4. Connecting Rod
Weight mark:
C to G
(with G as the maximum)
5. Piston
Each piston must be mated with a cyl-
inder in the upper crankcase that has
the same size mark as the piston. The
pistons are marked with either A or
B , where B stands for the larger
and A for the smaller of the two
available diameters.
The pistons have been made light-
weight by use of a special aluminum
alloy, as well as by the reduction of
their height.
11-6
11
6. Timing Gears
All gears, except the vacuum pump gear, each has timing mark(s) to ensure correct engagement during assem-
bly.
7. Flywheel
11-7
8. Balance Shafts
The balance shaft RH and balance shaft LH are mounted in the upper crankcase on the right and left sides of the
crankshaft. The balance shafts reduce the vibration of the engine caused by the rotation of the crankshaft.
The balance shaft RH and balance shaft LH are both driven by timing gears. Each balance shaft is held in the up-
per crankcase by way of three balance shaft bushings.
The balance shaft LH has a locating hole to enable correct installation.
8.1 Reduction of vertical vibration
(secondary vibration element)
When the piston moves up and down,
vertical vibrations are generated at the
top dead center (TDC) and bottom
dead center (BDC) due to inertia.
The balance shaft LH and the balance
shaft RH rotate so that their weight
portions are at the bottom positions
when a piston is at TDC and at the top
positions when the piston is at BDC,
i.e., the weight portions are always on
the opposite side to the piston head.
This creates centrifugal forces in the
balance shaft RH and balance shaft
LH, the total of which is equal in
amount to the inertia force that the pis-
ton creates when it is at TDC or BDC.
These centrifugal forces in the bal-
ance shafts cancel out the inertia forc-
es resulting from piston s movements
and reduce the amount of vertical vi-
bration.
The balance shafts also reduce the
moment created around the crank-
shaft (which constitutes secondary vi-
bration elements) when the engine is
running in the middle-to-high speed
range.
11-8
11
9. Crankcase and Main Bearings
9.1 Crankcase
The crankcase is a two-piece type
consisting of an upper crankcase and
a lower crankcase, which hold the
crankshaft in between.
Cylinder liners are inserted into the
cylinder bores in the upper crankcase.
An water jacket is formed in the walls
of these cylinders to cool them down.
The main cap bolts and the bolts that
fasten the upper and lower crankcas-
es together are tightened using a spe-
cial method.
11-9
The upper crankcase is marked with a
size mark ( 1 or 2 ) to be used as a
reference in selecting cylinder liners.
The first to forth size marks from the
front of the engine correspond to the
No. 1 to No. 4 cylinders.
9.2 Main bearing

The upper main bearings have oil
holes through which engine oil is sup-
plied to the crankshaft journals.
An oil groove is provided in the No. 1
lower bearing.
9.3 Thrust plates

Two upper and lower thrust plate pairs
are installed on both sides of the up-
per and lower main bearings at the
rearmost journal of the crankshaft.
Select the thrust plates of a thickness
that can accommodate the crankshaft
end play. The thrust plates each have
two oil grooves, which assures their
minimum friction against the crank-
shaft journal.
11-10
11
10. Oil Seals
10.1Front oil seal

The front oil seal is fitted in the front
case and prevents oil from leaking by
contact of its lip with the front oil seal
slinger.
The front oil seal slinger is press-fitted
onto the fan shaft.
10.2Rear oil seal

The rear oil seal is fitted in the crank-
case assembly and prevents oil from
leaking by contact of its lip with the
rear oil seal slinger.
The rear oil seal slinger is press-fitted
onto the rear end of the crankshaft.
11-11
TROUBLESHOOTING
Symptoms
Abnormal engine noise

Reference Gr
Low power output

Possible causes
Incorrect valve clearance O O
Defective cylinder head gasket O O
Cylinder head and valve Worn valve and valve seat; carbon deposits O O
mechanism Weakened valve spring O O
Defective rocker shaft and camshaft frame O
Poor lubrication of rocker shaft and camshaft frame O
Incorrect backlash in timing gears O
Timing gears
Poor lubrication of timing gears and idler shaft O
Excessive end play in camshaft O
Camshaft
Worn camshaft O
Worn/damaged piston ring groove(s) O O
Pistons and connecting
Worn/damaged piston ring(s) O O
rods
Worn piston pin and connecting rod small end O
Excessive end play in crankshaft O
Incorrectly fitted crankshaft O
Crankshaft Worn/damaged crankshaft pins and connecting rod bear-
O
ings
Worn/damaged crankshaft journals and main bearings O
Defective supply pump O O Gr13E
Fuel system Faulty fuel spray from injector O O
Gr13A
Air trapped in fuel system O
Malfunctioning cooling system components O
Cooling system Gr14
Loose/damaged V-belts O
Intake and exhaust Clogged air cleaner O O
Gr15
system Clogged muffler O O
Incorrect oil viscosity O Gr12
Improper fuel O
Incorrectly fitted piping and hoses O
Defective/incorrectly fitted alternator and other auxiliaries O
11-12
11
M E M O
11-13
ON-VEHICLE INSPECTION AND ADJUSTMENT
1. Measuring Compression Pressure
Service standards
1960 kPa
2550 kPa
Each cylinder (at 200 rpm) {285 psi, Inspect
{370 psi, 26 kgf/cm2}
20 kgf/cm2}
Compression pressure 390 kPa
Cylinder-to-cylinder pres- {57 psi,
Inspect
sure difference 4 kgf/cm2}
or less
Special tools (Unit: mm {in.})

Compression gauge adapter

A B C
MH063434 Measuring compression pressure
W 16 58 7.2
H 18 {2.28} { 0.28}
A drop in compression pressure can be used as a guide to determine when the engine should be overhauled.
Measure the compression pressure at regular intervals. Keeping track of its transitions can provide a useful tool
for troubleshooting. On new vehicles and vehicles with newly replaced parts, the compression pressure will be
somewhat higher depending on the break-in condition of piston rings, valve seats, etc., but this will return to nor-
mal as the parts wear down.
Before the compression measurement, confirm that the engine oil, starter, and battery are in normal condition.
Place the vehicle in the following conditions.
Warm up the engine until the coolant temperature reaches approximately 75 to 85 C {167 to 185 F}.
Turn off the lights and auxiliaries.
Place the transmission in neutral (in the parking range P for automatic transmissions).
Place the steering wheel in the straight-ahead position.
Remove the fuse (M9) to prevent fuel from being injected when
the engine is cranked by the starter.
11-14
11
Disconnect the injector connector and remove all injectors.
Cover the injector mounting holes with shop towels. After crank-
ing the engine by the starter, check that no foreign substances
are deposited on the shop towels.
If there are deposits (such as engine oil or coolant) on the shop
towels, the following may be the cause:
Deposits of engine oil alone can mean a defective piston ring
seal; the piston rings must be inspected.
Deposits of both engine oil and coolant can mean cracks in
the cylinders; the crankcase must be replaced.
WARNING
When coolant and engine oil deposits are evident, cranking
the engine could be dangerous as these substances, heat-
ed to high temperatures, will blow out from the injector
mounting holes. Make sure to stay away from the injector
mounting holes when the engine is being cranked.
CAUTION
Never cut off the engine electronic control unit power sup-
ply when cranking the engine.
Attach the gasket and to one of the injector mounting

holes. Then, connect a compression gauge to .
Crank the engine and measure the compression pressure for all
the cylinders one after another. Determine the compression
pressure difference between the cylinders.
If the compression pressure is below the limit or the cylinder-to-
cylinder pressure differences is not within the limit, pour a small
amount of engine oil into the corresponding injector mounting
hole and remeasure the compression pressure.
If the compression pressure increases, the piston rings and
cylinder surfaces may be badly worn or otherwise damaged.
If the compression pressure remains unchanged, there may
be seizure in the valves, the valves may be incorrectly seated
or the cylinder head gasket may be defective.
11-15
2. Inspection and Adjustment of Valve Clearances
Intake valve 0.4 {0.016}
Valve clearance (when cold) Adjust
Exhaust valve 0.5 {0.020}

Lock nut (adjusting screw stopping) 20.6 {15, 2.1}
Special tools
Cranking handle MH063704 Turning the fan pulley
Valve clearances should be checked and adjusted as follows

while the engine is still cold.
[Inspection]
CAUTION
Never cut off the engine electronic control unit power sup-
ply when cranking the engine.
Remove the rocker cover.

Disconnect the injector connector.
Bring the No. 1 or No. 4 cylinder piston to the top dead center
(TDC) on the compression stroke by the following procedure:
Hook onto the grooves in the fan pulley.
Turn the fan pulley in the illustrated direction to align the point-
er with the I, IV or 1 to 4 mark on the flywheel.
This will place either the No. 1 or No. 4 cylinder piston at TDC
on the compression stroke. The cylinder in which the rocker
arms for both the intake and exhaust valves can be pushed
down by hand by the valve clearance amounts has its piston
at TDC. Rotate the engine by one full turn to switch the TDCs
of the No. 1 and No. 4 cylinder pistons.
11-16
11
With the No. 1 or No. 4 cylinder piston at TDC, measure the
clearance of the valves marked with a circle in the table below.
Cylinder No. 1 2 3 4
Valve IN EX IN EX IN EX IN EX
No. 1 cylinder piston at
TDC on compression O O O O
stroke
No. 4 cylinder piston at
TDC on compression O O O O
stroke
To insert the thickness gauge under the adjusting screw pad,

push the pad at the bottom on one side with a flat-blade screw-
driver or a similar tool. Insert the thickness gauge into the small
space created under the other side of the pad, as shown in the il-
lustration.
The thickness gauge cannot be inserted under the adjusting

screw pad without carrying out the above step, as the pad will
block the thickness gauge as shown in the illustration.
The thickness gauge must have a slight drag when taking mea-
surements.
If the thickness gauge can be moved without any resistance, the
measurement will be incorrect.
If the measurements are not within the standard value range,
adjust the value clearance by the following procedures.
[Adjustment]
Adjust the valve clearance by loosening the lock nut and rotating
the adjusting screw so that the thickness gauge can only be
moved with a slight drag.
After the adjustment, hold the adjusting screw in position with a
screwdriver and tighten the lock nut to the specified torque.
Recheck the valve clearance with the thickness gauge, and re-
adjust if the measurements are not within the specified value
range.
11-17
ENGINE REMOVAL AND INSTALLATION <TILT CAB>
<Except for FG>
CAUTION
Only use hoisting equipment appropriate for the engine and transmission weight (approximately 600 kg
{1320 lb}).

Nut (front mounting installation) 69 to 88 {51 to 65, 7 to 9}
Nut (rear mounting installation) 130 to 170 {96 to 125, 13 to 17}
11-18
11
Special tools
Engine front hanger MH063636 Removal and installation of engine
MF140429
Flange bolt MF140433 Installation of engine front hanger
MF140421
Engine rear hanger MH063711 Removal and installation of engine
Work before removal

Preparing for engine removal: Installation of engine front
hanger and flange bolt
Install , and on the engine.
11-19
Removal procedure
Removal: Engine and transmission
Hook the wire rope on and hitch the chain block to .
Then, pull all the slack out of the slings by a crane.
CAUTION
The slings must be strong enough to hang the engine and
transmission assembly (weighing approximately 600 kg
{1320 lb}).
Be sure to keep the slings away from the exhaust gas recir-
culation pipes.
Make sure that all harnesses and pipes are disconnected.

Lift the engine and transmission assembly slowing. Take care
not to bump the assembly against the frame and cab.
CAUTION
When lifting the engine and transmission assembly, do not
incline it larger than 40 .
11-20
11
M E M O
11-21
<FG>
Removal sequence
1 Roll stopper
2 Transmission
3 Engine
Installation sequence
Follow the removal sequence in reverse.
CAUTION
Be careful not let the engine hit the cab or the rear body when hoisting the engine.
Only use hoisting equipment appropriate for the engine weight (approximately 500 kg {110 lb}).

Nut (Front mounting installation) 69 to 88 {51 to 65, 7 to 9}
Bolt (Roll stopper bracket installation)
45 to 65 {33 to 48, 4.6 to 6.6}
Bolt (Rear mounting installation)
Bolt (Transmission installation) 82.4 {61, 8.4}
Bolt (Transmission installation) 47.1 {35, 4.8}
Nut (Roll stopper bracket installation) 38 to 54 {28 to 40, 3.9 to 5.5}
11-22
11
Special tools
Engine front hanger MH063636 Removal and installation of engine
MF140429
Flange bolt MF140433 Installation of engine front hanger
MF140421
Engine rear hanger MH063711 Removal and installation of engine
Work before removal

Preparing for engine removal: Installation of engine front
hanger and flange bolt
Install , and on the engine.
11-23
Removal procedure
Removal: Engine
Hook the wire rope on and hitch the chain block to .
Pull all the slack out of the slings.
CAUTION
The slings must be strong enough to hang the engine
(weighing approximately 500 kg {1100 lb}).
Be sure to keep the slings away from the exhaust gas recir-
culation pipes.
Make sure that all harnesses and pies are disconnected.

Hoist the engine slowly, taking care not to let the engine hit the
frame and the cab.
CAUTION
When lifting the engine and transmission assembly, do not
incline it larger than 40 .
Once the bottom of the engine is out of the frame, turn the en-
gine by 90 degrees and remove it out of the vehicle.
11-24
11
M E M O
11-25
ENGINE REMOVAL AND INSTALLATION <FIXED CAB>
CAUTION
Before removing each part, support the engine and transmission assembly in place using an engine lifter
and a transmission jack.

Nut (Front mounting installation) 69 to 88 {51 to 65, 7 to 9}
11-26
11
Removal procedure
Removal: Engine and transmission assembly
Support the engine and transmission assembly with an engine
lifter and a transmission jack.
Check that all wiring and piping have been disconnected from
the engine.
Lower the engine and transmission assembly to the greatest ex-

tent possible while keeping it horizontally balanced.
Jack up the vehicle and slide the engine and transmission as-
sembly forward.
11-27
ROCKER COVER
11-28
11
Disassembly sequence
1 Oil filler cap 8 Fuel return hose 15 Cylinder sensor
2 Cover <except crew cab> 9 Injection pipe 16 Rocker cover
3 Rear cover <crew cab> 10 Bolt (with hexagonal hole) 17 Rocker cover gasket A
4 Rear cover gasket <crew cab> 11 Injector 18 Rocker cover gasket B
5 Front cover <crew cab> 12 O-ring
6 Rocker cover rubber 13 Tip gasket : Non-reusable parts
7 Snap ring 14 PCV pipe PCV: Positive Crankcase Ventilation
Assembly sequence
Follow the disassembly sequence in reverse.

Bolt (cover installation)
Bolt (rocker cover installation) 23.2 {17, 2.4}
Bolt (PCV pipe installation)
Injection pipe (union nut installation) 30.4 to 35 {22 to 26, 3.1 to 3.6}
Bolt (injector installation) 5.2 to 7.2 {3.8 to 5.3, 0.53 to 0.73}
Bolt (clinder sensor installation) 8 {5.9, 0.82}
Lubricant and/or sealant

Mark Points of application Specified lubricant and/or sealant Quantity
O-ring Engine oil As required
11-29
ROCKERS AND CAMSHAFTS
1 Exhaust rocker shaft
(See later sections.)
2 Intake rocker shaft
3 Camshaft frame
4 Gasket
5 O-ring
6 Upper camshaft bearing
7 Packing
8 Intake camshaft
9 Exhaust camshaft
10 Lower camshaft bearing
*a:: Head idler gear

Locating pin
: Non-reusable parts
CAUTION
The camshaft frame and cylinder
head are manufactured as a
matched set. Never replace the
camshaft frame or the cylinder head
individually.
Do not change the upper and lower
camshaft bearing combinations. Do
not interchange the position of an
upper and lower camshaft bearing
set with that of another.
Assembly sequence
Follow the disassembly sequence in re-
verse.

Head idler gear-to-camshaft
0.080 to 0.126 {0.0031 to 0.0050} 0.3 {0.012}
Backlash gear Replace
Head idler gear-to-idler gear 0.103 to 0.158 {0.0041 to 0.0062} 0.3 {0.012}
Camshaft 0.10 to 0.20 {0.0039 to 0.0079} 0.3 {0.012}
End play Inspect
Head idler gear 0.10 to 0.20 {0.0039 to 0.0079} 0.3 {0.012}
Camshaft bearing-to-intake camshaft
6, 8, 10 0.07 to 0.12 {0.0028 to 0.0047} 0.16 {0.024} Replace
clearance
Camshaft bearing-to-exhaust camshaft
6, 8, 10 0.07 to 0.12 {0.0028 to 0.0047} 0.16 {0.024} Replace
clearance
35.5 {1.40}
6, 10 Camshaft bearing span (when free) Replace
or less
11-30
11
Bolt (rocker shaft installation: 10 places)
27.5 {20, 2.8} Wet
Bolt (camshaft frame installation: 13 places)
Bolt (camshaft installation: 2 places) 23.5 {17, 2.4}
Bolt (camshaft frame installation: 4 places) 23.2 {17, 2.4}

Bolt threads and seat
Camshaft bearing inner surface Engine oil As required
Camshaft journals and cams
Cylinder head mounting surface of camshaft frame
THREEBOND 1207C or D As required
Entire periphery of packing
Work before removal

Inspection: Backlash between gears
Measure the backlash at three or more locations for each pair of
gears.
If any of the measurements exceeds the specified limit, replace
the defective part(s).
Inspection: Camshaft end play

If the end play exceeds the specified limit, replace the defective
part(s).
Releasing valve spring tension

Before removing the bolts in the next process, loosen the adjust-
ing screws on the rockers whose valve springs are compressed
(due to the cams lifting these rockers). This operation is neces-
sary to release the tension in the valve springs, thus preventing
other parts from undue forces when the bolts are removed.
11-31
Removal procedure
Removal: Rocker shafts and camshaft frame
Loosen the rocker shaft installation bolts (10 places) and the
camshaft frame installation bolts (13 places) in several passes in
the order indicated in the illustration (1 to 23). Then, remove the
rocker shafts and the camshaft frame.
Inspection procedure
Inspection: Camshaft bearing free span
CAUTION
Do not force the bearings open.
When replacing the bearings, always replace the upper and
lower bearings as a set.
Replace the bearings if the measurement is not within the stan-

dard value range.
Inspection: Camshaft bearing-to-camshaft clearance

If the measurement is not within the standard value range, re-
place the defective part(s).
11-32
11
Installation procedure
Installation: Camshaft
Install the upper camshaft bearing on the camshaft frame and
the lower camshaft bearing on the cylinder head by fitting their
lugs into the notches in the camshaft frame and cylinder head.
Place the No. 1 cylinder piston at the top dead center on the
compression stroke.
Align the mating marks on the camshaft gears with those on the
camshaft frame when installing the camshafts.
NOTE
Each camshaft gear also has mating mark L or R for
alignment with the head idler gear. This mark may not be
exactly aligned with that on the head idler gear, as the posi-
tion that the head idler gear takes when it is installed may
make it impossible to align them. Such a misalignment
does not lead to any undesirable consequences.
Installation: Rocker shafts and camshaft frame
Clean the sealant application surfaces on each part.
Apply sealant to the entire periphery of the four packings evenly
and without any breaks.
Apply sealant to the camshaft frame evenly and without any
breaks.
Mount the camshaft frame and packing on the cylinder head
within three minutes of applying the sealant, being careful not to
dislodge the sealant in the process.
CAUTION
Do not run the engine within one hour of installing the rock-
er shafts and camshaft frame.
11-33
When installing the camshaft frame on the cylinder head, also
install the rocker shafts. Then, tighten the rocker shaft bolts (10
places) and the camshaft frame bolts (13 places) in the order in-
dicated below.
CAUTION
Reapply sealant to the areas specified above if any of the
bolts is loosened or removed after the rocker shafts and
camshaft frame are installed.
Tighten the bolts (1 to 23) to the specified torque in the order in-
dicated in the illustration.
11-34
11
M E M O
11-35
Rocker Shafts and Rockers
1 Adjusting screw 7 Long rocker
2 Rocker bushing 8 Exhaust rocker shaft
3 Short rocker 9 Intake rocker shaft
4 Rocker shaft spring
5 Adjusting screw : Hole for camshaft frame locating pin
6 Rocker bushing : Non-reusable parts
Assembly sequence
CAUTION
The short rockers and long rockers must be installed alternately. Be aware that the order of installation
for the intake rockers is different from the order of installation for the exhaust rockers.

0.038 to 0.100
3, 7 Rocker (roller) radial play Replace
{0.0015 to 0.0039}
2, 6, 0.01 to 0.08 0.12
Rocker bushing-to-rocker shaft clearance Replace
8, 9 {0.00039 to 0.0031} {0.0047}

Lock nut (adjusting screw stopping) 20.6 {15, 2.1}

Rocker bushing inner surface Engine oil As required
11-36
11
Rocker bushing puller

A B Removal and installation of rocker
MH062536
22 24.5 bushing
{ 0.87} { 0.96}
Inspection: Rocker (roller) radial clearance
Replace the rocker if the radial play measurement is not within
the standard value range.
Inspection: Rocker bushing-to-rocker shaft clearance

Replace the bushing if the measurement exceeds the specified
limit.
Replacement of rocker bushing

[Removal]
11-37
[Installation]
Press-fit each rocker bushing in the rocker with its ends facing
in the illustrated directions.
11-38
11
M E M O
11-39
Camshafts
1 Intake camshaft gear
2 Key
3 Intake camshaft
4 Exhaust camshaft gear
5 Key
6 Exhaust camshaft
NOTE
Do not remove the camshaft gears
unless defects are evident.
Assembly sequence
verse.
NOTE
The exhaust camshaft gear has the
sensor plate. Do not mistake it for
the intake camshaft gear. If the
gears are incorrectly installed, en-
gine malfunction will occur.
0.007 to 0.041
1, 3, 4, 6 Camshaft gear-to-camshaft interference Replace
{0.00028 to 0.0016}
Lobe height: 42.219 {1.66}
Cams for
7.21 {0.284} 7.16 {0.282} Base circle diameter:
long rockers
Re- 35.009 {1.38}
Cam lift
3 Intake camshaft place Lobe height:44.281 {1.74}
Cams for
short rockers
35.012 {1.38}
Bend 0.01 {0.00039} 0.03 {0.0012} Replace
Lobe height: 42.279 {1.66}
Cams for
long rockers
Re- 35.095 {1.38}
Exhaust Cam lift
6 place Lobe height: 44.359 {1.75}
camshaft Cams for
short rockers
35.117 {1.38}
Bend 0.01 {0.00039} 0.03 {0.0012} Replace
Removal procedure
Removal: Camshaft gears
Remove the camshaft gear by pushing on the camshaft using a
press.
CAUTION
Do not use a hammer to remove the camshaft gear. Be sure
to use a press for this purpose.
11-40
11
Inspection: Camshaft gear-to-camshaft interference
Inspection: Camshaft
(1) Cam lift
Replace the camshaft if the difference between the cam lobe
height and base circle diameter measurements is less than the
specified limit.
NOTE
The cams for the long rockers (L) are different from the
cams for the short rockers (S).
(2) Bend
Place supports under the journals at the ends of the camshaft
and measure the bend of the camshaft at the central journal.
If the measurement exceeds the specified limit, replace the cam-
shaft.
NOTE
Turn the camshaft by one turn and read the dial gauge. Di-
vide the reading by two to obtain the amount of camshaft
bend.
Installation: Camshaft gears
Heat the camshaft gears to approximately 150 C {302 F} with a
gas burner.
Install the camshaft gear on the camshaft with a mating mark
( R or L ) facing in the illustrated direction.
Press the gear until its end comes in close contact with the
flange on the camshaft.
11-41
CYLINDER HEAD AND VALVE MECHANISM
11-42
11
1 Connection plates 6 Thrust plate
*a: Idler gear
2 Glow plug 7 Cylinder head bolt *b: Upper crankcase
3
4
Head idler shaft
Head idler gear bushing
8 Cylinder head
*c:: Front case
Locating pin
5 Head idler gear 9 Cylinder head gasket : Non-reusable parts
CAUTION
Be careful not to damage the glow plugs and injectors when placing the cylinder head on the worktable,
as they are protruding out of the bottom of the cylinder head.
The cylinder head bolts are tightened using the torque-turn method. Any cylinder head bolt that has three
marks indicating that the bolt has been tightened three times already must be replaced with a new one.
Assembly sequence
CAUTION
Do not forget to install the thrust plate.

0.1 to 0.2
Head idler gear end play 0.3 {0.012} Replace
{0.0039 to 0.0079}
0.01 to 0.05
3, 4 Head idler shaft-to-head idler gear bushing clearance 0.1 {0.0039} Replace
{0.00039 to 0.0020}

Cylinder head bolt 147 {110, 15} + 90 Wet
Nut (connection plate installation) 1.0 to 1.5 {0.7 to 1.1, 0.1 to 0.15}
Glow plug 19.6 to 24.5 {14 to 18, 2 to 2.5}
Bolt (head idler shaft installation) 51.0 {38, 5.2}

O-ring
Bolt (head idler gear installation) threads and seating sur-
face under head Engine oil As required
Head idler shaft outer peripheral surface
Cylinder head bolt threads
Top surfaces of joints between upper crankcase and front
THREEBOND 1207C As required
case
11-43
Idler gear bushing puller

A B Removal and installation of idler gear
MH061779
32 35 bushing
{ 1.26} { 1.38}
Inspection before removal

Inspection: Head idler gear end play
If the measurement exceeds the specified limit, replace the de-
fective part(s).
Removal procedure
Removal: Cylinder head
Loosen the cylinder head bolts (1 to 18) in several passes in the
order indicated in the illustration and remove the cylinder head.
Removal: Cylinder head gasket

CAUTION
When removing the cylinder head gasket, be careful not to
scratch the cylinder head, the upper crankcase and the
front case.
Inspection: Head idler shaft-to-head idler gear bushing
clearance
limit.
11-44
11
Replacement of head idler gear bushing
[Removal]
[Installation]
Position the bushing on the head idler gear with their ends fac-
ing the illustrated directions and their oil holes on the same line.
Using , press the bushing into the head idler gear until it is
flush with the lower edge of the chamfer on the head idler gear.
Remeasure the clearance between the bushing and head idler
shaft.
Ream the bushing if the measurement is less than the standard
value.
Installation: Cylinder head
CAUTION
Before fitting the cylinder head bolts, check the punch
marks on each bolt s head. Do not use the bolt if there are
three punch marks.
The punch marks indicate the number of times each bolt
has been tightened using the torque-turn tightening meth-
od. Any bolt that already has three punch marks must be re-
placed.
The cylinder head gasket comes in three sizes. Choose the gas-
ket appropriate for the cylinder head by the following procedure.
Measure the amount of piston projection for every cylinder.
(See the PISTONS, CONNECTING RODS AND CYLINDER
LINERS section.)
Select a cylinder head gasket with the appropriate thickness
for the average of the piston projection measurements from
the table below.
If any of the piston projection measurements is more than
0.05 mm {0.0020 in.} larger than the average value, then use
the gasket one class higher than that classs (A B, B C).
Unit: mm {in.}
Cylinder head gasket
Piston projection Thickness
Size
when tightened
0.088 to 0.027 0.75 0.03
A
{ 0.0035 to 0.0011} {0.030 0.0012}
0.027 to 0.033 0.80 0.03
B
{ 0.0011 to 0.0013} {0.031 0.0012}
0.033 to 0.094 0.85 0.03
C
{0.0013 to 0.0037} {0.033 0.0012}
11-45
The size class of the cylinder head gasket can be determined
from the size mark or the shape of the notches cut on the gasket
edge.
CAUTION
Replacement of the piston or connecting rod alters the pis-
ton projection. Always measure the amount of piston pro-
jection after either or both of them are replaced.
Clean the sealant application surfaces of each part.

Apply sealant to the top surfaces of the joints between the upper
crankcase and front case (at two places).
Install the cylinder head and its gasket on the upper crankcase
within three minutes of applying the sealant, being careful not to
dislodge the sealant.
CAUTION
Do not run the engine within one hour of mounting the cyl-
inderhead. If any cylinder head bolts are loosened or re-
moved, be sure to reapply sealant to the surfaces specified
above.
Tighten the cylinder head bolts (1 to 18) to a torque of 147 N m

{110 ft.lbs, 15 kgf m} (wet) in the order indicated in the illustra-
tion. Then, tighten them further by 90 in the same order.
After tightening each bolt, make a punch mark on the head of
the bolt to indicate the number of times that it has been used.
CAUTION
Cylinder head bolts that have been tightened using the
torque-turn method must never be additionally tightened af-
ter the final angular tightening.
11-46
11
M E M O
11-47
Cylinder Head
1 Valve cotter 10 Exhaust valve seat 16 Stud (short)
2 Upper retainer 11 Intake valve seat 17 Stud (long)
3 Outer valve spring 12 Sealing cap 18 Cylinder head
4 Inner valve spring (diameter: 22 mm {0.87 in.})
5 Valve stem seal 13 Sealing cap : Non-reusable parts
6 Exhaust valve (diameter: 30 mm {1.18 in.})
7 Intake valve 14 Sealing cap
8 Exhaust valve guide (diameter: 40 mm {1.57 in.})
9 Intake valve guide 15 Taper plug
Assembly sequence
CAUTION
When an intake valve or exhaust valve have been removed, make sure to replace the valve stem seal.
11-48
11
Free length 87.8 {3.46}
Installed load
3 Outer valve spring 360 N {81 lbs, 36.7 kgf} Replace
(57 {2.24} in installed length)
Squareness 2.5 {0.098}
Free length 78.8 {3.10}
Installed load
4 Inner valve spring 168 N {38 lbs, 17.1 kgf} Replace
(52.3 {2.06} in installed length)
Squareness 2.5 {0.098}
0.060 0.0024
Stem outside diameter 8 0.075 { 0.31 0.0030 } Replace
Sinkage from cylinder head 1.5 0.25
Inspect
6 Exhaust valve bottom surface {0.059 0.0098}
Valve margin 1.5 {0.059} Reface or replace
Seat angle 45 15 Reface
0.07 to 0.10
6, 8 Exhaust valve stem-to-valve guide clearance 0.2 {0.0079} Replace
{0.0028 to 0.0039}
0.025 0.00098
Stem outside diameter 8 0.040 { 0.31 0.0016 } Replace
Sinkage from cylinder head 1.5 0.25
Inspect
7 Intake valve bottom surface {0.059 0.0098}
Valve margin 1.5 {0.059} Reface or replace
Seat angle 45 15 Reface
0.03 to 0.06
7, 9 Intake valve stem-to-valve guide clearance 0.2 {0.0079} Replace
{0.0012 to 0.0024}
2.5 0.2 Correct or
10 Exhaust valve seat width 3.5 {0.14}
{0.098 0.0079} replace
2 0.2 Correct or
11 Intake valve seat width 2.8 {0.11}
{0.079 0.0079} replace
Correct or
Bottom surface distortion 0.05 {0.0020} or less 0.2 {0.0079}
replace
18 Cylinder head
Height from top surface to bot-
107 0.5 {4.21 0.020} 106.5 {4.19} Replace
tom surface
Tightening torque (Unit: N m {kgf m})

Tapered plug 14 {10, 1.4}
Stud 20 {15, 2.0}

Lip of valve stem seal
Engine oil As required
Valve stem and valve end
11-49
Valve lifter MH061668
Valve lifter seat

A MH061772
38
{ 1.50} Removal and installation of valve cot-
ters
Valve lifter hook MH061679
Valve stem seal installer

A B C MH063607 Installation of valve stem seals
26.5 14.7 8
{ 1.04} { 0.58}{ 0.31}
Valve lapper 30091-07500 Lapping valves and valve seats
Valve guide remover

A B 31391-10500 Removal of valve guides
8 12
{ 0.31} { 0.47}
Valve guide installer

A B C MH063604 Installation of valve guides
25.5 13 29
{ 1.00} { 0.51}{ 1.14}
Caulking tool body

A
31391-13100
8
{ 0.31}
Installation of valve seat
Installer ring
B
MH063605
38
{ 1.50}
11-50
11
Removal procedure
Removal: Valve cotters
Remove the valve cotters by evenly compressing the valve
springs.
Inspection: Intake valves and exhaust valves
(1) Inspection of valve stem
Replace the valve if the stem s outside diameter is below the lim-
it or is severely worn.
When the valve has been replaced with a new one, make sure to
lap the valve and valve seat.
(2) Valve seat angle and valve margin

Reface or replace the valve if the valve seat angle or valve mar-
gin exceeds the specified limits.
Refacing
Limit grinding to a necessary minimum.
If the valve margin is below the limit after grinding, replace the
valve.
After grinding, make sure to lap the valve and valve seat.
Inspection: Valve-to-valve guide clearance

If the clearance exceeds the specified limit, replace the defective
part(s).
11-51
Replacement of valve guides
[Removal]
[Installation]
Install the valve guide until sits snugly on the cylinder head.
CAUTION
The valve guides must be pressed to the specfied depth. Be
sure to use for this operation.
Exhaust valve guides are longer than intake valve guides.
Make sure to install the correct type of guide in each loca-
tion.
Inspection: Contact between valve and valve seat

Before starting inspection, check that the valve and valve guide
are intact.
Apply an even coat of red lead to the valve contact surface of
the valve seat.
Strike the valve once against the valve seat. Do not rotate the
valve during this operation.
If the red lead deposited on the valve indicates a poor contact

pattern, take either of the following corrective actions.
Corrective action
Minor defect Lapping
Serious defect Reface or replace valve and valve seat
Lapping
Perform the valve lapping in the following procedure.
Apply a thin coat of lapping compound to the seat contact sur-
face of the valve.
CAUTION
Do not put any compound on the stem.
Start with an intermediate-grit compound (120 to 150 grit)
and finish with a fine-grit compound (200 grit or more). Do
not put any compound on the stem.
Adding a small amount of engine oil to the lapping com-
pound can facilitate even application.
11-52
11
Strike the valve several times against the valve seat while rotat-
ing the valve a little at a time.
Wash away the compound with diesel fuel.
Apply engine oil to the valve contact surface of the valve seat
and rub in the valve and seat well.
Inspect the contact pattern of the valve and valve seat again.
If the contact pattern is still defective, replace the valve seat.
Inspection: Valve seats

(1) Valve seat width
If the measurement exceeds the limit, reface or replace the
valve seat.
CAUTION
After refacing or replacing the valve seat, make sure to lap
the valve seat and valve.
(2) Valve sinkage from cylinder head bottom surface

Make sure that the valve and valve seat are pressed together
tightly when measuring the sinkage.
If the measurement exceeds the limit, reface or replace the de-
fective part(s).
Refacing the valve seat

Grind the valve seat using a valve seat cutter or valve seat
grinder.
Place a sandpaper of around #400 between the cutter and valve
seat and grind the valve seat lightly.
Use a 15 or 75 cutter to cut the valve seat to a width within the
standard range. If the valve seat cannot be refaced to a width
within the standard range, replace it.
CAUTION
Make sure that the valve seat refacing does not cause the
valve sinkage to exceed the specified limit.
Lap the valve and valve seat.
11-53
Replacement of valve seat
[Removal]
The valve seats are installed by expansion fitting. To remove a
valve seat, grind inside the metal stock to reduce the wall thick-
ness, then remove the valve seat at room temperature.
[Installation]
Check that the diameter of the valve seat hole in the cylinder
head conform with the value shown below.
+0.025 +0.00098
Valve seat hole diameter 38 0 mm { 1.50 0 in.}
Replace the cylinder head if the measurement deviates from
specification.
Chill the valve seat thoroughly by immersing in it in liquid nitro-

gen.
Install the valve seat in the cylinder head using and ,
with the chamfered edge of toward the valve seat.
Turn over so that its chamfered edge is toward , and
calk the valve seat.
Lap the valve seat and valve.
Inspection: Cylinder head bottom surface distortion

If the distortion exceeds the specified limit, rectify it using a sur-
face grinder.
CAUTION
When griding the cylinder head bottom surface, make sure
that the height of the cylinder head (from the top surface to
the bottom surface) is not reduced to a value below the
specified limit.
11-54
11
Installation: Sealing caps
Drive the sealing caps into the cylinder head to the specified
depth.
Installation: Valve stem seal

Apply engine oil to the lip of the valve stem seal.
Install the valve stem seal until sits snugly on the cylinder
head.
CAUTION
After installing the valve stem seal, check that its spring is
not deformed or damaged.
Installation: Valve cotter

To install the valve cotter, follow the removal procedure. (See
Removal: Valve cotter .)
11-55
PISTONS, CONNECTING ROD AND CYLINDER LINERS
1 Lower connecting rod bearing
2 Connecting rod cap
3 Upper connecting rod bearing
4 Piston and connecting rod assem-
bly (See later sections.)
5 Cylinder liner
: Locating pin
Assembly sequence
verse.

Piston projection from crankcase top surface (average 0.088 to 0.094
Inspect
value) { 0.0035 to 0.037}
0.15 to 0.45
Connecting rod end play 0.6 {0.024} Inspect
{0.0059 to 0.018}
Less than
Span when free
69.5 {2.74}
1, 3 Connecting rod bearing Replace
0.034 to 0.093
Oil clearance 0.2 {0.0079}
{0.0013 to 0.0037}
0.181 to 0.201
4, 5 Piston-to-cylinder liner clearance Replace
{0.0071 to 0.0079}
Flange projection above 0.01 to 0.07
crankcase top surface {0.00039 to 0.0028}
114 to 114.02 114.25
Bore diameter
{ 4.4881 to 4.4889} { 4.50}
5 Cylinder liner Out-of-roundness 0.08 {0.0031} or less Replace
Taper 0.03 {0.0012} or less
Difference in flange projec-
tion from neighboring cylin- 0.04 {0.0016} or less
der liner

Bolt (connecting rod cap installation) 29 {2.1, 3.0} + 90 5 Wet
11-56
11
Bolt threads
Connecting rod bearing inside surface
Upper crankcase contact surface of cylinder liner Engine oil As required
Piston outside surface
Cylinder liner wall surface

Piston guide clamp MH064332
Installation of piston and connecting

rod assembly
Piston guide lever MH061658
Cylinder liner extractor MH062537 Removal of cylinder liner
Cylinder liner installer

A MH063606 Installation of cylinder liner
113.5
{ 4.47}
Adapter MH063433
Bolt Measurement of cylinder liner flange

projection above upper crankcase top
A B MF130625 surface and difference in flange pro-
40 {1.57} M14 2 jection between neighboring cylinder
liners
Washer MH005012

Retaining cylinder liners
The cylinder liners slips out of the upper crankcase easily when
the upper crankcase is turned over or the crankshaft is rotated
with pistons inside liners. To prevent this from happening, retain
the flange of each cylinder liner in position with a bolt and wash-
er.
11-57
Inspection: Piston projection from upper crankcase top sur-
face
CAUTION
The amount of piston projection affects engine perfor-
mance and must therefore be inspected without fail.
Set the piston at the top dead center.

Mark reference points A (five points in total) on the top surface of
the upper crankcase as shown in the illustration. Using each of
the marks as a zero point, measure the amount of piston projec-
tion relative to the zero point (height of measurement point B
height of reference point A).
Make the measurements at the two measurement points B for
each cylinder (eight points in total) using the reference point A
nearest to each measurement point, and calculate the average
value of all the measurements.
If the average value is out of the standard value range, check
the clearances between all relevant parts.
Select and use a cylinder head gasket that can accommodate
the average piston projection (average value of the eight mea-
surements).
Inspection: Connecting rod end play
Measure the end play for every connecting rod.
If any measurement exceeds the specified limit, replace the de-
fective part(s).
Inspection: Difference in flange projection between neigh-

boring cylinder liners
Install on the upper crankcase so that it is not lying on top
of any part of the flanges. Tighten to a torque of 49 N m {36
ft.lbs, 5 kgf m}.
Measure the amount of projection of the cylinder liner flange

above the upper crankcase top surface.
If the measurement is not within the standard value range, in-
spect the state of installation of the cylinder liner and then re-
CAUTION
Insufficient projection of the flange can lead to a reduced
pressure around the bore of the cylinder head gasket, caus-
ing gas leakage.
11-58
11
Inspection: Connecting rod bearing span when free
CAUTION
Do not attempt to manually expand the bearings.
The upper and lower connecting rod bearings must be re-
placed as a set.
If the span is less than the specified limit, replace both the upper
and lower bearings.
Inspection: Connecting rod bearing-to-crankshaft clearance

(oil clearance)
Fit the lower bearing to the connecting rod cap and the upper
bearing to the connecting rod, then tighten the bolts to a torque
of 30 N m {22 ft.lbs, 3.1 kgf m}.
Measure the inside diameter of the bearing and the diameter of
the crankshaft pin.
If the clearance exceeds the limit, replace the defective part(s).
If a bearing has to be replaced with an undersized one, machine
the crankshaft pin to the specified undersize diameter.
Inspection: Piston-to-cylinder liner clearance

A: Cylinder bore measurement (in direction of crankshaft axis)
B: Cylinder bore measurement (in direction perpendicular to
crankshaft axis)
C: Piston diameter measurement (in direction perpendicular to
piston pin hole)
11-59
Replacement of cylinder liner
[Removal]
[Installation]
Select cylinder liners with the same size marks as those on the
upper crankcase and the pistons.
The size marks on the upper crankcase are marked in the order
of No. 1 cylinder, No. 2 cylinder, No. 3 cylinder and No. 4 cylin-
der starting with the front of the engine.
Upper crankcase Cylinder liner Piston size mark

size mark size mark
1 1A A
1B
2A
2 2B B
Apply a thin coat of engine oil to the surfaces surrounding the

cylinder liner of the upper crankcase (the shaded areas in the il-
lustration).
Insert the cylinder liner into the upper crankcase by pushing

down on by hand slowly and evenly.
CAUTION
Handle the cylinder liner extremely carefully, as its wall is
relatively thin and can be easily damaged.
11-60
11
Installation: Connecting rod bearings
CAUTION
Do not reverse the positions of the lower bearing and the
upper bearing (with oil hole) when installing, as this may
cause seizure in the engine.
Installation: Piston and connecting rod assembly

Check that the piston ring end gaps are in their correct positions.
A: 1st compression ring gap
B: 2nd compression ring gap
C: Oil ring gap
D: Oil ring expander spring gap
: Front mark on piston
Check that the pistons and the cylinder liners have identical size
marks ( A or B ).
Install the pistons in the cylinder liners. Be careful not to scratch
the inner surface of the liner and the crankshaft pins.
Face the front mark of the piston toward the front of the en-
gine.
Using the adjusting bolt of , adjust the inside diameter of
such that it matches the piston s skirt diameter.
Remove the tools from the piston and apply engine oil to the fol-
lowing parts before reinstalling the tools around the piston rings:
Outside surface of piston
Inside surface of
Inside surface of cylinder liner
11-61
After installing the piston and connecting rod assembly, align the
mating marks on the connecting rod and connecting rod cap and
tighten the bolts alternately in the following manner.
First tighten the bolt to a torque of 29 N m {21 ft.lbs, 3.0
kgf m}.
Tighten the bolt further by turning it clockwise by 90 5 .
11-62
11
M E M O
11-63
Piston and Connecting Rod
1 1st compression ring
2 2nd compression ring
3 Oil ring
4 Snap ring
5 Piston pin
6 Connecting rod bushing
7 Connecting rod
8 Piston
Assembly sequence
verse.

0.3 to 0.45
1st compression ring
{0.012 to 0.018}
0.4 to 0.55 1.5
1 to 3 Piston ring end gap 2nd compression ring Replace
{0.016 to 0.022} {0.059}
0.3 to 0.5
Oil ring
{0.012 to 0.020}
0.129 to 0.178 0.2
1st compression ring
{0.0051 to 0.0070} {0.0079}
Piston ring side clearance 0.065 to 0.105
1 to 3, 8 2nd compression ring Replace
in piston groove {0.0026 to 0.0041} 0.15
0.025 to 0.065 {0.0059}
Oil ring
{0.00098 to 0.0026}
0.020 to 0.055 0.1
4, 6 Piston pin-to-connecting rod bushing clearance Replace
{0.00079 to 0.0022} {0.0039}
0.004 to 0.022 0.05
4, 8 Piston pin-to-piston clearance Replace
{0.00016 to 0.00087} {0.0020}
0.05
Bend
{0.0020}
7 Connecting rod Replace
0.1
Twist
{0.0039}

Piston pin outside surface
Connecting rod bushing outside surface Engine oil As required
Connecting rod bushing fitting surface of connecting rod
11-64
11
Special tools
Removal and installation of piston

Piston ring tool MH060014
rings
Connecting rod bushing Removal and installation of connect-

MH062225
puller kit ing rod bushings
Removal procedure
Removal: Piston ring
Removal: Piston pin

Remove the piston pin by striking it with a rod and hammer.
If the piston pin is difficult to remove, first heat the piston in hot
water or with a piston heater.
Inspection: Piston ring end gap
Using the crown of a piston, push the piston ring horizontally into
a cylinder in the cylinder liner until it reaches the lower part of the
cylinder liner, where there is relatively small wear.
Taking care not to move the piston ring, measure the end gap.
If any of the rings has a gap exceeding the specified limit, re-
place all the piston rings as a set.
11-65
Inspection: Piston ring side clearance in piston groove
Remove any carbon deposits from the ring groove in the piston.
Measure the side clearance of each ring around the piston s en-
tire periphery.
the defective part(s). If any of the piston rings is defective, re-
place all the rings on the piston as a set.
Inspection: Piston pin-to-piston clearance

fective part(s).
Inspection: Piston pin-to-connecting rod bushing clearance

the bushing.
Replacement of connecting rod bushing

Replace the connecting rod bushing using .
[Removal]
Remove the upper bearing (if fitted) from the big end of the con-
necting rod.
Mount the connecting rod on the base and lock it in position with
the bracket and plate.
Fit collar A over the puller with its ends facing in the illustrated di-
rections. Then, slowly apply a pressure of approximately 49 kN
{11020 lbs, 5000 kgf} to the puller with a press to force out the
connecting rod bushing.
11-66
11
[Installation]
Apply engine oil to the outside surface of the connecting rod
bushing and the bushing fitting surface of the connecting rod.
Fit collar B, the bushing, and collar A over the puller in the illus-
trated directions and lock this arrangement together with the nut.
Align the oil holes in the connecting rod bushing and the con-
necting rod. Then, use a press to slowly apply a pressure of ap-
proximately 49 kN {11020 lbs, 5000 kgf} to the puller until the
bushing is forced into place.
After press-fitting the connecting rod bushing, measure the
clearance between the piston pin and connecting rod bushing.
If the measurement is less than the standard clearance range,
ream the bushing.
Inspection: Connecting rod bend and twist

Mount the connecting rod on the connecting rod aligner. Also
mount the connecting rod bearings, piston pin, and connecting
rod cap to create the same conditions as are expected when the
connecting rod is mounted on a crankshaft. Tighten the bolts of
the connecting rod bearing cap to a torque of 30 N m {22 ft.lbs,
3.1 kgf m}.
Measure the extent of bend and twist in the connecting rod.
If either measurement exceeds the specified limit, replace the
connecting rod.
11-67
Installation: Piston and connecting rod
When replacing a piston and connecting rod assembly, select
and install a new piston and connecting rod by the following pro-
cedure.
Choosing pistons
Choose pistons of the same weight for all cylinders.
Check that the size marks ( A or B ) on the piston and cyl-
inder liner are identical.
CAUTION
Make sure to use pistons and cylinder liners of the same
size. Failure to do so may result in seizures in the engine.
Choose connecting rod of the same weight for every cylinder.

Apply engine oil to the piston pin, and assemble the piston and
connecting rod with their marks facing in the illustrated direc-
tions.
: Front mark
If the piston pin is difficult to insert, heat the piston in hot water or
with a piston heater.
Installation: Piston rings

With the manufacturer s marks (found near the piston ring end
gaps) facing up, install the piston rings so that the end gap of
each ring is positioned as illustrated.
A: 1st compression ring end gap
B: 2nd compression ring end gap
C: Oil ring end gap
D: Oil ring s expander spring end gap
: Front mark on piston
The manufacturer s marks are present only on the 1st and 2nd
compression rings.
11-68
11
M E M O
11-69
FLYWHEEL
1 Plate <Manual transmission> 3 Ring gear
Wear plate <Automatic transmission> 4 Flywheel assembly
2 Bearing <Manual transmission> *
a: Crankshaft
Drive plate <Automatic transmission> : Locating pin
Assembly sequence

Friction surface runout
0.2 {0.0079}
Flywheel assembly (when fitted)
4 <Manual Rectify or replace
Friction surface height 19.5 {0.77} 18.5 {0.73}
transmission>
Friction surface distortion 0.05 {0.0020} or less 0.2 {0.0079}

Bolt (flywheel assembly installation) 39 {44, 6.0} + 40 Wet
Bolt (flywheel assembly installation) 118 {87, 12} + 90 Wet

Bolt threads Engine oil As required
11-70
11
Socket wrench
A
MH062183
Bolt head width
across flats: 22 {0.87}
Installation of flywheel assembly
Magnet base MH062356

Inspection: Flywheel runout <Manual transmission>
If the runout exceeds the specified limit, check that the bolts are
tightened correctly and that there are no abnormalities on the
crankshaft mounting surface. If the runout is still excessive even
after necessary steps have been taken according to the check
results, rectify or replace the flywheel sassembly.
Removal procedure
Removal: Ring gear
Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200 C {390 F}, then remove it from the
flywheel assembly.
WARNING
You could get burnt if you touch the heated ring gear.
Inspection: Flywheel assembly <Manual transmission>
(1) Friction surface height
If the height is below the specified limit, rectify or replace the fly-
wheel assembly.
11-71
FLYWHEEL
(2) Friction surface distortion
If the measured amount of distortion is above the specified limit,
rectify or replace the flywheel assembly.
Rectification of friction surface

Rectify the friction surface so that its height is not below the
specified limit, and it is parallel with surface A with an error not
exceeding 0.1 mm {0.0039 in.}.
Installation: Ring gear
Heat the ring gear evenly with a gas burner or the like until it
reaches approximately 200 C {390 F}.
WARNING
You could get burnt if you touch the heated ring gear.
Fit the ring gear with the side having non-chamfered tooth edges
toward the flywheel.
Installation: Flywheel <Manual transmission>

Tighten all the bolts to 59 N m {44 ft.lbs, 6.0 kgf m} and then ad-
ditionally tighten them by the following procedure.
Rotate the holder of counterclockwise to pretension the in-
ternal spring.
Fit on the bolt and set so that the rod (extension) is

held pressed against it by the spring force.
Align a scale mark on the socket with a scale mark on the hold-
er. (This point will be the point of reference, or the 0 point.)
Starting with this point of reference, turn the socket clockwise
with a wrench by 40 5 (one graduation on the socket scale
represents 10 ).
11-72
11
M E M O
11-73
FRONT CASE
1 Eye bolt <Unisia JKC type> 7 O-ring 14 Oil jet
2 Power steering pipe 8 Fan pulley 15 O-ring
3 Power steering oil pump 9 Water pump (See Gr14) 16 Front oil seal slinger
(See Gr37) 10 Gasket
4 O-ring 11 Front oil seal : Non-reusable parts
5 Vacuum pipe 12 Front case
6 Vacuum pump (See Gr35A) 13 Eye bolt
CAUTION
Do not remove the front oil seal unless defects are evident.
Assembly sequence

Nut (power steering pipe installation) 29.4 to 39.2 {22 to 29, 3 to 4}
Vacuum pipe 29.4 {22, 3.0}
Nut (fan pulley installation) 196.1 {145, 20.0}
Eye bolt (oil jet installation) 10 {7.4, 1.0}
Eye bolt (power steering pipe installation) 49.0 to 63.7 {36 to 47, 5.0 to 6.5}
11-74
11
O-ring
Front oil seal lip
Front case installation surfaces THREEBOND 1207C or D As required
Installation: Oil jet
When installed, the oil jet must be in contact with the front case
and its nozzle must face in the illustrated direction.
Installation: Front case

Clean the sealant application surfaces of each part.
Apply evenly thick beads of sealant to the upper crankcase
mounting surface of the front case without any breaks.
Mount the front case within three minutes of applying the seal-
ant, being careful not to dislodge the sealant.
CAUTION
Do not run the engine within one hour of installing the front
case.
If the front case mounting bolts are loosened or removed,
be sure to reapply sealant to the front case.
Installation: Vacuum pump

The vacuum pump also serves as an element holding the bal-
ance shaft LH in place. Therefore, before installing the vacuum
pump, hold the balance shaft LH in the correct position by the
following procedure.
Place the No. 1 cylinder piston at the top dead center on com-
pression stroke.
Remove the upper crankcase plug.
Insert a screwdriver or a similar tool into the plug hole until it
lightly touches the balance shaft LH.
CAUTION
Do not press the screwdriver strongly against the balance
shaft LH, as this may damage the No. 1 journal of the bal-
ance shaft.
Turn the balance shaft LH slowly until the screwdriver aligns

with the shaft support hole at the No. 1 journal and insert the
screwdriver into the hole.
Install the vacuum pump.
After installing the vacuum pump, remove the screwdriver and
reinstall the plug.
11-75
TIMING GEARS AND BALANCE SHAFTS
11-76
11
1 Thrust plate 12 No. 1 idler gear 23 Key
2 Idler gear bushing 13 No. 1 idler shaft 24 Thrust plate
3 Idler gear 14 Oil pump (See Gr12) 25 Balance shaft LH
4 Idler shaft 15 O-ring
5 Fan shaft case bushing 16 Balance shaft gear RH
*a: Crankshaft gear
6 Fan shaft case 17 Thrust spacer *b: Supply pump idler gear
7 Thrust plate 18 Key
8 Fan shaft 19 Thrust plate : Locating pin
9 Fan gear shaft 20 Balance shaft RH : Non-reusable parts
10 Thrust plate 21 Balance shaft gear LH
11 No. 1 idler gear bushing 22 Thrust spacer
Assembly sequence
0.09 to 0.14
Idler gear and fan shaft 0.3 {0.012}
{0.0035 to 0.0055}
0.06 to 0.10
Fan shaft and No. 1 idler gear 0.3 {0.012}
{0.0024 to 0.0039}
No. 1 idler gear and crankshaft 0.11 to 0.13
0.3 {0.012}
Backlash between gear {0.0043 to 0.0051}
Replace
gears No. 1 idler gear and supply pump 0.12 to 0.15
0.3 {0.012}
idler gear {0.0047 to 0.0059}
Oil pump gear and crankshaft 0.12 to 0.15
0.3 {0.012}
gear {0.0047 to 0.0059}
Oil pump gear and balance shaft 0.19 to 0.22
0.3 {0.012}
gear RH {0.0075 to 0.0087}
0.10 to 0.20
Idler gear 0.3 {0.012}
{0.0039 to 0.0079}
0.07 to 0.19
Fan shaft 0.3 {0.012}
{0.0028 to 0.0075}
End play of gears 0.15 to 0.25
No. 1 idler gear 0.3 {0.012} Replace
and shafts {0.0059 to 0.0098}
0.1 to 0.2
Balance shaft RH 0.3 {0.012}
{0.0039 to 0.0079}
0.1 to 0.2
Balance shaft LH 0.3 {0.012}
{0.0039 to 0.0079}
0.02 to 0.06
2, 4 Idler gear bushing-to-idler shaft clearance 0.1 {0.0039} Replace
{0.00079 to 0.0024}
0.03 to 0.07
5, 8 Fan shaft case bushing-to-fan shaft clearance 0.1 {0.0039} Replace
{0.0012 to 0.0028}
0.01 to 0.05
8, 9 Fan shaft-to-fan gear shaft clearance 0.1 {0.0039} Replace
{0.00039 to 0.0020}
0.03 to 0.07
11, 13 No. 1 idler gear bushing-to-No. 1 idler shaft clearance 0.1 {0.0039} Replace
{0.0012 to 0.0028}
20 Balance shaft RH bend 0.025 {0.00098} 0.05 {0.0020} Replace
25 Balance shaft LH bend 0.025 {0.00098} 0.05 {0.0020} Replace

Bolt (idler shaft installation) 32.3 {24, 3.3}
Bolt (No. 1 idler shaft installation) 53.9 {40, 5.5}
Nut (balance shaft gear installation) 96.1 {71, 9.8} Wet
11-77
Inner surface of every bushing
Outside surface of every shaft
O-rings Engine oil As required
Nut threads
Balance shaft journals

A B Removal and installation of idler gear
MH062540
46.5 50 bushing
{ 1.83} { 1.97}

A B Removal and installation of fan shaft
MH062601
37 40 case bushing
{ 1.46} { 1.57}

A B Removal and installation of No. 1 idler
MH062541
54.5 58 gear bushing
{ 2.15} { 2.28}

Inspection: Backlash between gears
For each pair of gears, measure the backlash at more than three
teeth.
the defective part(s).
Inspection: End play of each gear and shaft

fective part(s).
11-78
11
Removal procedure
Removal: Balance shaft
Remove the balance shaft RH by turning its nut counterclock-
wise, and the balance shaft LH by turning its nut clockwise.
Inspection: Idler gear bushing-to-idler shaft clearance
If the measurement exceeds the specified limit, replace the
bushing.
Replacement of idler gear bushing

[Removal]
[Installation]
Place the idler gear with its ends facing as illustrated.
Press-fit the idler gear bushing until sits snugly on the
chamfered end of the idler gear.
After press-fitting the bushing, measure the clearance.
If the measurement is less than the minimum of the standard
value range, ream the idler gear bushing until the clearance falls
within the standard value range.
Inspection: Fan shaft case bushing-to-fan shaft clearance

Replace the fan shaft case bushing if the measurement exceeds
the specified limit.
11-79
Replacement of fan shaft case bushing
[Removal]
[Installation]
Position the fan shaft case with its ends facing in the illustrated
directions.
Press in the bushing until rests snugly on the chamfered
end of the fan shaft case.
After press-fitting the bushing, remeasure the clearance be-
tween it and the fan shaft.
Ream the bushing if the measurement is below the standard val-
ue range.
Inspection: Fan shaft-to-fan gear shaft clearance

Replace the fan shaft if the measurement exceeds the specified
limit.
Inspection: No. 1 idler gear bushing-to-No. 1 idler shaft

clearance
limit.
Replacement of No. 1 idler gear bushing

[Removal]
11-80
11
[Installation]
Position the No. 1 idler gear with its ends facing in the illustrated
directions.
Press in the gear bushing until sits snugly on the cham-
fered end of the No. 1 idler gear.
After press-fitting the bushing, remeasure the clearance be-
tween it and the No. 1 idler shaft.
Ream the busing if the measurement is below the standard val-
ue range.
Inspection: Balance shaft bend

Place supports under the No. 1 and No. 3 journals of the bal-
ance shaft and measure the bend of the balance shaft at the No.
2 journal.
NOTE
Turn the balance shaft by one turn and read the dial gauge.
Divide the reading by two to obtain the balance shaft bend.
If the measurement exceeds the specified limit, replace the bal-

ance shaft.
Installation: Balance shafts
Insatall all the indicated parts on each balance shaft with their
ends facing in the illustrated directions.
Install the balance shaft RH by turning its nut clockwise, and the
balance shaft LH by turning its nut counterclockwise.
Install the balance shaft RH assembly and the balance shaft LH

assembly into the crankcase according to the following proce-
dures, which include different instructions between the two bal-
ance shafts.
The balance shaft RH can be installed in the crankcase with-
out following any special procedure. (The positioning of the
gear of the balance shaft RH will be finally determined by in-
stalling the oil pump.)
11-81
The gear of the balance shaft LH can be engaged with other
gears only after the front case is installed and then the vacuum
pump is installed on the crankcase. This necessitates perform-
ing the following steps before installing the front case and vacu-
um pump. (The balance shaft LH cannot be rotated to adjust the
gear position after the front case is installed on the crankcase.)
Remove the plug on the upper crankcase.
Insert a screwdriver through the plug hole and into the shaft sup-
port hole (diameter: 5 mm {0.20 in.}) on the No. 1 journal of the
balance shaft LH to hold the shaft against rotation.
Align the mating marks on each timing gear.
This positions the balance shaft LH correctly. Leave the balance
shaft in this state until installation of the front case and vacuum
pump is completed.
Installation: Timing gears

Place the No. 1 cylinder piston at top dead center to position the
crankshaft gear.
Install the oil pump gear by aligning mating mark 6 with that on
the crankshaft gear, and mating mark 7 with that on the bal-
ance shaft gear RH.
Install the No. 1 idler gear by aligning mating mark 1 with that
on the crankshaft gear.
Install the fan shaft by aligning mating mark 2 with that on the
No. 1 idler gear.
Install the idler gear by aligning mating mark 4 with that on the
fan shaft.
11-82
11
M E M O
11-83
CRANKSHAFT AND CRANKCASE
1 Rear plate 7 Lower thrust plate 13 Check valve
2 Rear oil seal 8 Upper thrust plate 14 Oil jet
3 Main bearing cap bolt 9 Crankshaft gear 15 Upper crankcase
4 No.1 Lower bearing 10 Rear oil seal slinger
5 Lower main bearing 11 Crankshaft : Locating pin
6 Lower crankcase 12 Upper main bearing : Non-reusable parts
NOTE
Do not remove the parts marked unless defects are evident.
The lower crankcase and the upper crankcase are machined as a matched set, and cannot be replaced in-
dividually.
11-84
11
Assembly sequence
CAUTION
The main bearing cap bolts are tightened using the torque-turn tightening method. Any bolt that has three
punch marks must be replaced.
Do not overtighten the check valve. If it is tightened to a torque exceeding the specification, the check
valve may malfunction, resulting in seizures in the engine.
The No. 1 lower bearing has a oil groove. Be sure to install it in the correct position, otherwise a crank-
shaft seizure may result.

0.10 to 0.28 Replace thrust
Crankshaft end play 0.4 {0.016}
{0.0039 to 0.011} plate
0.038 to 0.1
All except No. 3
{0.0015 to 0.0039} 0.15
Oil clearance
0.058 to 0.12 {0.0059}
4, 5, 12 Main bearing No. 3 Replace
{0.0023 to 0.0047}
Less than
Span when free
91.5 {3.60}
0.05
Bend 0.02 {0.00079} or less Replace
{0.0020}
11 Crankshaft Out-of-round- 0.03
0.01 {0.00039} or less
Pins and journals ness {0.0012} Rectify or replace
Taper 0.006 {0.00024} or less
15 Distortion of upper crankcase top surface 0.07 {0.0028} or less 0.2 {0.0079} Rectify or replace

Bolt (rear plate installation) 63.7 {47, 6.5}
Bolt (lower crankcase installation) 23.5 {17, 2.4} Wet
Wet
Main cap bolt (lower crankcase installation) 49 {36, 5.0} +90 Reusable up to 3
times
Check valve 29.4 {22, 3.0} Wet

Rear oil seal lip
Bolt and main bearing cap bolt threads and seating sur-
face of head Engine oil As required
Main bearing inside surface
Check valve threads
Upper and lower crankcase mating surface of rear oil
seal THREEBOND 1207C or D As required
Lower crankcase mounting surface of upper crankcase
11-85
Gear puller MH061326 Removal of crankshaft gear
Rear oil seal slinger

installer
A B C MH062677 Installation of rear oil seal slinger
103 100 15
{ 4.06} { 3.94} { 0.59}

Inspection: Crankshaft end play
thrust plates with oversize ones.
Available oversizes:
+0.15 mm, +0.30 mm, +0.45 mm {0.0059, 0.012, 0.018 in.}
Replace the crankshaft if the end play is too large to adjust using
oversize thrust plates.
Removal procedure
Removal: Lower crankcase
Loosen the bolts little by little in the order indicated in the illustra-
tion (1 to 16).
After loosening the bolts, loosen the main cap bolts little by little
in the order indicated in the illustration (17 to 26), then remove
the main cap bolts.
Removal: Crankshaft gear

CAUTION
Do not tap off the crankshaft gear as this can damage it.
Removal: Rear oil seal slinger

Taking care not to damage the crankshaft, split the rear oil seal
slinger using a chisel or a similar tool.
11-86
11
Inspection: Main bearing span when free
CAUTION
Do not attempt to manually expand the bearings.
Always replace the upper and lower bearings as a set.

bearing.
Inspection: Main bearing-to-crankshaft clearance

Fit the upper bearing into the upper crankcase and the lower
bearing into the lower crankcase.
Tighten the main bearing cap bolts to a torque of 49 N m {36
ft.lbs, 5.0 kgf m}.
Measure the inside diameter of the main bearing and the diame-
ter of the corresponding crankshaft journal.
If the difference between the measurements exceeds the speci-
fied limit, machine the crankshaft journal to one of the specified
undersize dimensions indicated on the next page.
Inspection: Crankshaft
(1) Bend
Support the crankshaft at its No. 1 journal and No. 5 journal.
Measure the extent of bending in the crankshaft at the center of
the No. 3 journal.
crankshaft.
NOTE
Turn the crankshaft through one revolution. One-half of the
dial indicator reading represents the extent of bending.
(2) Out-of-roundness and taper of crankshaft journals and

pins
If any of the measurements exceeds the specified limits, grind
the crankshaft journal(s) and/or pin(s) to undersize(s) or replace
the crankshaft.
11-87
Grinding of crankshaft
CAUTION
If the crankshaft is ground to an undersize, the main bear-
ings must be replaced with the undersize ones of the corre-
sponding undersize.
Do not change the center-to-center distance A between the jour-

nal and pin.
A: 60 0.05 mm {2.36 0.0020 in.}
Do not change the journal width B and the pin width C.
B: 33.5 mm {1.32 in.} (No. 1 journal)
35 mm {1.38 in.} (No. 2 to No. 4 journals)
35 +0.039
0 mm {1.38 +0.0015
0 in.} (No. 5 journal)
C: 41 0 mm {1.61 +0.0079
+0.2
0 in.} (No. 5 journal)
Finish the fillets D smoothly.
D: R4 mm {R0.16 in.}
Carry out a magnetic inspection to check for cracks possibly
caused by grinding. Also, check that the harness of the surface
has not dropped below Shore hardness number (Hs) 75.
Replace the crankshaft if defects are evident.
Crankshaft undersize dimensions (Unit: mm {in.})
Undersizes
0.25 {0.0098} 0.50 {0.020} 0.75 {0.030} 1.00 {0.039}
85.68 to 85.70 85.43 to 85.45 85.18 to 85.20 84.93 to 84.95
No. 1, 2, 4, 5
Finished journal {3.37 to 3.37} {3.36 to 3.36} {3.35 to 3.35} {3.34 to 3.34}
diameter 85.66 to 85.68 85.41 to 85.43 85.16 to 85.18 84.91 to 84.93
No. 3
{3.37 to 3.37} {3.36 to 3.36} {3.35 to 3.35} {3.34 to 3.34}
64.69 to 64.71 64.44 to 64.46 64.19 to 64.21 63.94 to 63.96
Finished pin diameter
{2.55 to 2.55} {2.54 to 2.54} {2.53 to 2.53} {2.52 to 2.52}
Out-of-roundness 0.01 {0.00039} or less
Taper 0.006 {0.00024} or less
When grinding, turn both the crankshaft and the grinder counter-
clockwise as viewed from the crankshaft front end.
When finishing the crankshaft with whetstone or sandpaper, ro-
tate the crankshaft clockwise.
Inspection: Distortion of upper crankcase top surface

If the measurement exceeds the specified limit, grind the crank-
case top surface with a surface grinder.
Limit the amount of removed metal to make sure that the amount
of piston projection above the crankcase top surface stays within
11-88
11
Installation: Rear oil seal slinger
Press in the rear oil seal slinger until sits snugly on the
crankshaft end surface.
Installation: Crankshaft gear

Heat the crankshaft gear to approximately 150 C {300 F} with a
gas burner or the like.
CAUTION
Be careful not to get burned.
Align the locating pin in the crankshaft with the slot in the crank-
shaft gear. Drive the gear into position by lightly striking its end
face with a plastic hammer.
Installation: Thrust plate

Install the thrust plates on both sides of the rearmost main bear-
ing with the oil grooves on the inner plates facing inward and
those on the outer plates outward as shown in the illustration.
CAUTION
Be sure to orient the oil grooves as indicated above, other-
wise seizures may occur in the engine.
Use oversize thrust plates when adjusting the crankshaft end

play. The upper and lower thrust plates on the same side must
be of the same size. The thrust plates on one side may differ in
size from those on the other side.
Installation: Main bearings

Install the main bearings with their lugs aligned as shown in the
illustration. When the crankshaft journals have been ground to
an undersize, use undersize main bearings.
Available main bearing undersizes:
0.25 mm {0.0098 in.}, 0.50 mm {0.020 in.}, 0.75 mm {0.030 in.},
1.00 mm {0.039 in.}
CAUTION
The upper main bearing has an oil hole. The lower main
bearing has no oil hole. Do not confuse the upper and lower
bearings, as this can cause seizure in the engine.
11-89
Installation: Lower crankcase
CAUTION
Before installing the main bearing cap bolts, check the
number of punch marks on the head of each bolt. (A bolt
with two or less marks is reusable.)
The number of punch marks corresponds with the number
of times the main cap bolt has been tightened using the
torque-turn tightening method. Any bolt that has three
marks (i.e. that has been used three times) must be re-
placed.
Clean all sealant application surfaces.

Apply evenly thick beads of sealant to the upper crankcase
without any breaks as shown in the illustration.
Install the lower crankcase within three minutes of applying the
sealant, being careful not to dislodge the sealant.
Apply engine oil to the main cap bolt threads and seating surfac-
es of the bolt heads, then tighten them to a torque of 49 N m {36
ft.lbs, 5.0 kgf m} in the order indicated in the illustration (1 to 10).
Tighten each main cap bolt further by 90 in the same order.
Finally, tighten each bolt to the specified torque in the order indi-
cated in the illustration (11 to 26).
CAUTION
After installing the bolts, wait at least an hour before start-
ing the engine.
Apply new beads of sealant whenever the main cap bolts
have been loosened or removed.
After tightening the bolts using the above torque-turn tightening

method, make a punch mark on the head of each bolt to indicate
the number of times that it has been used.
CAUTION
The bolts that have been tightened using the torque-turn
method must never be additionally tightened after the final
angular tightening.
After installing the main bearing caps, rotate the crankshaft by

hand. If it cannot be rotated smoothly, inspect the main bearing
caps for correct installation.
11-90
11
Installation: Rear oil seal
Apply engine oil to the lip of the rear oil seal.
Clean the seal surface of the crankshaft.
Apply a bead of sealant along the line on the rear oil seal evenly
without any breaks.
Install the rear oil seal within three minutes after applying the
sealant. Be careful not to let the applied sealant slip out of place
during installation.
CAUTION
After fitting the rear oil seal, wait at least an hour before
starting the engine.
Apply a new bead of sealant whenever the mounting bolts
of the rear oil seal have been loosened.
11-91
BALANCE SHAFT BUSHINGS
1 No. 1 balance shaft bushing
*a:: Balance shaft

Non-reusable parts
NOTE
Do not remove the balance shaft
bushings unless defects are evi-
dent.
Assembly sequence
verse.

0.055 to 0.099
No. 1
{0.0022 to 0.0039}
1 to 3, Balance shaft journal-to-balance shaft 0.075 to 0.119 0.15
No. 2 Replace
* a bushing clearance {0.030 to 0.0047} {0.0059}
0.055 to 0.099
No. 3
{0.0022 to 0.0039}

Balanceshaft bushing inner surface Engine oil As required
Special tools
Balance shaft bushing in- Removal and installation of balance

MH062782
staller and extractor shaft bushing
11-92
11
Inspection: Balance shaft-to-balance shaft bushing clear-
ance
limit.
Replacement of balance shaft bushing

Replace the bushing using .
[Removal]
To remove the bushings, use the rod fitted with an adapter corre-
sponding to the size of each bushing.
Unit: mm {in.}
Adapter
Bushing Identification
A B C
mark
Left 5 55.25 51.5 26.5 {1.04}
No. 1
Right 6 { 2.18} { 2.03}
No. 2 7 55 { 2.17} 51 { 2.01}
21.5 {0.85}
54.75 50.5
No. 3 8
{ 2.16} { 1.99}
Remove the No. 1 bushing by tapping on the rod from the front
of the engine.
11-93
Remove the No. 2 bushing by tapping on the rod from the front
of the engine.
Remove the No. 3 bushing by tapping on the rod from the back
of the engine.
[Installation]
To install the bushings, use the rod fitted with an adapter corre-
sponding to the size of each bushing. Each bushing has an iden-
tification mark. These identification marks are used to
distinguish between the No. 1, No. 2 and No. 3 bushings. If the
identification mark is not clear, measure the outside diameter of
the bushing and use the measurement as a means of identifica-
tion.
Unit: mm {in.}
Bushing Adapter Guide piece
Identi- Identi- Iden-
Out-
fica- fica- tifica-
side di- A B C D
tion tion tion
ameter
mark mark mark
26.5
Left LH1 55.25 5 5
{1.04}
{ 2.18} 51.5
No. 1 55.25 55.25
{ 2.03}
{ 2.18} { 2.18}
Right 1 55.25 6 6
{ 2.18}
55 55 51 21.5 55
No. 2 2 7 7
{ 2.17} { 2.17} { 2.01} {0.85} { 2.17}
No. 3 3 54.75 8 54.75 50.5 8 54.75

{ 2.16} { 2.16} { 1.99} { 2.16}
11-94
11
Align the oil hole in the No. 3 bushing with the oil hole in the up-
per crankcase.
Force the No. 3 bushing into the upper crankcase as deep as
the mark in the illustration by tapping on the rod from the rear
of the engine.
Align the oil hole in the No. 2 bushing with the oil hole in the up-
per crankcase.
Force the No. 2 bushing into the upper crankcase to the illustrat-
ed position by tapping on the rod from the front of the engine.
11-95
Align the oil hole(s) in the No. 1 bushing with the oil hole(s) in the
upper crankcase.
Force the No. 1 bushing into the upper crankcase as deep as
the mark in the illustration by tapping on the rod from the front
of the engine.
CAUTION
The left and right No. 1 bushings are different from each
other, and should not be installed in reverse positions.
The left No. 1 bushing has two oil holes, whereas the right
No. 1 bushing has only one oil hole.
11-96
INDEX
SPECIFICATIONS .............................................................................. 12-2

1. Lubrication System ............................................................................. 12-3
2. Oil Pump ............................................................................................... 12-4
3. Oil Cooler.............................................................................................. 12-5
4. Oil Filter ................................................................................................ 12-6
5. Lubrication of Engine Components ................................................... 12-7
TROUBLESHOOTING...................................................................... 12-10

1. Oil Filter Replacement ....................................................................... 12-12
2. Engine Oil Replacement.................................................................... 12-16
3. Oil Pressure Measurement ............................................................... 12-18
OIL PAN, OIL STRAINER AND OIL JETS....................................... 12-20
OIL PUMP......................................................................................... 12-22
OIL FILTER ....................................................................................... 12-26
OIL COOLER.................................................................................... 12-30
12-1
SPECIFICATIONS
Item Specifications
Method of lubrication Forced lubrication by oil pump
Oil filter Spin-on filter paper type
Oil cooler Shell and plate type (multiple-plate type)
API classification CD, CD/SF, CE, CE/SF, CF-4
Grade
or JASO classification DH-1
Engine oil
Oil pan Approx. 9
Quantity L (qts)
Oil filter Approx. 1
Regulator valve opening pressure kPa {psi, kgf/cm2} 600 +100 +15 +1
0 {87 0 , 6 0 }
Bypass valve opening pressure kPa {psi, kgf/cm2} 390 29 {57 4.2, 4.0 0.3}
12-2
STRUCTURE AND OPERATION 12
1. Lubrication System
1 Main oil gallery 17 Crankshaft main bearing

2 Bypass valve 18 Connecting rod bearing
3 Bypass valve 19 Connecting rod bushing
4 Regulator valve 20 Piston
5 Engine oil pressure switch 21 Balance shaft bushing RH
6 Oil cooler 22 Supply pump gear bushing
7 Full-flow filter element 23 Supply pump idler gear bushing
8 Bypass filter element 24 Supply pump idler gear shaft
9 Oil pump 25 Check valve for oil jet
10 Oil strainer 26 Rocker bushing
11 Turbo charger 27 Camshaft bushing
12 Oil jet for gear 28 Rocker roller
13 Vacuum pump 29 Oil pan
14 Idler bushing
15 Timing gear A: Orifice
16 Balance shaft bushing LH
12-3
2. Oil Pump
This engine uses a gear-type oil pump driven by the rotation of the crankshaft transmitted through the engage-
ment of the crankshaft gear and the oil pump gear.
12-4
12
3. Oil Cooler
3.1 Bypass valve

When the engine oil is cool and its vis-
cosity is high, or when the oil cooler el-
ement becomes clogged and restricts
the flow of the engine oil, the bypass
valve opens to let the engine oil by-
pass the oil cooler and flow directly to
the main oil gallery.
3.2 Engine oil pressure switch

When the pressure of the engine oil to
the main oil gallery drops below the
specified level, an electrical contact in-
side the engine oil pressure switch
closes.
This causes a warning lamp on the
meter cluster to illuminate and notify
the operator of the excessive pressure
drop.
12-5
4. Oil Filter
The oil filter used in this engine is a spin-on, paper-filter type that incorporates both a bypass filter and a full-flow
filter.
A bypass valve is installed in the lower part of the oil filter. When the filter elements are clogged, this valve opens
to let the engine oil bypass the filter elements and flow directly to the oil cooler, thereby preventing seizures in the
engine.
A regulator valve is installed on the oil filter head. When the oil pressure in the main oil gallery exceeds the speci-
fied level, the regulator valve opens to adjust the oil pressure by returning part of the engine oil to the oil pan.
12-6
12
5. Lubrication of Engine Components
The engine oil in the main oil gallery lubricates the engine components in the following ways.
5.1 Main bearing and connecting rod bearing
Engine oil supplied through an oil passage in the crankshaft lubricates the big end (connecting rod bearing) of
each connecting rod. Simultaneously, engine oil supplied through an oil passage in the connecting rod lubricates
the connecting rod s small end.
5.2 Timing gears
12-7
5.3 Valve mechanism
The engine oil flows from the main oil gallery to the rocker shaft through the oil passages in the upper crankcase,
cylinder head, and camshaft frame.
The engine oil in the rocker shaft lubricates the rocker arms and camshaft, then returns to the oil pan.
5.4 Check valves and oil jets

An oil jet is fitted in the lower part of
the main oil gallery for each cylinder.
Engine oil is sprayed out of the oil jet
into the piston to cool the piston.
Each oil jet is fitted with a check valve
that opens and closes at predeter-
mined oil pressure levels. At low en-
gine speeds, the check valve closes to
maintain the required volume of oil in
the lubrication system and prevent re-
ductions in oil pressure.
12-8
12
5.5 Vacuum pump
Engine oil flows through the oil pas-
sages in the front case to the vacuum
pump.
The oil in the pump lubricates the
vanes, and then is discharged into the
front case from the air discharge port
of the vacuum pump along with air,
and returns to the oil pan.
5.6 Turbocharger
Engine oil flows from the main oil gallery through the oil pipes to the turbocharger bearing housing and lubricates
the inner surfaces of the bearing housing.
The piston rings mounted on both sides of the turbine wheel shaft act as oil seals.
12-9
TROUBLESHOOTING
Symptoms
Excessive oil consumption (oil leakage)

Engine is difficult to start
Reference Gr
Low oil pressure

Overheating
Possible causes
Incorrectly mounted element O O O
Defective gasket O O O
Defective O-ring O O O
Oil cooler
Clogged element O O
Damaged element O O O
Weakened bypass valve spring O
Malfunctioning oil pump O O
Oil pump Interference between oil pump gear and oil pump case
O O
and/or cover
Incorrect installation O
Oil filter Clogged element O O
Defective gasket O
Weakened regulator valve spring O
Incorrectly mounted and/or clogged oil strainer O O
Defective fan shaft front oil seal O
Defective crankshaft rear oil seal O Gr11
Incorrectly mounted front case O
Defective piston cooling oil jet(s) O O
Incorrectly mounted gear lubrication oil jet O
Oil working its way up into combustion chamber(s) through piston rings O
Oil working its way down into combustion chamber(s) through valves O
Too high oil viscosity O
Poor oil quality O
Deterioration of oil O
Fuel mixed with oil O
12-10
12
M E M O
12-11
1. Oil Filter Replacement
<Downward type>
Engine oil (API classification CD,
Approx. 1 L
Oil filter CD/SF, CE, CE/SF, CF-4 or
{1.1 qts}
JASO classification DH-1)
Special tools
Oil filter element socket MH061566 Removal of oil filter
WARNING
Wipe up any spilled engine oil, as it can cause fires.
CAUTION
Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
grease may easily slip, resulting in deteriorated performance of the cooling system.
[Removal]
Remove the drain plug and drain the oil out of the oil filter.
12-12
12
[Installation]
Clean the oil filter mounting surfaces of the oil filter head.
Apply a thin coat of engine oil on the oil filter gasket.
Screw in the oil filter by hand until the gasket touches the oil filter
head. Then, tighten the filter by turning it further by three quar-
ters (3/4) of a turn.
After installing the oil filter, start the engine and check that there
are no oil leaks.
Remove and reinstall the oil filter if it is leaky.
Stop the engine and check the engine oil level.
Add engine oil if necessary.
12-13
<Upward type>
Drain plug (oil pipe) 34.3 to 39.2 {25 to 29, 3.5 to 3.9}

Engine oil (API classification CD,
Approx. 1 L
Oil filter CD/SF, CE, CE/SF, CF-4 or
{1.1 qts}
JASO classification DH-1)
Special tools
WARNING
CAUTION
Make sure not to put any engine oil on the V-belt when working on the oil filter. V-belts soiled with oil or
[Removal]
Remove the drain plug and drain the oil out of the oil filter.
NOTE
When the oil filter is removed, a small amount of engine oil
may spill out. Before proceeding to the removal procedure,
keep a piece of waste cloth ready for catching any spilled
oil.
12-14
12
[Installation]
Clean the oil filter mounting surfaces of the oil filter head.
head. Then, tighten the filter by turning it further by three quar-
ters (3/4) of a turn.
are no oil leaks.
12-15
2. Engine Oil Replacement
<Downward type>
Drain plug (oil filter) 9.8 1.96 {7.2 1.4, 1.0 0.2}
Drain plug (oil pan) 34.3 to 43.1 {25 to 32, 3.5 to 4.4}

Approx. 1 L
Oil filter Engine oil (API classification CD, {1.1 qts}
CD/SF, CE, CE/SF, CF-4 or
JASO classification DH-1) Approx. 9 L
Oil pan
{9.5 qts}
WARNING
CAUTION
Make sure not to put any engine oil on the V-belt during engine oil replacement. V-belts soiled with oil or
[Draining]
Remove the filler cap.
Remove the drain plugs of the oil filter and oil pan to drain out
the engine oil.
[Refilling]
Tighten the drain plug to the specified torque, then pour a speci-
fied amount of new engine oil into the engine.
12-16
12
<Upward type>
Drain plug (oil pan) 34.3 to 43.1 {25 to 32, 3.5 to 4.4}

Approx. 1 L
Oil filter Engine oil (API classification CD, {1.1 qts}
CD/SF, CE, CE/SF, CF-4 or
JASO classification DH-1) Approx. 9 L
Oil pan
{9.5 qts}
WARNING
CAUTION
Make sure not to put any engine oil on the V-belt during engine oil replacement. V-belts soiled with oil or
[Draining]
Remove the filler cap.
Remove the drain plugs of the oil filter and oil pan to drain out
the engine oil.
[Refilling]
Tighten the drain plug to the specified torque, then pour a speci-
fied amount of new engine oil into the engine.
12-17
3. Oil Pressure Measurement
Service standards
98 kPa
195 kPa
No-load minimum speed {14 psi,
Oil pressure {28 psi, 2.0 kgf/cm2}
1.0 kgf/cm2}
(oil temperature at 70 to Inspect
90 C {158 to 195 F}) 295 to 490 kPa 195 kPa
No-load maximum speed {43 to 71 psi, {28 psi,
3 to 5 kgf/cm2} 2.0 kgf/cm2}

Sealant
Engine oil pressure switch 7.8 to 14.7 {5.8 to 11, 0.8 to 1.5}
With cold engine

Engine oil pressure switch threads THREEBOND 1215 As required
Remove the engine oil pressure switch.
Using an adapter, connect an oil pressure gauge to the engine

oil pressure switch mounting hole.
Warm up the engine until the oil temperature reaches 70 to 90 C
{158 to 195 F}.
Measure the oil pressure while running the engine at a minimum
speed and then at maximum speed, both under no load.
If the measurements are below the specified limits, overhaul the
lubrication system.
After taking the measurements, apply sealant to the threads of
the oil pressure switch and tighten the switch to the specified
torque.
CAUTION
Reinstall the oil pressure switch only when the engine is
cold.
12-18
12
M E M O
12-19
OIL PAN, OIL STRAINER AND OIL JETS
1 Drain plug
2 Stiffner RH
3 Stiffner LH
4 Oil pan
5 Oil strainer
6 O-ring
7 Engine oil level sensor
8 O-ring
9 Check valve
10 Oil jet
Assembly sequence
verse.
CAUTION
Make sure to tighten the check
valve only to the specified torque.
Overtightening it can cause defec-
tive operation, resulting in engine
seizure.

Drain plug 34.3 to 43.1 {25 to 32, 3.5 to 4.4}
Check valve 29.4 {22, 3.0} Wet
Bolt (oil pan mounting) 23.5 {17, 2.4}
Bolt (oil strainer mounting) 23.2 {17, 2.4}

Crankcase mounting surface of oil pan THREEBOND 1207C As required
O-ring
Check valve threads
12-20
12
Installation: Oil pan
Clean the mating surfaces of each part.
Apply a bead of sealant to the mating surface of the oil pan
evenly and without any breaks as shown in the illustration.
Mount the oil pan within three minutes of applying the sealant.
Make sure that the sealant stays in place.
CAUTION
Do not start the engine less than an hour after installation.
If the oil pan mounting bolts were loosened or removed, be
sure to reapply sealant.
12-21
OIL PUMP
1 Oil pump
2 Oil pump cover
3 Driven gear
4 Gear and case assembly
5 O-ring
*a:: Drive gear

Locating pin
Assembly sequence
Follow the disassembly procedure in re-
verse.

0.04 to 0.075 0.15
2, 3 Oil pump cover-to-driven gear shaft clearance Replace
{0.0016 to 0.0030} {0.0059}
0.04 to 0.075 0.15
*
2, a Oil pump cover-to-drive gear shaft clearance
{0.0016 to 0.0030} {0.0059}
Replace
0.04 to 0.075 0.15

3, 4 Gear and case assembly-to-driven gear shaft clearance Replace
{0.0016 to 0.0030} {0.0059}
Sinkage of each gear from gear and case assembly end 0.05 to 0.11 0.15
Replace
surface {0.0020 to 0.0043} {0.0059}
*
3, 4, a
Gear and case assembly-to-tooth tip clearance for each 0.13 to 0.22 0.23
Replace
gear {0.0051 to 0.0087} {0.0091}

Bolt (oil pump cover mounting) 8.2 2.46 {6.0 1.8, 0.8 0.25} M6 20
Bolt (oil pump cover mounting) 9.8 2.0 {7.2 1.5, 1.0 0.2} M6 25

Oil pump contact surfaces
O-ring
12-22
12
Pump cover pin

A B
0 MH063431 Installation of oil pump cover
7 0.14 20 {0.79}
{ 0.28 00.0055 }
Inspection: Driven gear, drive gear and gear and case
assembly
Carry out the following inspection. Replace the oil pump if any
defects are found.
(1) Sinkage of each gear from gear and case assembly end
surface
(2) Gear and case assembly-to-tooth tip clearance for each

gear
Inspection: Oil pump cover, driven gear, and gear and case
assembly
Measure the clearance between each gear s shaft and the oil
pump cover, as well as between each gear s shaft and the gear
and case assembly.
If the measurements are not within the standard value range, re-
place the oil pump.
12-23
OIL PUMP
Installation: Oil pump cover and gear and case assembly
Apply engine oil to each component.
Hold the oil pump cover in place on the gear and case assembly
by fitting two s in the illustrated locations.
Install a bolt into an empty bolt hole and tighten it to the specified
torque.
Remove the two s. Install the rest of the bolts and tighten
them to the specified torque.
After installing all the bolts, turn the oil pump gear by hand and
check that it rotates smoothly.
Disassemble and reassemble the oil pump cover and gear and
case assembly if the oil pump gear does not rotate smoothly.
Installation: Oil pump

Place the No.1 cylinder piston at top dead center to bring the
crankshaft gear to an appropriate position.
Inject approximately 5 cm3 {0.3 cu. in.} of engine oil.
Align the mating mark 6 on the crankshaft gear and the mating
mark 7 on the balance shaft gear RH with the corresponding
mating marks on the oil pump gear, and then install the oil pump
gear.
12-24
12
M E M O
12-25
OIL FILTER
<Downward type>
1 Drain plug
2 Oil filter
3 Oil pipe
4 O-ring
5 O-ring
6 Plug
7 Regulator valve spring
8 Regulator valve
9 Oil filter head
10 Gasket
Assembly sequence
verse.
WARNING
Wipe up any spilled engine oil, as it
can cause fires.
CAUTION
Make sure not to put any engine oil
on the V-belt when working on the
oil cooler and oil filter. V-belts
soiled with oil or grease may easily
slip, resulting in deteriorated per-
formance of the cooling system.
Make sure to install the gasket in
the correct position so that it does
not cover up the oil hole.

93.5 0.5 N
Load of installed regulator valve spring
7 {21 0.1 lbs, Replace
(installed length: 39 +0.3 {1.54 +0.012})
0 0 9.5 0.05 kgf}

Drain plug 9.8 1.96 {7.2 1.4, 1.0 0.2}
Plug (regulator valve mounting) 60 {44, 6.0}

Oil filter gasket
O-ring
12-26
12
Special tools
Removal procedure
Removal: Oil filter
Installation: Oil filter
Clean the oil filter mounting surface of the oil filter head.
head. Then, tighten the filter by turning further by three quarters
(3/4) of a turn.
are no oil leaks from the gasket.
12-27
OIL FILTER
<Upward type>
1 Drain plug
2 Drain plug
3 Oil filter
4 Oil pipe
5 Gasket
6 O-ring
7 Plug
8 Regulator valve spring
9 Regulator valve
10 Oil filter head
11 Gasket
Assembly sequence
verse.
WARNING
Wipe up any spilled engine oil, as it
can cause fires.
CAUTION
Make sure not to put any engine oil
on the V-belt when working on the
oil cooler and oil filter. V-belts
soiled with oil or grease may easily
slip, resulting in deteriorated per-
formance of the cooling system.
Make sure to install the gasket in
the correct position so that it does
not cover up the oil hole.

93.5 0.5 N
Load of installed regulator valve spring
8 {14 0.1 psi, Replace
(installed length: 39 +0.3 {1.54 +0.012})
0 0 9.5 0.05 kgf}

Drain plug (oil filter) 9.8 1.96 {7.2 1.4, 1.0 0.2}
Plug (regulator plug mounting) 60 {44, 6.0}
12-28
12
Oil filter gasket
O-ring
Special tools
Removal procedure
Removal: Oil filter
Installation: Oil filter
Clean the oil filter mounting surface of the oil filter head.
head. Then, tighten the filter by turning further by three quarters
(3/4) of a turn.
are no oil leaks from the gasket.
12-29
OIL COOLER
1 Eye bolt 7 Oil cooler element 12 Coolant temperature sensor
2 Oil pipe 8 Gasket (for engine control)
3 Plug 9 Water drain valve 13 Oil cooler body
4 O-ring 10 Engine oil pressure switch 14 Gasket
5 Bypass valve spring 11 Coolant temperature sensor
6 Bypass valve (for water temperature gage) : Non-reusable parts
Assembly sequence
12-30
12
95.3 4.9 N
Load of bypass valve spring
5 {21 1.1 lbs, Replace
(installed length: 48 0-0.5 {1.89 0-0.02 })
9.7 0.5 kgf}
Air leakage from oil cooler element (air pressure: 980
7 0 cm3 {0 cu. in.} Replace
kPa {140 psi, 10 kgf/cm2} for 15 seconds)

Eye bolt (oil pipe mounting) 21.6 {16, 2.2}
Plug 34.3 4.9 {25 3.6, 3.5 0.5}
Nut (oil cooler element mounting)
24.5 4.9 {18 3.6, 2.5 0.5}
Water drain valve
Sealant
Engine oil pressure switch 7.8 to 14.7 {5.8 to 11, 0.8 to 1.5}
With cold engine
Coolant temperature sensor (for water temperature gage)
34.3 {25, 3.5}
Coolant temperature sensor (for engine control)

Engine oil pressure switch threads THREEBOND 1215 As required
Inspection: Oil cooler element
Plug the outlet of the oil cooler element and connect a hose to
the engine oil inlet port. Then, immerse the oil cooler element in
a tank of water.
Apply an air pressure of 980 kPa {140 psi, 10 kgf/cm2} for
15 seconds through the hose, and check for any air leaks.
Replace the element if it leaks air.
12-31
INDEX
SPECIFICATIONS ........................................................................... 13A-2

1. Fuel System (Flow of Fuel) ......................................................... 13A-3
2. Engine Control ........................................................................... 13A-4
3. Fuel Filter ................................................................................... 13A-5
TROUBLESHOOTING..................................................................... 13A-6

1. Inspecting and Adjusting No-load Minimum and
Maximum Speeds............................................................................. 13A-8
2. Air-bleeding of Fuel System ....................................................... 13A-9
3. Fuel Filter Replacement ........................................................... 13A-10
FUEL TANK .................................................................................... 13A-12
FUEL FILTER ................................................................................. 13A-14
ENGINE CONTROL....................................................................... 13A-16
COMMON RAIL .............................................................................. 13A-19
SUPPLY PUMP............................................................................... 13A-20
INJECTOR ...................................................................................... 13A-22
13A-1
SPECIFICATIONS
Item Specifications
Manufacturer BOSCH AUTOMOTIVE SYSTEMS
Model CP3.3
Control method Electronic
Type Radial, 3-cylinder
Supply pump Type External gear type
Injection quantity Model MPROP
adjustment valve Rated voltage V 12
Max. common rail pressure
160 {23200, 1631}
MPa {psi, kgf/cm2}
Common rail volume cm3 {cu.in., ml} 16.5 {1.01, 16.5}
Common rail Pressure limiting valve opening pressure
185 to 195 {26830 to 28280, 1886 to 1988}
MPa {psi, kgf/cm2}
Common rail pressure sensor supply
5
voltage V
Control method Electrical
Injectors Max. operating pressure
160 {23200, 1631}
MPa {psi, kgf/cm2}
Min. operating pressure
25 {3630, 255}
MPa {psi, kgf/cm2}
Common rail Manufacturer BOSCH AUTOMOTIVE SYSTEMS
electronic control
unit Rated voltage V 12
13A-2
STRUCTURE AND OPERATION 13A
1. Fuel System (Flow of Fuel)
The feed pump, which is driven by the camshaft inside the supply pump, draws up the fuel from inside the fuel
tank and sends it through the fuel filter, where dust and other impurities in the fuel are filtered out.
The filtered fuel is then sent to the supply pump, where it is compressed. The compressed fuel is accumulated in
the common rail for a time, then sprayed out through the injection nozzles into the combustion chamber.
If fuel leaks from an injection pipe at the pipe joint, the flow limiter is activated to close the fuel passage, prevent-
ing the fuel from flowing elsewhere.
The excess fuel from the injectors returns to the fuel tank through the fuel return hose.
When the internal fuel pressure of the Common Rail exceeds the limit, the pressure limiting valve opens to allow
part of the fuel to return to the fuel tank.
When the internal fuel pressure of the supply pump exceeds the limit, the overflow valve opens to allow part of the
fuel to return to the fuel tank.
13A-3
2. Engine Control
The engine is electronically controlled
by the engine electronic control unit
(ECU).
The accelerator position sensor de-
tects how much the accelerator pedal
is depressed and sends the corre-
sponding electronic signal to the en-
gine electronic control unit, which
calculates an appropriate amount of
fuel based on the signals and controls
fuel injection accordingly.
13A-4
13A
3. Fuel Filter
The fuel filter removes impurities in the fuel through the filter element and also separates water from fuel.
The water that has been separated from the fuel collects at the bottom of the fuel filter. A water separator sensor
is installed in the fuel filter, which activates the warning lamp on the meter cluster when the water reaches a cer-
tain level.
The water can be drained through the drain port by loosening the water separator sensor.
A priming pump is provided at the fuel filter head. The priming pump is used for air-bleeding the fuel system.
When the fuel temperature rises, the thermostat swells and the valve of the fuel filter head is closed. The high-
temperature fuel entirely returns to the fuel tank through the fuel return pipe.
When the fuel temperature lowers, the thermostat does not swell and the valve to the fuel filter remains open. The
high-temperature fuel returning through the fuel return pipe is let through the valve to mix into the fuel around the
element. The fuel around the element is warmed as a result and wax in it (precipitated when the fuel temperature
is low) is dissolved to prevent clogging of the element.
13A-5
TROUBLESHOOTING
Symptoms
Engine does not reach maximum speed

Engine maximum speed is too high
Engine stops soon after starting
warning lamp illuminates

Accelerator pedal is too stiff
Engine output is insufficient
Engine output is unstable
Fuel supply is insufficient

Engine is idling unstably

Reference
Engine refuses to start
Engine does not stop

Gr
Engine knocks
Possible causes
Faulty electronic fuel control system O Gr13E
Malfunctioning feed pump check valve O O O O *
Defective feed pump O O O O *
Poorly airtight supply pump overflow valve O O O O *
Supply pump
Open or short circuit failure, poor contact of
O O O O O *
supply pump M/V
Defective supply pump M/V, defective supply
O O O O *
pump
Open or short circuit failure, poor contact of
O O O O O *
injector M/V
Injectors
Defective injector, defective injector M/V, de-
O O O O *
fective nozzle
Clogged fuel filter O O O O
No fuel in fuel tank O
Clogged fuel pipe and/or leaky pipe joints O
Air or water in fuel system O O O O
Use of low quality fuel O O O O
Open or short circuit failure, poor contact of common rail pressure
O O O O O O *
sensor, defective sensor
Flow limiter activated O O O *
Fuel leakage from high pressure pipe joint O O O O O *
Poorly adjusted accelerator pedal stopper bolt O O
Engine control
Defective accelerator pedal position sensor O
Cracked fuel pipe and/or hose O
*: Contact a Bosch Automotive Systems service station for repair.
13A-6
13A
Symptoms
Engine does not reach maximum speed

Engine maximum speed is too high
Engine stops soon after starting
warning lamp illuminates

Accelerator pedal is too stiff
Engine output is unstable
Fuel supply is insufficient

Engine is idling unstably

Reference
Engine refuses to start
Engine does not stop

Gr
Engine knocks
Possible causes
Inappropriate oil viscosity O O Gr12
Poorly adjusted valve clearance O O
Defective cylinder head gasket O O
Wear of and/or carbon deposits on valve and valve seat O O
Distorted valve springs O O Gr11
Worn or damaged piston rings O O
Worn or damaged piston ring groove O
Worn piston and/or cylinder liner O O
Poorly functioning cooling system O O Gr14
Defective starter switch O O
Gr54
Defective glow plug O
Open-circuited, short-circuited or poorly connected engine speed
O O O
sensor and/or cylinder sensor
Open-circuited, short-circuited or poorly connected boost pressure
O O O O O
sensor
Gr13E
Open-circuited, short-circuited or poorly connected coolant tempera-
O O O
ture sensor
Poorly connected injection rate adjusting resistor O O O
Poorly connected idling adjustment control O O O
Blown fuse O O O O Gr54
13A-7
1. Inspecting and Adjusting No-load Minimum and Maximum Speeds
Service standards
No-load minimum speed (idling speed) 650 25 rpm Adjust
No-load maximum speed 3,100 50 rpm Adjust
[Work before inspection and adjustment]

Before starting the inspection and adjustment, carry out the fol-
lowing preparatory steps:
Warm up the engine until the engine coolant temperature is ap-
proximately 80 to 95 C {176 to 203 F};
turn off all lamps and accessories;
put the transmission in neutral (P-range for automatic transmis-
sion);
set the steering wheel at the straight-ahead position; and
attach the probe of the tachometer to an in ector.
[Inspection and adjustment]

(1) No-load minimum speed
Without depressing the accelerator pedal, measure the engine
speed.
If the speed is not within the standard value range, inspect the
accelerator position sensor and accelerator switch assembly.
(See Gr13E)
If no defects are evident during the above inspection, check for
any diagnosis codes related with the fuel system and inspect the
supply pump and engine electronic control unit. (See Gr13E)
(2) No-load maximum speed

Depress the accelerator pedal as far as it will go.
With the accelerator lever touching the stopper bolt, measure
the engine speed.
If the speed is not within the standard value range, inspect the
accelerator position sensor and accelerator switch assembly.
(See Gr13E)
If no defects are evident during the above inspection, check for
any diagnosis codes related with the fuel system and inspect the
supply pump and engine electronic control unit. (See Gr13E)
13A-8
13A
2. Air-bleeding of Fuel System
Tightening torque (Unit: N m ft.lbs, kgf m )
Air vent plug 10 2 {7.4 1.5, 1 0.2}
Loosen one of the air vent plugs on the fuel filter.

Move the priming pump up and down to pump out the fuel.
Continue operating the priming pump until the fuel flowing out of
the air vent plug is free of air bubbles.
When no more air bubbles are evident, tighten the air vent plug
to the specified torque.
Feed the fuel some more by operating the priming pump further
until a strong resistance is felt.
NOTE
When the fuel temperature is low, you may not feel the re-
sistance. Be sure to operate the priming pump several
times even in such a case.
Wipe up any spilled fuel and start the engine.

Check that there is no fuel leakage.
WARNING
Fuel is highly flammable. Keep it away from flames and
sources of heat.
To avoid risk of fire, wipe up any spilled fuel.
13A-9
3. Fuel Filter Replacement
Water separator sensor 5 1 {3.7 0.7, 0.5 0.1}
Case 30 2 {22 1.5, 3.1 0.2}

Fuel filter gasket Engine oil As required
Special tools
Filter wrench MH063203 Removal and installation of case
[Removal]
Loosen the water separator sensor and drain fuel from the case.
Remove the case using .
[Installation]
Clean the O-ring mounting surface of the fuel filter head.
13A-10
13A
Replace the filter element and O-ring with new one.
Apply a thin coat of engine oil to the O-ring, and install it on the
case and water separator sensor.
CAUTION
Be sure to use only genuine MITSUBISHI filter elements.
The use of non-genuine fuel filters can cause engine failure.
Prevent fine dust particles from entering the fuel filter and
fuel pipe, as they can cause problems such as faulty fuel in-
jection.
Use to tighten the case to the specified torque.

Install the water separator sensor, and then air-bleed the fuel
system.
Start the engine, and check that there is no fuel leakage.
Reinstall the fuel filter if there is any leakage.
13A-11
FUEL TANK
Removal sequence
1 Drain plug
2 Suction hose
3 Return hose
4 Fuel level sensor
5 Lock nut
6 Fuel tank band
7 Fuel tank
8 Fuel tank bracket
DANGER
Do not allow any flames or sources of heat near the fuel tank, as it may explode.
WARNING
Fuel is highly flammable. Keep it away from flames and sources of heat.
To avoid risk of fire, wipe up any spilled fuel.

Drain plug 49 to 88.2 {36 to 65, 5.0 to 9.0}
0.98 to 1.47
Screw (fuel level sensor mounting)
{0.7 to 1.1, 0.10 to 0.15}
Lock nut (fuel tank band mounting) 9 to 28 {6.6 to 21, 0.9 to 2.8}
Nut (fuel tank band mounting) 6 to 10 {4.4 to 7.4, 0.6 to 1.0}
Bolt (fuel tank bracket mounting) 70 to 90 {52 to 66, 7.1 to 9.2}
13A-12
13A
M E M O
13A-13
FUEL FILTER
1 Fuel hose
2 Water separator sensor
3 O-ring
4 Case
5 O-ring
6 Filter element
7 Plug
8 Fuel filter head
Assembly sequence
verse.

Water separator sensor 5 1 {3.7 0.7, 0.5 0.1}
Case 30 2 {22 1.5, 3.1 0.2}
Plug 10 2 {7.4 1.5, 1 0.2}

Special tools
Filter wrench MH063203 Removal and installation of case
13A-14
13A
Removal: Case
Loosen the water separator sensor and drain fuel from the case.
Remove the case using .
Installation: Case
Clean the O-ring mounting surface of the fuel filter head.
Replace the filter element and O-ring with new one.

Apply a thin coat of engine oil to the O-ring, and install it on the
case and water separator sensor.
CAUTION
Be sure to use only genuine MITSUBISHI filter elements.
The use of non-genuine fuel filters can cause engine failure.
Prevent fine dust particles from entering the fuel filter and
fuel pipe, as they can cause problems such as faulty fuel in-
jection.
Use to tighten the case to the specified torque.

Install the water separator sensor, and then air-bleed the fuel
system.
Start the engine, and check that there is no fuel leakage.
Reinstall the fuel filter if there is any leakage.
13A-15
ENGINE CONTROL
Removal sequence
1 Accelerator pedal (See later sec-
tions.)
2 Accelerator link (See later sec-
tions.)
Removal procedure
Removal: Accelerator pedal
Using pliers, pinch the hook of the stopper on the accelerator
pedal. Separate the stopper from the pedal while turning the
hook by about 15 degrees.
CAUTION
Do not yank on the stopper, as this may damage it.
Installation: Accelerator pedal
Depress the accelerator pedal until the accelerator lever touches
the accelerator link stopper bolt.
Check that the clearance between the stopper and the stopper
bolt contact surface of the pedal is as indicated in the illustration.
If the clearance is not within the indicated value range, adjust
the stopper bolt and lock it with the nut.
13A-16
13A
Accelerator Pedal
1 E-ring
2 Clevis pin
3 Accelerator pedal
4 Stopper bolt
5 Accelerator pedal bracket
Assembly sequence
verse.

Accelerator pedal and bracket contact surfaces Chassis grease [NLGI No. 1 (Li soap)] As required
13A-17
ENGINE CONTROL
Accelerator Linkage
1 Cover
2 Spring
3 Washer
4 Bushing
5 Return spring
6 Accelerator lever
7 Accelerator position sensor and
accelerator switch assembly
8 Lever stopper
9 Rubber stopper
10 Accelerator link bracket
Assembly sequence
verse.
NOTE
Inspection and adjustment of accel-
erator position sensor (See Gr13E).

Accelerator lever and return spring sliding surface Chassis grease [NLGI No. 1 (Li soap)] As required
13A-18
COMMON RAIL 13A
1 Injection pipe
2 Fuel pipe
3 Eyebolt
4 Fuel return pipe
5 Common rail
Assembly sequence
verse.
CAUTION
Contact each seating surface fully and evenly, tighten the bolt or nut temporarily, and finally tighten it to
the specified torque.
For servicing the common rail, contact a Bosch Automotive Systems service station.
If dust enters the common rail, the engine performance will be greatly affected. To prevent it, be sure to
cover up openings left after pipes and other parts are removed. Also, wash eyebolts, gaskets, etc. in light
oil to clear of dirt.
Before installing, make sure that the seat surfaces of fuel pipes and injection pipes are free of scratches
and irregularities.

Location Parts to be tightened Tightening torque Remarks
Injection pipe (union nut tightening)
30.4 to 35 {22 to 26, 3.1 to 3.6}
Fuel pipe (union nut tightening)
Eyebolt (fuel return pipe attaching) 25 to 29 {18 to 21, 2.6 to 3.0}
Bolt (common rail attaching) 23.2 {17, 2.4}
13A-19
SUPPLY PUMP
Removal sequence
1 Eye bolt 5 Fuel pipe 9 O-ring
2 Oil pipe 6 Eye bolt
3 Eye bolt 7 Fuel suction pipe *a: Front case
4 Fuel return pipe 8 Supply pump : Non-reusable parts
CAUTION
Have the injection pump assembly serviced by a Bosch Automotive Systems service station.
Dirt and dust in the injection pump assembly can seriously detract from engine performance. To prevent
this from happening, fully cover all open joints after removing any pipes or hoses.
Eye bolt (Oil pipe mounting) 23.5 {17, 2.4}
Eye bolt (fuel return pipe mounting)
38.2 {28, 3.9}
Eye bolt (fuel pipe mounting)
Fuel pipe (union nut mounting) 20.5 {15, 2.1}

13A-20
13A
Special tools
Cranking handle MH063704 Rotating the fan pulley
Installation: Supply pump
Remove the rocker cover.
Bring the No. 1 cylinder piston to the top dead center (TDC) on
the compression stroke by the following procedure:
Hook on a groove in the fan pulley.
Turn the fan pulley in the illustrated direction so that the pointer
is aligned with the I IV or 1 4 mark on the inscribed scale
on the flywheel.
This will place either the No. 1 or No. 4 cylinder piston at TDC on
the compression stroke. The cylinder in which the rocker arms
for both the intake and exhaust valves can be pushed down by
hand by the valve clearance amounts has its piston at TDC. Ro-
tate the engine by one full turn to switch the TDCs of the No. 1
and No. 4 cylinder pistons.
Align the match mark P on the supply pump idler gear with that
of the supply pump gear.
Align the notch on the flange plate with the notch on the supply
pump gear.
Check that the notch on the flange plate and the notch on the
supply pump gear are correctly aligned, and then push the sup-
ply pump.
13A-21
INJECTOR
1 Snap ring 5 Injector
2 Fuel return hose 6 O-ring
3 Injection pipe 7 Nozzle gasket
4 Bolt (with hexagonal hole) : Non-reusable parts
Assembly sequence
WARNING
The harnesses and connectors between injectors and engine ECU contain high voltage. Be careful not to
receive an electric shock. Before removing the injectors, always turn the starter switch to the LOCK posi-
tion.
Fuel is highly flammable. Wipe up spilled fuel to avoid the risk of fire.
CAUTION
When removing the injectors, take care not to strike them with the tool, etc.
To prevent an injection failure or any other trouble, make sure that no dust enters the injectors and injec-
tion pipes.
13A-22
13A
Injection pipe (union nut mounting) 30.4 to 35 {22 to 26, 3.1 to 3.6}
Bolt (injector mounting) 5.2 to 7.2 {3.8 to 5.3, 0.53 to 0.73}

13A-23
INDEX
SPECIFICATIONS .............................................................................13E-2

1. Overview .....................................................................................13E-3
2. Electronic Control System ........................................................13E-12
3. Electronic Control Unit Connection Diagram.............................13E-18
TROUBLESHOOTING
1. Inspection Procedure ................................................................13E-20
2. Cautions to Observe when Performing Inspections ..................13E-21
3. Inspections Based on Diagnosis Codes ....................................13E-22
4. Multi-Use Tester Service Data....................................................13E-36
5. Actuator Tests Performed Using Multi-Use Tester .....................13E-38
6. Inspections Performed at Electronic Control Unit Connectors ..13E-40
INSPECTION OF ELECTRICAL EQUIPMENT ...............................13E-43
INSTALLED LOCATIONS OF PARTS ............................................13E-50
ELECTRIC CIRCUIT DIAGRAM .....................................................13E-56
13E-1
SPECIFICATIONS
Item Specifications
Model CP3.3
Control method Electronic
Type Radial, 3-cylinder
Supply pump Type External gear type
MPROP
(injection quantity Rated voltage V 12
adjustment valve)
Max. common rail pressure
160 {23200, 1631}
MPa {psi, kgf/cm2}
Common rail volume cm3 {cu. in., ml} 16.5 {1.01, 16.5}
Common rail Pressure limiting valve opening pressure
185 to 195 {26830 to 28280, 1886 to 1988}
MPa {psi, kgf/cm2}
Common rail pressure sensor supply
5
voltage V
Control method Electrical
Injectors Max. operating pressure
160 {23200, 1631}
MPa {psi, kgf/cm2}
Min. operating pressure
25 {3630, 255}
MPa {psi, kgf/cm2}
Common rail Manufacturer BOSCH AUTOMOTIVE SYSTEMS
electronic control
unit Rated voltage V 12
13E-2
STRUCTURE AND OPERATION 13E
1. Overview
In the common rail system, an electronic control unit monitors various aspects of the engine (engine speed, throt-
tle opening, coolant temperature, etc.) using information from sensors. In accordance with these data, the elec-
tronic control unit effects control over the fuel injection quantity, fuel injection timing, and fuel injection pressure in
order to optimize the engine s operation.
The electronic control unit has a diagnosis function that enables it to recognize abnormalities in the common rail
system s major components and alert the driver to them.
The common rail system consists mainly of an electronically controlled supply pump; injectors; a common rail;
and the electronic control unit and sensors that are used to control the other components.
13E-3
When the engine is cranked by means of the starter switch, the feed pump (this is located inside the supply pump)
simultaneously draws fuel from the fuel tank and feeds it via the fuel filter to the MPROP (injection quantity adjust-
ment valve). A quantity of fuel metered by the MPROP is supplied via the inlet valves to the plunger chambers.
The fuel in the plunger chambers is pressurized. The outlet valves are then opened, and the fuel is fed under
pressure to the common rail.
The pressurized fuel is held in the common rail and then uniformly fed to the injectors.
In response to signals from the engine electronic control unit, a magnetic valve in each injector causes the injector
to inject fuel into the relevant combustion chamber at the optimal timing and in the optimal quantity.
13E-4
13E
1.1 Supply pump
13E-5
CAUTION
Be sure to connect the MPROP (injection quantity adjustment valve) connector to the engine harness be-
fore starting the engine. If the engine were started with the MPROP connector not connected, control of
the supply pump by the engine electronic control unit would not be possible and a fault would ensue.
The supply pump pressurizes fuel and supplies it in a highly pressurized state.
Fuel drawn from the fuel tank by the feed pump is not supplied directly to the plungers. It is supplied first to the
MPROP (injection quantity adjustment valve), which controls the amount of fuel reaching the plungers.
If the fuel pressure exceeds a certain level, the overflow valve returns fuel to the inlet side of the feed pump. This
operation keeps the fuel pressure constant.
Rotation of the eccentric drive shaft causes (via the tappets) up-down movement of the plungers. Fuel in the
plunger chambers is thus highly pressurized.
13E-6
13E
(1) MPROP (injection quantity adjustment valve)
The MPROP receives fuel from the feed pump and feeds fuel to-
ward the plungers of the supply pump in such a quantity that the
fuel pressure corresponds to that required by the engine elec-
tronic control unit.
When the MPROP is not operating, i.e., when current is not flow-
ing, fuel flows at its maximum rate. When current flows, the pis-
ton in the MPROP is pressed down such that fuel is not fed
toward the plungers.
13E-7
1.2 Common rail
The common rail distributes to the injectors high-pressure fuel that has been fed from the supply pump.
Each flow limiter prevents an abnormal outflow of fuel. It does so by blocking the fuel passage in the event of fuel
leakage from the injection pipe or excessive injection of fuel from the injector.
The common rail pressure sensor is used in feedback control. It senses the fuel pressure inside the common rail
and feeds a corresponding signal to the electronic control unit.
If the fuel pressure in the common rail exceeds a certain, set level, the piston in the pressure limiting valve pushes
and compresses the spring such that fuel is able to escape. The pressure limiting valve thus prevents the fuel
pressure from becoming higher than the set pressure.
Flow limiter
During normal operation, the piston moves (thus pushing and compressing the spring) to the extent necessary for
one injection quantity to pass through. The piston does not make contact with the seat at this time. When injection
is complete, the piston is returned to its initial position by the spring.
If the amount of fuel passing through the flow limiter becomes excessively great, the piston presses against the
seat, thereby closing the fuel passage and preventing an abnormal outflow of fuel.
When the piston has pressed against the seat, it does not return to its original position until the engine has been
stopped and the pressure in the common rail has come down.
13E-8
13E
1.3 Injector
In accordance with electrical signals from the engine electronic control unit, each injector supplies high-pressure
fuel from the common rail to the relevant combustion chamber of the engine at the optimal timing and in the opti-
mal quantity.
The valve body and valve piston together form the control chamber.
The functional units of each injector can be broadly defined as follows:
(1) Control section

The control section consists of the control chamber, magnet, valve spring, armature plate, valve ball, valve body,
valve piston, orifice A, and orifice Z. The valve piston is located between the control section and the injection sec-
tion.
(2) Injection section
The injection section consists of the nozzle body, nozzle needle, nozzle spring, and nozzle nut.
13E-9
(3) Operation
(3.1) Injection not taking place
With the magnet not energized, the ar-
mature plate is pushed up by the valve
spring such that the ball seat is closed.
The high-pressure fuel acts upon the
control chamber via orifice Z. The
same pressure acts upon the nozzle
needle.
The fuel pressure acting on the nozzle
needle cannot overcome the valve pis-
ton and nozzle spring, so the nozzle
needle stays in its downward-pushed
position and injection does not take
place.
(3.2) Start of injection

When the magnet is energized, the re-
sulting electromagnetic force draws
the armature plate upward, causing
the ball seat to open.
Fuel in the control chamber passes
through the ball seat and orifice A and
flows to the fuel tank.
With the pressure in the control cham-
ber reduced, the fuel acting on the
nozzle needle overcomes the valve
piston and nozzle spring, pushing up
the nozzle needle such that injection
starts.
If the magnet remains energized, the
injection rate reaches its maximum
level.
13E-10
13E
(3.3) End of injection
When energization of the magnet is
stopped, the armature plate is pushed
downward by the valve spring such
that the ball seat closes. At this time,
fuel flows into the control chamber via
orifice Z, pushing down the valve pis-
ton and nozzle needle such that injec-
tion finishes.
13E-11
2. Electronic Control System
2.1 System block diagram
Input signals Engine electronic control unit Output signals
Engine speed sensor Injectors

Cylinder recognition sensor Fuel injection pressure MPROP (injection quantity
control adjustment valve)
Water temperature sensor
Fuel injection rate
Engine
Boost pressure sensor Warm-up acceleration

function control
Common rail pressure sensor
Fuel temperature sensor Fuel injection quantity
Auxiliary brake
Boost air temperature sensor function control
Fuel injection timing

control
Intake throttle control
function (see Gr17)
Starter switch
Engine warning lamp
Accelerator pedal position sensor Exhaust gas
Accelerator pedal switch recirculation valve Tachometer
(incorporated into accelerator pedal control function
position sensor) (see Gr17)
Glow drive relay
Pulse divider (vehicle speed sensor)
Idling speed adjustment potentiometer
Starter continuous
Warm-up switch energization
Fuel injection rate adjustment resistor prevention function Glow plugs
Memory clear switch (see Gr54)
Vehicle
Exhaust brake 3-way

Diagnosis switch Pre-heat control magnetic valve
Multi-Use Tester connector function (see Gr54)
Air conditioner switch Safety relay
Clutch switch <M/T> Automatic transmission
Transmission neutral switch <M/T> electronic control unit
Inhibitor switch <A/T> Fault diagnosis
function Electronic drive unit relay
Exhaust brake switch
Automatic transmission exhaust brake
cut relay <A/T>
Torque limit switch <M/T>
Exhaust gas recirculation electronic

drive unit (see Gr17)
Exhaust gas recirculation valve

Motor
Position sensor
Throttle electronic drive unit

(see Gr17)
CAN: Control Area Network
EGR:Exhaust gas recirculation Intake throttle
EDU: Electronic drive unit Motor
CAN Position sensor
M/T: Manual Transmission communication
A/T: Automatic Transmission
13E-12
13E
Part Main function/operation
Engine speed sensor Sensing of engine speed
Cylinder recognition sensor Cylinder recognition
Water temperature sensor Sensing of coolant temperature
Boost pressure sensor Sensing of boost pressure
Common rail pressure sensor Sensing of common rail pressure
Fuel temperature sensor Sensing of fuel temperature
Boost air temperature sensor Sensing of boost air temperature
Senses that the engine is in starting condition with the starter switch in
Starter switch
START position.
Accelerator pedal position sensor Sensing of extent of accelerator pedal depression
Accelerator pedal switch (incorporated into accelera- Sensing of released/depressed condition of accelerator pedal (ON with
tor pedal position sensor) pedal released)
Pulse divider (vehicle speed sensor) Sensing of vehicle speed
Idling speed adjustment potentiometer
Acceleration of warm-up
Warm-up switch
Fuel injection rate adjustment resistor Correction of fuel injection rate
Diagnosis switch Output of diagnosis codes
Memory clear switch Deletion of diagnosis codes; output of past diagnosis codes
Multi-Use Tester connector Communication between Multi-Use Tester and common rail system
Air conditioner switch ON when air conditioner is operating
Sensing of released/depressed condition of clutch pedal
Clutch switch <manual transmission>
(OFF with pedal released)
Detection of transmission neutral condition
Transmission neutral switch <manual transmission>
(OFF with transmission in neutral)
Detection of transmission neutral condition
Inhibitor switch <automatic transmission>
(high idle inhibited with transmission in any range except N )
Exhaust brake switch <manual transmission>
Automatic transmission exhaust brake cut relay <auto- Exhaust brake ON/OFF control
matic transmission>
Torque limit switch <manual transmission> Detection of 1st and reverse positions
Control of fuel injection rate, fuel injection quantity, and fuel injection
Injectors
timing
MPROP (injection quantity adjustment valve) Control of fuel injection pressure
Engine warning lamp Indication of system abnormalities
Tachometer Indication of engine speed (in meter cluster)
Glow drive relay ON/OFF control of glow plugs
Exhaust brake 3-way magnetic valve ON/OFF control of exhaust brake valve
Safety relay Control of starter continuous energization prevention function
Output of signals corresponding to engine speed and extent of acceler-
Automatic transmission electronic control unit
ator pedal depression
Supply of power to exhaust gas recirculation electronic drive unit and
Electronic drive unit relay
throttle electronic drive unit
Engine data recognized by the engine electronic control unit are output-
ted to the CAN bus to enable systems to obtain data that they need for
CAN communication (exhaust gas recirculation elec-
control. Each electronic drive unit issues signals to the engine electron-
tronic drive unit and throttle electronic drive unit)
ic control unit via the CAN bus to enable it to effect engine control ap-
propriate for each type of system control.
13E-13
2.2 Fuel injection rate control
(1) Pilot injection
Pilot injection entails the injection of an extremely small amount
of fuel ahead of the main injection.
Pilot injection suppresses heat generation early in the injection
cycle and thus suppresses NOx generation and noise at the
start of combustion.
(2) Split injection control

Split injection entails the injection of an extremely small amount
of fuel two or more times ahead of the main injection.
Split injection increases the fuel s combustibility and thus en-
hances the engine s cold startability.
2.3 Fuel injection quantity control

(1) Fuel injection quantity during engine startup
During engine startup, the fuel injection quantity is determined in
accordance with the engine speed and coolant temperature.
(2) Basic fuel injection quantity

The basic fuel injection quantity is determined in accordance
with the engine speed and throttle opening.
(3) Maximum injection quantity

The maximum injection quantity is calculated from the engine
speed and boost pressure.
13E-14
13E
(4) Fuel injection rate adjustment resistor correction amount
To limit inconsistency in the injection quantity, the injection quan-
tity is corrected by the fuel injection rate adjustment resistor.
2.4 Fuel injection timing control

(1) Main injection timing
The main injection timing is calculated from the fuel injection
quantity and engine speed.
(2) Pilot injection timing (pilot interval)

The pilot interval is calculated from the fuel injection quantity and
engine speed.
2.5 Fuel injection pressure control

The fuel injection pressure is calculated from the fuel injection
quantity and engine speed.
13E-15
2.6 Warm-up acceleration
Engine electronic function
control unit
The warm-up acceleration function in-
Input signals creases engine warm-up by varying
Comparison
Water temperature sensor operations Output signals the engine s idling speed in accor-
Accelerator pedal position dance with the engine s coolant tem-
sensor Idling speed
control perature. It can operate either
Idling speed adjustment
potentiometer Target injection automatically or manually. Selection is
quantity
made using the idling speed adjust-
ment potentiometer.
2.7 Fault diagnosis function

While the starter switch is in the ON position, the sensors and other components are continuously monitored for
faults. In the event that a component is found faulty, an indication is made in the meter cluster to alert the driver,
the fault location is memorized in the form of a diagnosis code, and the control during fault is initiated.
While the control during fault is taking place, the system s functionality is limited to ensure vehicle and driver safe-
ty. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the warning
lamp.
NOTE
Diagnosis codes shown by the Multi-Use Tester and those indicated by flashing of the warning lamp are
different.
The Multi-Use Tester is capable of showing more detailed diagnosis codes.
13E-16
13E
M E M O
13E-17
3. Electronic Control Unit Connection Diagram
13E-18
13E
13E-19
TROUBLESHOOTING
1. Inspection Procedure
System inspection can be performed most effectively using a Multi-Use Tester-III. Types of system inspection are
broadly classified in accordance with fault symptoms and diagnosis codes as follows:
Inspection based on diagnosis code memorized by electronic control unit
Inspection performed on assumption of intermittent fault
Vehicle enters workshop.
Diagnosis code(s) is read.
Error code Normal code Communication

output Normal code output with Multi-Use
output after Tester impossible
deletion of
error code
Ascertain cause of Take steps on

diagnosis code generation; assumption of
perform inspection. intermittent fault.
If communication between the Multi-Use Tester and all

other systems is impossible, a fault in the diagnosis
circuitry is highly probable. If communication between the
Perform test drive. Multi-Use Tester and only the common rail system is
impossible, an open circuit in the common rail system s
diagnosis output circuitry or power supply circuitry
(including the earth circuit) is conceivable.
If diagnosis code is generated during test drive, again ascertain cause of code generation and perform inspection.
If diagnosis code memorized by electronic control unit is not generated during test drive, perform inspection based
on diagnosis code and on assumption of intermittent fault.
Delete diagnosis code.
13E-20
13E
2. Cautions to Observe when Performing Inspections
CAUTION
The battery voltage must be the standard voltage.
Make sure no harness connector or component connector is loose. Before disconnecting any connector,
place the starter switch in the LOCK position and wait 20 seconds.
After making a repair, delete the diagnosis code using the Multi-Use Tester or memory clear switch.
As a general rule, inspection work should be performed with the starter switch in the LOCK position.
However, it may be necessary to perform certain tasks with the starter switch in the ON position. At these
times, be careful not to cause short circuits between connector terminals and between terminals and the
vehicle body.
Indicated component resistances may not fall within the standard ranges if they are unduly affected by
the temperature and/or by the accuracy of the tester. Standard values in the text are given on the assump-
tion of room temperature (10 to 35 C {50 to 95 F}).
After rectification of an abnormality, the system s ability or inability to automatically return to normal con-
trol from the control during fault that begins when a fault occurs depends upon the diagnosis code, i.e.,
the fault location. When the system resumes normal control, the warning lamp goes off.
Even when an abnormality has been rectified and the system has automatically returned to normal con-
trol, the diagnosis code corresponding to the fault location remains in the memory of the electronic con-
trol unit as a past diagnosis code.
Following a fault that does not permit an automatic return to normal control from the control during fault
that begins when a fault occurs, it is necessary to clear the diagnosis code from memory in order for the
system to recover.
13E-21
TROUBLESHOOTING
3. Inspections Based on Diagnosis Codes
3.1 Diagnosis code list
NOTE
different.
Code Message Flashes Remarks Code Message Flashes Remarks

P0107 Atmospheric Pressure Sensor 19 P0506 Idle Volume 31
P0108 Atmospheric Pressure Sensor 19 P0507 Idle Volume 31
P0112 INT Air Temp. SNSR (Upstream) 44 P0510 Accel SW 65
P0113 INT Air Temp. SNSR (Upstream) 44 P0560 M/V Supply Voltage 79
P0117 Water Temperature Sensor 21 P0605 ECU System (Hardware) 33
P0118 Water Temperature Sensor 21 P0615 Starter Safety Relay 48 Gr54
P0121 Accel Pedal Check (Plausibility) 58 P0616 Starter Safety Relay 48 Gr54
P0122 Accel Pedal Sensor 1 24 P0617 Starter Safety Relay 48 Gr54
P0123 Accel Pedal Sensor 1 24 P1121 Intake Throttle 1 28 Gr17
P0182 Fuel Temp. Sensor (inlet) 41 P1171 Q Adjustment Resister 34
P0183 Fuel Temp. Sensor (inlet) 41 P1172 Q Adjustment Resister 34
P0192 Common Rail Pressure Sensor 11 P1200 Injector Circuit 2 82
P0193 Common Rail Pressure Sensor 11 P1251 Common Rail Pressure M/V 1 63
P0200 Injector Circuit 1 82 P1255 Common Rail Pressure M/V 1 63
P0201 Injector M/V-Cylinder 1 37 P1256 Common Rail Pressure M/V 1 63
P0202 Injector M/V-Cylinder 2 38 P1335 Revolution & Position Sensor 14
P0203 Injector M/V-Cylinder 3 39 P1460 Exhaust Brake M/V 1 93
P0204 Injector M/V-Cylinder 4 08 P1462 Exhaust Brake M/V 1 93
P0219 Engine Overrunning 07 P1463 Exhaust Brake M/V 1 93
P0222 Accel Pedal Sensor 2 16 P1562 Sensor Supply Voltage 1 81
P0223 Accel Pedal Sensor 2 16 P1563 Sensor Supply Voltage 1 81
P0237 Boost Pressure Sensor 32 P1567 Sensor Supply Voltage 2 81
P0238 Boost Pressure Sensor 32 P1568 Sensor Supply Voltage 2 81
P0251 Common Rail Pressure Defect 36 P1572 Sensor Supply Voltage 3 81
P0253 Common Rail Pressure Defect 22 P1573 Sensor Supply Voltage 3 81
P0254 Common Rail Pressure Defect 23 P1577 Segment Sensor Supply Voltage 81
P0335 Engine Revolution Sensor 15 P1578 Segment Sensor Supply Voltage 81
P0340 Camshaft Position Sensor 12 P1605 ECU System (EEPROM) 33
P0380 Relay for Glow Relay 26 Gr54 P1606 ECU System (Software) 33
P0381 Glow Lamp 89 Gr54 P1625 EDU Relay 84 Gr17
P0403 EGR 1 67 Gr17 P1630 CAN (EGR) 95 Gr17
P0404 EGR System 02 Gr17 P1635 CAN (Intake Throttle) 96 Gr17
P0500 Vehicle Speed Sensor 25 P1700 Torque Cut SW 86
13E-22
13E
3.2 Diagnosis code generation conditions and inspection items
P0107: Atmospheric Pressure Sensor (warning lamp flashes: 19)

Atmospheric pressure sensor (incorporated into engine electronic control unit)
Generation condition
voltage is below standard value (2 V).
Recoverability System recovers if signal becomes normal with starter switch in ON position.
Control is effected using backup value of 101.3 kPa {15 psi, 1.03 kgf/cm2}.
Control effected by electronic control unit (Exhaust emissions worsen.)
Exhaust gas recirculation control and throttle control are stopped.
Service data 38: Atmospheric Pressure
Inspection
Electrical equipment Engine electronic control unit
P0108: Atmospheric Pressure Sensor (warning lamp flashes: 19)

Atmospheric pressure sensor (incorporated into engine electronic control unit)
voltage is below standard value (4.7 V).
Control is effected using backup value of 101.3 kPa {15 psi, 1.03 kgf/cm2}.
Service data 38: Atmospheric Pressure
Inspection
Electrical equipment Engine electronic control unit
P0112: INT Air Temp. SNSR (Upstream) (warning lamp flashes: 44)
Generation condition Boost air temperature sensor voltage is below standard value (0.15 V).
Control effected by electronic control unit Control is effected using backup value (25 C {77 F}).
Service data 27: Intake Air Temperature
Electronic control unit connector 01 : Boost air temperature sensor
Inspection
Electrical equipment #305: Boost air temperature sensor
Electric circuit diagram Boost air temperature sensor system
P0113: INT Air Temp. SNSR (Upstream) (warning lamp flashes: 44)
Generation condition Boost air temperature sensor voltage is below standard value (4.85 V).
Control effected by electronic control unit Control is effected using backup value (25 C {77 F}).
Service data 27: Intake Air Temperature
Electronic control unit connector 01 : Boost air temperature sensor
Inspection
Electrical equipment #305: Boost air temperature sensor
Electric circuit diagram Boost air temperature sensor system
13E-23
TROUBLESHOOTING
P0117: Water Temperature Sensor (warning lamp flashes: 21)
Generation condition Water temperature sensor voltage is below standard value (0.2 V).
Water temperature is assumed as constant 20 C { 4 F} during engine start-
up and as constant 80 C {175 C} while vehicle is being driven.
Glow control is stopped.
Service data 35: Water Temperature
Electronic control unit connector 02 : Water temperature sensor
Inspection
Electrical equipment #262: Water temperature sensor
Electric circuit diagram Water temperature sensor system
P0118: Water Temperature Sensor (warning lamp flashes: 21)

Generation condition Water temperature sensor voltage is above standard value (4.85 V).
Water temperature is assumed as constant 20 C { 4 F} during engine start-
up and as constant 80 C {175 C} while vehicle is being driven.
Glow control is stopped.
Service data 35: Water Temperature
Electronic control unit connector 02 : Water temperature sensor
Inspection
Electrical equipment #262: Water temperature sensor
Electric circuit diagram Water temperature sensor system
P0121: Accel Pedal Check (Plausibility) (warning lamp flashes: 58)

Accelerator pedal position sensor output voltages 1 and 2 are outside standard
range; or compared value is out of specification.
Recoverability (Low output)
Control is effected using value of 30 % with accelerator pedal depressed and
Control effected by electronic control unit
using value of 0 % with accelerator pedal not depressed. (Output is reduced.)
22: Accel Pedal Position (unfiltered), 23: Accel Pedal Position (filtered)
Service data
24: Accel Pedal Sensor Voltage 1, 25: Accel Pedal Sensor Voltage 2
Inspection Electronic control unit connector 03 : Accelerator pedal position sensor
Electrical equipment #324: Accelerator pedal position sensor
Electric circuit diagram Accelerator pedal position sensor system
P0122: Accel Pedal Sensor 1 (warning lamp flashes: 24)

Generation condition Accelerator pedal position sensor 1 voltage is below standard value (0.5 V).
Control effected by electronic control unit Control is effected using accelerator pedal position sensor 2.
Service data
24: Accel Pedal Sensor Voltage 1
Electric circuit diagram Accelerator pedal position sensor 1 system
13E-24
13E
Service data
P0182: Fuel Temp. Sensor (inlet) (warning lamp flashes: 41)

Generation condition Fuel temperature sensor voltage is below standard value (0.15 V).
Control effected by electronic control unit Control is effected using backup value.
Service data 36: Fuel Temperature (inlet)
Electronic control unit connector 04 : Fuel temperature sensor
Inspection
Electrical equipment #323: Fuel temperature sensor
Electric circuit diagram Fuel temperature sensor system
P0183: Fuel Temp. Sensor (inlet) (warning lamp flashes: 41)

Generation condition Fuel temperature sensor voltage is below standard value (4.8 V).
Control effected by electronic control unit Control is effected using backup value.
Service data 36: Fuel Temperature (inlet)
Electronic control unit connector 04 : Fuel temperature sensor
Inspection
Electrical equipment #323: Fuel temperature sensor
Electric circuit diagram Fuel temperature sensor system
P0192: Common Rail Pressure Sensor (warning lamp flashes: 11)

Generation condition Common rail pressure sensor voltage is below standard value (0.2 V).
System recovers (power is re-supplied to electronic control unit) if signal becomes
Recoverability
normal when starter switch is turned OFF ON.
Common rail pressure open loop control is effected.
Control effected by electronic control unit (Output is reduced, and exhaust emissions worsen.)
Service data 0C: Difference Common Rail Pressure
Inspection Electrical equipment #319: Common rail pressure sensor
Electric circuit diagram Common rail pressure sensor system
P0193: Common Rail Pressure Sensor (warning lamp flashes: 11)

Generation condition Common rail pressure sensor voltage is below standard value (4.8 V).
Recoverability
Common rail pressure open loop control is effected.
13E-25
TROUBLESHOOTING
P0200: Injector Circuit 1 (warning lamp flashes: 82)
Generation condition Injector circuit is short-circuited, open-circuited, or overloaded.
Faulty circuit is stopped, resulting in two-cylinder operation.
Actuator tests BB: Injector Test 1, BD: Injector Test 3
Electronic control unit connector 05 : Injector magnetic valve
Inspection
Electrical equipment #582: Injector magnetic valve
Electric circuit diagram Injector magnetic valve (No. 1 cylinder) or (No. 3 cylinder) system
P0201: Injector M/V-Cylinder1 (warning lamp flashes: 37)

Generation condition Injector magnetic valve (No. 1 cylinder) is short-circuited or open-circuited.
Short circuit: System recovers (power is re-supplied to electronic control unit) if
signal becomes normal when starter switch is turned OFF ON.
Recoverability
Open circuit: System recovers if signal becomes normal with starter switch in ON
position.
Exhaust gas recirculation control is stopped.
Intake throttle control is stopped.
Control effected by electronic control unit Open circuit: Energization is stopped.
Short circuit: Injector magnetic valves 1 and 4 are stopped.
(Output is reduced, fuel economy worsens, and exhaust emissions worsen.)
Actuator test BB: Injector Test 1
Inspection
Electric circuit diagram Injector magnetic valve (No. 1 cylinder) system

Recoverability
position.
Actuator test BC: Injector Test 2
Inspection
13E-26
13E
Recoverability
position.
Actuator test BD: Injector Test 3
Inspection

Recoverability
position.
Actuator test BE: Injector Test 4
Inspection
P0219: Engine Overrunning (warning lamp flashes: 07)

Generation condition Engine speed is higher than specified level.
Injectors are turned OFF.
MPROP stops feeding fuel.
Inspection Electronic control unit connector Engine electronic control unit

Service data
13E-27
TROUBLESHOOTING
Generation condition Accelerator pedal position sensor 2 voltage is above standard value (4.7 V).
Service data
P0237: Boost Pressure Sensor (warning lamp flashes: 32)

Generation condition Boost pressure sensor voltage is below standard value (0.3 V).
Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
(Output is reduced, and fuel economy worsens.)
Service data 26: Boost Pressure
Inspection Electrical equipment #318: Boost pressure sensor
Electric circuit diagram Boost pressure sensor system
P0238: Boost Pressure Sensor (warning lamp flashes: 32)

Generation condition Boost pressure sensor voltage is above standard value (4.7 V).
Control is effected using backup value of 101.3 kPa {1.03 kgf/cm2}.
(Output is reduced, and fuel economy worsens.)
Service data 26: Boost Pressure
Inspection Electrical equipment #318: Boost pressure sensor
Electric circuit diagram Boost pressure sensor system
P0251: Common Rail Pressure Defect (warning lamp flashes: 36)

Difference between target rail pressure and actual rail pressure is above standard
value.
Recoverability
Control effected by electronic control unit Injectors are turned OFF. (Engine is stopped.)
Actuator test B9: Fuel Leak Check
Air-bleeding of fuel system (See Gr13.)
Inspection of fuel piping (See Gr13.)
Inspection Fuel filter (See Gr13.)
Other
Supply pump (Have work performed by Bosch Automotive Systems.)
Pressure limiting valve (Have work performed by Bosch Automotive Systems.)
Injectors (Have work performed by Bosch Automotive Systems.)
13E-28
13E
Generation condition Actual rail pressure is below standard value.
Air-bleeding of fuel system (See Gr13.)
Inspection of fuel piping (See Gr13.)
Inspection Fuel filter (See Gr13.)
Other
Supply pump (Have work performed by Bosch Automotive Systems.)
Pressure limiting valve (Have work performed by Bosch Automotive Systems.)
Injectors (Have work performed by Bosch Automotive Systems.)

Actual rail pressure is high even with delivery rate of zero; or actual rail pressure
is above standard value.
Recoverability
Injection quantity is limited. (Output is reduced.)
Inspection Other Supply pump (Have work performed by Bosch Automotive Systems.)
P0335: Engine Revolution Sensor (warning lamp flashes: 15)

Generation condition Engine speed sensor emits no pulses or too many pulses.
Control is effected using cylinder recognition sensor.
(Output decreases owing to reduced control accuracy.)
Service data 01: Engine Revolution
Electronic control unit connector 06 : Engine speed sensor
Inspection
Electrical equipment #263: Engine speed sensor
Electric circuit diagram Engine speed sensor system
P0340: Camshaft Position Sensor (warning lamp flashes: 12)

Generation condition Cylinder recognition sensor emits no pulses or too many pulses.
Control effected by electronic control unit Control is effected using engine speed sensor.
Electronic control unit connector 07 : Cylinder recognition sensor
Inspection
Electrical equipment #320: Cylinder recognition sensor
Electric circuit diagram Cylinder recognition sensor system
P0500: Vehicle Speed Sensor (warning lamp flashes: 25)

Generation condition Vehicle speed sensor signal is missing or indicates an abnormally high speed.
Control effected by electronic control unit Engine is controlled normally.
Service data 3C: Vehicle Speed
Electronic control unit connector 08 : Vehicle speed sensor
Inspection
Electrical equipment #265: Vehicle speed sensor
Electric circuit diagram Vehicle speed sensor system
13E-29
TROUBLESHOOTING
P0506: Idle Volume (warning lamp flashes: 21)
Generation condition Idling speed adjustment potentiometer voltage is below standard value (0.7 V).
Control effected by electronic control unit Control is effected with auto idle permanently selected.
Service data 3B: Idle Volume Voltage
Electronic control unit connector 09 : Idling speed adjustment potentiometer
Inspection
Electrical equipment #157: Idling speed adjustment potentiometer
Electric circuit diagram Idling speed adjustment potentiometer system
P0507: Idle Volume (warning lamp flashes: 31)

Generation condition Idling speed adjustment potentiometer voltage is above standard value (4.6 V).
Control effected by electronic control unit Control is effected with auto idle permanently selected.
Service data 3B: Idle Volume Voltage
Electronic control unit connector 09 : Idling speed adjustment potentiometer
Inspection
Electrical equipment #157: Idling speed adjustment potentiometer
Electric circuit diagram Idling speed adjustment potentiometer system
P0510: Accel SW (warning lamp flashes: 65)

Accelerator pedal switch signal is abnormal when compared with accelerator ped-
al position sensor outputs 1 and 2.
Control effected by electronic control unit Normal control is effected.
Service data 73: Accel SW
Electronic control unit connector 10 : Accelerator pedal switch
Inspection #324: Accelerator pedal switch (incorporated into accelerator pedal position sen-
Electrical equipment
sor)
Electric circuit diagram Accelerator pedal switch system
P0560: M/V Supply Voltage (warning lamp flashes: 79)

Generation condition Circuit (magnetic valve power supply) in electronic control unit is abnormal.
Recoverability
Control effected by electronic control unit No specific control is effected. Failure occurs owing to circuit abnormality.
Inspection Other Engine electronic control unit
P0605: ECU System (Hardware) (warning lamp flashes: 33)

Generation condition Circuit (hardware power supply) in electronic control unit is abnormal.
System recovers if signal becomes normal with starter switch in ON position.
Recoverability
System does not recover unless diagnosis code is deleted.
Control effected by electronic control unit No specific control is effected. Failure occurs owing to circuit abnormality.
13E-30
13E
P1171: Q Adjustment Resistor (warning lamp flashes: 34)
Generation condition Fuel injection rate adjustment resistor voltage is below standard value (0.2 V).
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Electronic control unit connector 11 : Fuel injection rate adjustment resistor
Inspection
Electrical equipment #828: Fuel injection rate adjustment resistor
Electric circuit diagram Fuel injection rate adjustment resistor
P1172: Q Adjustment Resistor (warning lamp flashes: 34)

Generation condition Fuel injection rate adjustment resistor voltage is above standard value (4.8 V).
Control effected by electronic control unit Control is effected using backup value (No. 1). (Output is slightly reduced.)
Service data 3E: Q Adjustment Resistor No.
Electronic control unit connector 11 : Fuel injection rate adjustment resistor
Inspection
Electrical equipment #828: Fuel injection rate adjustment resistor
Electric circuit diagram Fuel injection rate adjustment resistor
P1200: Injector Circuit 2 (warning lamp flashes: 82)

Generation condition Injector circuit is short-circuited, open-circuited, or overloaded.
System recovers (power is re-supplied to electronic control unit) if signal be-
Recoverability
comes normal when starter switch is turned OFF ON.
Faulty circuit is stopped, resulting in two-cylinder operation. (Output is re-
Control effected by electronic control unit duced, and exhaust emissions worsen.)
Actuator tests BC: Injector Test 2, BE: Injector Test 4
Inspection
Electric circuit diagram Injector magnetic valve (No. 2 cylinder) or (No. 4 cylinder) system
P1251: Common Rail Pressure M/V 1 (warning lamp flashes: 63)

Current flowing to MPROP (injection quantity adjustment valve) is above standard
value.
Recoverability
Injection quantity is limited. (Output is reduced, fuel economy worsens, and
Control effected by electronic control unit exhaust emissions worsen.)
Electronic control unit connector 12 : MPROP (injection quantity adjustment valve)
Inspection
Electrical equipment #574: MPROP (injection quantity adjustment valve)
Electric circuit diagram MPROP (injection quantity adjustment valve) system
13E-31
TROUBLESHOOTING
Generation condition MPROP (injection quantity adjustment valve) voltage is below standard value.
Recoverability
Inspection

Generation condition MPROP (injection quantity adjustment valve) voltage is above standard value.
High voltage: System recovers if signal becomes normal with starter switch in ON
position.
Recoverability
Exhaust gas recirculation control and intake throttle control are stopped.
Inspection
P1335: Revolution & Position Sensor (warning lamp flashes: 14)

Engine speed sensor and cylinder recognition sensor emit no pulses or too many
pulses.
Electronic control unit connector 06 : Engine speed sensor, 07 : Cylinder recognition sensor
Inspection
Electrical equipment #263: Engine speed sensor, #320: Cylinder recognition sensor
Electric circuit diagram Engine speed sensor and cylinder recognition sensor systems
P1460: Exhaust Brake M/V 1 (warning lamp flashes: 93)

Generation condition Current flowing to exhaust brake 3-way magnetic valve is above standard value.
Control effected by electronic control unit Operation of exhaust brake is stopped.
Service data 87: Exhaust Brake M/V 1
Actuator test AC: Auxiliary Brake M/V 1
Inspection Electronic control unit connector 13 : Exhaust brake 3-way magnetic valve
Electrical equipment #565: Exhaust brake 3-way magnetic valve
Electric circuit diagram Exhaust brake 3-way magnetic valve system
13E-32
13E
Generation condition Exhaust brake 3-way magnetic valve voltage is below standard value.

Generation condition Exhaust brake 3-way magnetic valve voltage is above standard value.
P1562: Sensor Supply Voltage 1 (warning lamp flashes: 81)

Circuit voltage (sensor supply voltage 1) in electronic control unit is below standard
value.
Control effected by electronic control unit No specific control is effected. Failure occurs only to circuit abnormality.
Service data 24: Accel Pedal Sensor Voltage 1, 3B: Idle Volume Voltage
03 : Accelerator pedal position sensor 1,
Electronic control unit connector
09 : Idling speed adjustment potentiometer
Inspection #157: Idling speed adjustment potentiometer, #324: Accelerator pedal position
sensor 1
Boost air temperature sensor, accelerator pedal position sensor 1, and idling
Electric circuit diagram
speed adjustment potentiometer systems

Circuit voltage (sensor supply voltage 1) in electronic control unit is above standard
value.
Service data 24: Accel Pedal Sensor Voltage 1, 3B: Idle Volume Voltage
03 : Accelerator pedal position sensor 1,
Electronic control unit connector
09 : Idling speed adjustment potentiometer
Inspection #157: Idling speed adjustment potentiometer, #324: Accelerator pedal position
sensor 1
Boost air temperature sensor, accelerator pedal position sensor 1, and idling
speed adjustment potentiometer systems
13E-33
TROUBLESHOOTING
value.
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Electronic control unit connector 03 : Accelerator pedal position sensor 2
Inspection Electrical equipment #318: Boost pressure sensor, #324: Accelerator pedal position sensor 2
Boost pressure sensor, accelerator pedal position sensor 2, and fuel temperature
sensor systems

value.
Service data 25: Accel Pedal Sensor Voltage 2, 26: Boost Pressure
Electronic control unit connector 03 : Accelerator pedal position sensor 2
Inspection Electrical equipment #318: Boost pressure sensor, #324: Accelerator pedal position sensor 2
Boost pressure sensor, accelerator pedal position sensor 2, and fuel temperature
sensor systems

value.

value.
13E-34
13E
P1577: Segment Sensor Supply Voltage (warning lamp flashes: 81)
Generation condition Cylinder recognition sensor supply voltage is below standard value (0 V).
Inspection
P1578: Segment Sensor Supply Voltage (warning lamp flashes: 81)

Generation condition Cylinder recognition sensor supply voltage is above standard value (5 V).
Recoverability
Inspection
P1605: ECU System (EEPROM) (warning lamp flashes: 33)

Generation condition Reading or writing error occurs during access.
Recoverability
P1606: ECU System (Software) (warning lamp flashes: 33)

System overload occurs.
Task execution time exceeds limit duration.
Recoverability
P1700: Torque Cut SW (warning lamp flashes: 86)

Generation condition Error occurs in comparison with VN ratio.
Service data 7F: Torque Cut Switch
Electronic control unit connector 14 : Torque limit SW
Inspection
Electrical equipment #163: Torque limit switch
Electric circuit diagram Torque limit switch system
13E-35
TROUBLESHOOTING
4. Multi-Use Tester Service Data
NOTE
It is possible to see service data and actuator tests simultaneously.
No. Item Data Inspection condition Requirement

Value corresponds to ta-
01 Engine Revolution .rpm Racing (engine running)
chometer indication.
02 Reference Injection Quantity . % Starter switch ON 0%
Difference Common Rail
0C . % Engine idling 0 % or lower
Pressure
1F EGR Position . % See Gr17.
20 Intake Throttle Position . % See Gr17.

Accelerator pedal not depressed 0%
Accel Pedal Position
22 . % Accelerator pedal gradually depressed Value gradually increases.
(unfiltered)
Accelerator pedal fully depressed 100 %
Accelerator pedal not depressed 0%
Accel Pedal Position
23 . % Accelerator pedal gradually depressed Value gradually increases.
(filtered)
Accelerator pedal fully depressed 100 %
Accelerator pedal gradually depressed
24 Accel Pedal Sensor Voltage 1 . V 0.85 to 4.15 V
from released position
Accelerator pedal gradually depressed
25 Accel Pedal Sensor Voltage 2 . V 0.85 to 4.15 V
from released position
26 Boost Pressure . inHg High idle 10.3 in.Hg
Value corresponds to
27 Intake Air Temperature . F Engine cold
ambient temperature.
Engine cold
35 Water Temperature . F Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Engine cold
36 Fuel Temperature (inlet) . F Engine in process of warming up Value gradually increases.
Engine stopped after warming up Value gradually decreases.
Altitude: 0 m {0 ft.} 29.8 in.Hg
38 Atmospheric Pressure . inHg
Altitude: 600 m {1,970 ft.} 28.1 in.Hg
3B Idle Volume Voltage . V SLOW to FAST 2.6 to 1.2 V
3C Vehicle Speed .MPH Vehicle in motion
speedometer indication.
Number matches number
1/2/3/4/5/6/7/8/9/10/
3E Q Adjustment Resistor No. marked on fuel injection
11/NON
rate adjustment resistor.
Value matches battery
42 Power Supply Voltage . V Starter switch ON
voltage.
Engine cranked by means of starter
ON
switch
71 Starter SW (S) ON/OFF
Starter switch in position except
OFF
START
Starter switch in ON position ON
72 Starter SW (M) ON/OFF
Starter switch in position except ON OFF
Accelerator pedal depressed ON
73 Accel SW ON/OFF
Accelerator pedal not depressed OFF
13E-36
13E
Combination switch ON <manual
transmission>
Accelerating <automatic transmis- ON
sion>
76 Auxiliary Brake SW 1 ON/OFF
Combination switch OFF <manual
transmission>
Decelerating <automatic transmis- OFF
sion>
Clutch pedal depressed ON
78 Clutch SW ON/OFF
Clutch pedal not depressed OFF
Transmission in neutral <manual
transmission>
Shift lever in D position <automatic ON
transmission>
7A Neutral SW ON/OFF
Transmission not in neutral <manual
transmission> OFF
Shift lever in N position <automatic
transmission>
Shift lever in D position <automatic
transmission> ON
Continuously <manual transmis-

7B Idle Up Cancel SW ON/OFF sion>
Shift lever in N position <automatic OFF
transmission>
[Actuator test] B8: Idle Up Cancel SW
Air conditioner compressor running ON
7C Air Conditioner SW 1 ON/OFF Air conditioner compressor not running OFF
[Actuator test] B6: Air Conditioner SW 1
7E Cold Start SW ON/OFF See Gr54.
Transmission in 1st or reverse ON
7F Troque Cut SW ON/OFF
Transmission not in 1st or reverse OFF
Switch ON ON
82 PTO SW ON/OFF
Switch OFF OFF
Diagnosis switch OFF (fuse fitted) ON
83 Diagnosis SW ON/OFF
Diagnosis switch ON (fuse removed) OFF
ON/OFF Memory clear switch OFF (fuse fitted) ON
84 Memory Clear SW Memory clear switch ON
ON/OFF OFF
(fuse removed)
Exhaust brake operating ON
87 Exhaust Brake M/V 1 ON/OFF Exhaust brake not operating OFF
[Actuator test] AC: Auxiliary Brake M/V 1
Exhaust brake operating ON
8C Auxiliary Brake Indicator Lamp ON/OFF Exhaust brake not operating OFF
[Actuator test] AE: Auxiliary Brake Indicator Lamp
8D Glow Relay ON/OFF See Gr54.
8E Glow Relay Indicator Lamp ON/OFF See Gr54.
8F Starter Safety Relay ON/OFF See Gr54.
90 EDU Power Relay ON/OFF See Gr54.
Starter switch ON (engine not started) ON
91 MIL Lamp ON/OFF No error after engine startup OFF
[Actuator test] B3: MIL Lamp
Starter switch ON (engine not started) ON
92 Diagnosis Lamp ON/OFF No error after engine startup OFF
[Actuator test] B4: Diagnosis Lamp
13E-37
TROUBLESHOOTING
5. Actuator Tests Performed Using Multi-Use Tester
No. Item Explanation Confirmation method

A1 EGR 1 See Gr17.
A7 Intake Throttle 1 See Gr17.
Exhaust brake 3-way magnetic valve drive signal Operating sound of mag-
(Can be executed with engine not running.) netic valve
[Service data]
87: Exhaust brake M/V 1
AC Auxiliary Brake M/V 1
Exhaust brake indicator lamp drive signal (Can be executed ON/OFF condition of indi-
with engine not running.) cator lamp
[Service data]
8C: Auxiliary Brake Indica-
tor Lamp
AE Auxiliary Brake Indicator Lamp
AF Relay for Glow Relay See Gr54.

B0 Glow Indicator Lamp See Gr54.
B1 Starter Safety Relay See Gr54.
B2 EDU Relay See Gr17.
Warning lamp (orange) drive signal ON/OFF condition of warn-
ing lamp (orange)
[Service data]
91: MIL Lamp
B3 MIL Lamp
Warning lamp (orange) drive signal ON/OFF condition of warn-

ing lamp (red)
[Service data]
92: Diagnosis Lamp
B4 Diagnosis Lamp
13E-38
13E
Idle up control reproduced by means of dummy signal (air Increase in idling speed
conditioner operation). (Can be executed with vehicle speed [Service data]
of zero and with transmission in neutral.) 7C: Air conditioner SW 1
B6 Air Conditioner SW 1
Idle up cancel condition reproduced by means of dummy sig- Idling speed low idle
nal (idle up cancel). (Can be executed with vehicle speed of [Service data]
zero and with transmission in neutral.) 7B: Idle Up Cancel SW
B8 Idle Up Cancel SW
Rail pressure increased on constant slope (Can be executed Check that no fuel leaks
B9 Fuel Leak Check with vehicle speed of zero and transmission in neutral and di- from fuel system.
agnosis switch open.)
Injector 1 not activated (Can be executed with engine speed Engine RPM should
BB Injector Test 1 not exceeding 1,500 rpm and no errors and transmission in decrease
neutral and vehicle speed of zero.)
BC Injector Test 2 not exceeding 1,500 rpm and no errors and transmission in decrease
BD Injector Test 3 not exceeding 1,500 rpm and no errors and transmission in decrease
BE Injector Test 4 not exceeding 1,500 rpm and no errors and transmission in decrease
13E-39
TROUBLESHOOTING
6. Inspections Performed at Electronic Control Unit Connectors
These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black numbers ( 01 , 02 , and so on) correspond to the similarly printed reference numbers in
section 3. Inspections based on diagnosis codes .
6.1 Electronic control unit connector terminal layout
6.2 Inspection instructions

CAUTION
Some inspections are performed with the connectors removed. Others are performed with the connectors
fitted. Observe the following caution:
Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.
Check item Measurement method

01 [Conditions]
Starter switch OFF
Resistance of boost air temperature sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A63-A32
0 C {32 F}: 15 +3.78
2.94 k
20 C {68 F}: 6.514 +1.473
1.147 k
80 C {176 F}: 0.874 +0.136
0.115 k
13E-40
13E
02 [Conditions]
Starter switch OFF
Resistance of water temperature sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A40-A41
20 C {68 F}: 2.3 to 2.6 k
80 C {176 F}: 0.30 to 0.34 k
03 [Conditions]
Starter switch ON
Output voltage of accelerator pedal position Vehicle-side harness connected (Perform inspection on back of connector.)
sensor [Requirements]
Terminals (+)-( )
B34-B33 and B45 (accelerator pedal position sensor 1)
B46-B33 and B45 (accelerator pedal position sensor 2)
With accelerator pedal not depressed: 0.85 0.1 V
With accelerator pedal depressed: 4.15 0.1 V
04 [Conditions]
Starter switch OFF
Resistance of fuel temperature sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A89-A65 +0.14
20 C {68 F}: 2.45 0.13 k
80 C {176 F}: 0.318 0.01 k
110 C {230 F}: 0.1417 0.01 k
05 [Conditions]
Starter switch OFF
Resistance of injector magnetic valve Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals:
A72-A23 (injector magnetic valve: No. 1 cylinder)
0.255 0.04
06 [Conditions]
Starter switch OFF
Resistance of engine speed sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A10-A9
860 86 k 20 C {68 F}
07 [Conditions]
Starter switch OFF
Resistance of cylinder recognition sensor Disconnect connector. Perform inspection on vehicle-side connector.
[Requirements]
Terminals: A78-A83 (+5 V to GND)
200 to 1800 k
08 [Conditions]
Starter switch ON
Output voltage of vehicle speed sensor Vehicle-side harness connected (Perform inspection on back of connector.)
Turn wheels slowly using chassis dynamometer.
[Requirements]
Terminals (+)-( ): A67-chassis earth
High pulse voltage: Approx. 8 1 V
Low pulse voltage: 0.5 V or lower
09 [Conditions]
Starter switch ON
Output voltage of idling speed adjustment Vehicle-side harness connected (Perform inspection on back of connector.)
potentiometer [Requirements]
Terminals (+)-( ): A12-A36
AUTO position: 4.0 0.1 V
SLOW position: 3.0 0.2 V
FAST position: 1.0 0.1 V
13E-41
TROUBLESHOOTING
10 [Conditions]
Starter switch ON
Operating voltage of accelerator pedal switch Vehicle-side harness connected (Perform inspection on back of connec-
tor.)
[Requirements]
Terminals (+)-( ): A20-B33 and B45
With accelerator pedal depressed: 0 V
With accelerator pedal not depressed: 5 V
11 [Conditions]
Starter switch OFF
Resistance of fuel injection rate adjustment Disconnect connector. Perform inspection on vehicle-side connector.
resistor [Requirements]
Terminals: A35-A88
No. 1 resistor: 270 13.5
No. 3 resistor: 820 41
No. 4 resistor: 1,300 65
No. 8 resistor: 15,000 750
No. 10 resistor: 4,300 215
No. 11 resistor: 9,100 455
12 [Conditions]
Starter switch OFF
Resistance of MPROP Disconnect connector. Perform inspection on vehicle-side connector.
(injection quantity adjustment valve) [Requirements]
Terminals: A69-A21, A69-A2, A3-A21, A3-A2
2.6 to 3.15
13 [Conditions]
Starter switch ON
Voltage of exhaust brake 3-way magnetic valve Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
Terminals (+)-( ): A76-A6
With exhaust brake operating: Corresponding to battery voltage
With exhaust brake not operating: 0 V
14 [Conditions]
Starter switch ON
Voltage of torque limit switch Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
Terminals (+)-( ): A92-chassis earth
Transmission in 1st or reverse: Corresponding to battery voltage
Transmission not in 1st or reverse: 0 V
13E-42
INSPECTION OF ELECTRICAL EQUIPMENT 13E
#001 Inspection of combination switch
AK14A connector connection table
Switch position Terminals with continuity
OFF
Exhaust brake switch
ON 8-9
If there is any abnormality, replace the switch.
#031 Inspection of clutch switch

A 1-4
B 2-3
#157 Inspection of idling speed adjustment potentiometer

Apply 5 V DC to terminals 1 and 2 of the idling speed adjustment
potentiometer.
Turn the knob fully counterclockwise. Then, measure the output
voltage across terminals 2 and 3 (see the diagrams on the left)
while slowly turning the knob clockwise.
If any measurement is out of specification, replace the idling
speed adjustment potentiometer.
Knob position Output voltage
AUTO (0 ) 4.0 0.1 V
Standard value
SLOW (30 ) 3.0 0.2 V
FAST (300 ) 1.0 0.1 V
13E-43
INSPECTION OF ELECTRICAL EQUIPMENT
#163 Inspection of torque limit switch
OFF
ON 1-2
#262 Inspection of water temperature sensor

Place the water temperature sensor in a container filled with en-
gine oil.
Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
Measure the resistance between terminals 1 and 2.
20 C {68 F} 2.3 to 2.6 k
Standard value
80 C {176 F} 0.30 to 0.34 k
If either measurement is out of specification, replace the sensor.
#263 Inspection of engine speed sensor

Standard value (at 20 C {68 F}) 860 86
If the measurement is out of specification, replace the sensor.
#265 Inspection of vehicle speed sensor

With the battery voltage applied to terminals 1 and 2, slowly turn
part A of the sensor.
Measure the maximum voltage (high pulse voltage B) and mini-
mum voltage (low pulse voltage C) occurring at each specified
pair of terminals.
Terminals Inspection condition Standard value
25-pulse output: Low pulse voltage 0.5 V or lower
terminals 1 and 4 High pulse voltage 8 1V
If any measurement is out of specification, replace the sensor.
13E-44
13E
#305 Inspection of boost air temperature sensor
Place the boost air temperature sensor in a container filled with
engine oil.
Heat the oil to each of the specified temperatures. Stir the oil
well while doing so.
0 C {32 F} 15 +3.78
2.94 k
Standard value 20 C {68 F} 6.514 +1.437
1.147 k
80 C {176 F} 0.874 +0.136
0.115 k
If either measurement is out of specification, replace the sensor.
#318 Inspection of boost pressure sensor

Apply 5 V DC to terminals 3 and 1.
Apply air pressure A. Gradually increase it and, while doing so,
measure the output voltage occurring at terminals 2 and 1 (see
the diagram on the left).
Part Name and shape of tool Part No.
Pressure
MH061366
gauge
Air pressure Voltage

66.6 kPa
Approx. 0.5 V
{19.7 in.Hg, 500 mmHg}
Standard value 200 kPa
Approx. 2.5 V
{59.1 in.Hg, 1500 mmHg}
333.3 kPa
Approx. 4.5 V
{98.4 in.Hg, 2500 mmHg}
#319 Inspection of common rail pressure sensor

The sensor cannot easily be inspected in isolation, so you must
evaluate it indirectly by inspection of system harnesses and re-
lated parts.
If there is no abnormality in any related part but the system is ab-
normal, replace the common rail.
#320 Inspection of cylinder recognition sensor

Standard value 200 to 1800
If the measurement is out of specification, replace the sensor.
13E-45
#323 Inspection of fuel temperature sensor
20 C {68 F} 2.45 +0.14
0.13 k
Standard value 80 C {176 F} 0.318 0.01 k
110 C {230 F} 0.1417 0.01 k
#324 Inspection of accelerator pedal position sensor

[Inspection]
Apply 5 V DC to terminals 4 and 2 of the accelerator pedal posi-
tion sensor.
Measure the output voltage at terminals 2 and 5 (sensor 1) and
the output voltage at terminals 1 and 2 (sensor 2) with the accel-
erator lever in each specified position.
Accelerator lever position Output voltage
Idling position A 0.85 0.1 V
Standard value Accelerator pedal switch
1.0 0.24 V
operating position B
Full load position C 4.15 0.1 V
A: Position in which accelerator lever is touching stopper
B: Position at which continuity between terminals 2 and 3 dis-
appears as accelerator pedal is pushed downward
C: Position in which accelerator lever is touching stopper bolt
If any output voltage is out of specification, make an adjustment.
If any output voltage is still out of specification when you have
made an adjustment, replace the sensor.
[Adjustment]
To adjust the output voltage for the idling position A, loosen the
screws and move the accelerator pedal position sensor. Tighten
the screws after making the adjustment.
To adjust the output voltage for the full load position C, loosen
the nut and make the adjustment using the stopper bolt. After
making the adjustment, lock the stopper bolt in position with the
nut.
13E-46
13E
#565 Inspection of exhaust brake 3-way magnetic valve
Perform the following checks. If there is any abnormality, replace
the exhaust brake 3-way magnetic valve.
(1) Check of operation
Gradually increase from zero the voltage applied to terminals 1
and 2.
Observe the voltage when the exhaust brake 3-way magenetic
valve operates.
(Determine the magnet valve s OFF-ON operation from the op-
erating sound.)
Standard value (min. operating voltage) 11 V or lower
(2) Check of continuity and airtightness

Vacuum pressure applied during check:
100 kPa { 29.5 in.Hg, 750 mmHg}
#574 Inspection of MPROP

(injection quantity adjustment valve)
Standard value 2.6 to 3.15
If the measurement is out of specification, replace the supply
pump.
#582 Inspection of injector magnetic valve

Standard value (at 20 C {68 F}) 0.255 0.04
If the measurement is out of specification, replace the injector.
13E-47
#828 Inspection of fuel injection rate adjustment resistor
Measure the resistance of the resistor number marked on the
fuel injection rate adjustment resistor.
1 270 13.5
2 510 25.5
3 820 41
4 1300 65
5 2000 100
Standard value
Resistor No. 6 3300 165
(at 20 C {68 F})
7 5600 280
8 15000 750
9 390 19.5
10 4300 215
11 9100 455
If the measurement is out of specification, replace the fuel injec-
tion rate adjustment resistor with one that has the same resistor
number and same specified resistance.
CAUTION
The fuel injection rate adjustment resistor is matched to the
engine. If you replace it, be sure to replace it with one that
has the same resistor number.
13E-48
13E
M E M O
13E-49
INSTALLED LOCATIONS OF PARTS
13E-50
13E
13E-51
13E-52
13E
13E-53
13E-54
13E
M E M O
13E-55
ELECTRIC CIRCUIT DIAGRAM
13E-56
13E
13E-57
13E-58
13E
13E-59
13E-60
13E
13E-61
INDEX
SPECIFICATIONS ............................................................................... 14-2

1. Cooling System (Flow of Coolant) ................................................. 14-4
2. Thermostat .................................................................................... 14-5
3. Water Pump .................................................................................. 14-5
TROUBLESHOOTING......................................................................... 14-6

1. Coolant Replacement and Cleaning of Cooling System ................ 14-8
2. Air Bleeding of Cooling System .................................................. 14-10
3. Air/Gas Leakage Test .................................................................. 14-10
DISCONNECTION AND CONNECTION OF HOSES AND PIPES ... 14-12
RADIATOR......................................................................................... 14-16
COOLING FAN, V-BELT AND WATER PUMP.................................. 14-24
TENSION PULLEY ............................................................................ 14-27
THERMOSTAT................................................................................... 14-28
PRESSURE CAP AND WATER OUTLET CASE .............................. 14-30
14-1
SPECIFICATIONS
Item Specifications
Cooling system Forced water circulation system
Water pump Belt-driven involute type
Thermostat Wax pellet, bottom bypass type (with jiggle valve)
Automatic cooling fan coupling Continuous control type
Radiator Tube and corrugated fin type
Coolant capacity L {qts} 16.0 {17}
14-2
14
M E M O
14-3
1. Cooling System (Flow of Coolant)
14-4
14
2. Thermostat
It is a bottom bypass type that uses a
wax-filled pellet as its flow-regulating
element. When the wax is heated, it
melts from solid to liquid, changing its
total volume. This allows the valve to
open or close in accordance with the
coolant temperature, regulating and
adjusting the flow of coolant to the ra-
diator and to the cylinder head (by-
passing the radiator).
3. Water Pump
The water pump has a drain hole to
prevent coolant from entering the unit
bearing in the case of defect of the unit
seal.
14-5
TROUBLESHOOTING
Symptoms
Overheating (poor cooling)
Excessive coolant loss

Reference Gr
Abnormal noise
Overcooling
Possible causes
Loose or damaged O O
V-belt Excessive tension O
Oil on belt O
Incorrectly mounted water pump O O
Defective gasket O O
Defective unit bearing O O
Water pump
Defective impeller O
Defective unit seal O O
Too loose fit of unit bearing on flange and impeller O O
Incorrectly mounted case O O
Valve opening temperature too high
Thermostat O
(valve remains closed)
Valve opening temperature too low (valve remains open) O
Clogged core O
Cracked core and/or separation in welds O O
Radiator Cracks in upper tank and/or lower tank O O
Poor clinching of upper tank and/or lower tank O O
Defective packing of upper tank and/or lower tank O O
Defective bearing O O
Automatic cooling fan Damaged bimetal O
coupling Contaminated bimetal O O
Silicon oil leakage O O
Incorrectly mounted cylinder head O O
Cylinder head Gr11
Defective gasket O O
Incorrectly mounted oil cooler O O
Oil cooler Defective gasket O O Gr12
Leakage from coolant temperature sensor O O
Poor installation of exhaust gas recirculation cooler
O O
bracket
Poor installation of exhaust gas recirculation cooler O O
Exhaust gas recircula-
Gr17
tion system Poor installation of connectors O O
Poor installation of adapter O O
Damaged O-rings O O
14-6
14
Symptoms
Overheating (poor cooling)
Excessive coolant loss

Reference Gr
Abnormal noise
Overcooling
Possible causes
Poor installation of breather cover O O
Breather cover Poor installation of gaskets O O Gr17
Damaged O-rings O O
Poorly airtight pressure cap O
Insufficient coolant amount O
Clogged or scaled coolant passage O
Incorrectly connected hoses O O
Poor installation of pipes O O
Excessively low exterior temperature O
14-7
1. Coolant Replacement and Cleaning of Cooling System
Radiator drain cock 15 0.3 {1.1 0.2, 0.15 0.03}
Water drain plug 24.5 4.9 {18 3.6, 2.5 0.5}
Using the radiator for extended periods of time without cleaning can increase chance of rust and scale formation,
which may cause engine overheating. The cooling system must be cleaned periodically.
NOTE
Coolants containing FUSO DIESEL LONGLIFE COOLANT require replacement every two years. This re-
placement interval can be extended to a maximum of six years by adding FUSO DIESEL LONGLIFE
COOLANT ADDITIVE to the coolant once every year for the four years following the first two-year limit.
For instructions on the use of this product, refer to the Owner s Handbook.
1.1 Draining of coolant
Before draining the coolant, loosen the pressure cap to reduce
the pressure in the cooling system. Remember to drain the cool-
ant out of the reservoir tank as well.
WARNING
Drain the coolant only after it has cooled sufficiently to
avoid getting scalded.
Opening the pressure cap while the coolant temperature is
still high can cause hot coolant to spray out. Cover the
pressure cap with a cloth, and loosen it slowly to let the
pressure out before opening it fully.
1.2 Cleaning procedure

Keep the coolant temperature at approximately 90 C {195 F} so that the thermostat valve remains open and the
coolant continues to circulate in the radiator.
For the sake of convenience you can raise the coolant temperature quickly by covering the front of the radiator
with corrugated cardboard or something similar.
Set the temperature adjusting lever of the heater controller at maximum so that the coolant can circulate freely in
the heater piping area.
In cases where a great amount of rust has accumulated it often happens that as a result of cleaning the radiator
starts leaking. Conduct a thorough check for leakage after cleaning.
Soft water to be used should have the following properties.
CAUTION
Do not use hard water as it causes scale and rust.
Required properties of soft water

Total hardness 300 ppm or less
Sulfate SO 4 100 ppm or less
Chloride Cl 100 ppm or less
Total dissolved solids 500 ppm or less
pH 6 to 8
14-8
14
Select an appropriate cleaning method according to the condition of the cooling system as shown below.
Ordinary condition Coolant extremely dirty Radiator clogged
Cleaning using FUSO RADIATOR CLEANER (RADIPET-7).

Flushing with water.
Drain out coolant.
Make water solution of FUSO RADIATOR CLEANER

(RADIPET-7) at 5 to 10% concentration in volume.
(Procedure)
Pour solution into reservoir tank.
Let the engine idle for 30 minutes with the solution at

approximately 90 C {195 F}.
CAUTION
Limit the engine idling period to one hour. Operating
an engine containing the cleaning solution for long-
er time may lead to damage of the cooling system.
Drain out coolant/cleaning solution.
Pour tap water (preferably hot) into the reservoir tank.
Let the engine idle for 10 minutes with water at

approximately 90 C {195 F}.
Drain out water.
Cleaning is complete if drained water is clear.

Repeat procedure if drained water is not clear.
CAUTION
After cleaning the cooling system using cleaning so-
lution, fill it with coolant containing the specified ad-
ditive as soon as possible.
To prevent free ing of the coolant and corrosion of
the cooling system, add to the coolant the specified
portion of FUSO DIESEL LONGLIFE COOLANT. (See
the Owner s Handbook for instructions on the use of
the additive.)
DANGER
If you accidentally splash FUSO DIESEL LONGLIFE COOLANT, FUSO ANTIFREEZE, or RADIATOR ANTI-
RUST (RADIPET 9) in your eyes, wash it out immediately with water and seek medical attention.
WARNING
FUSO DIESEL LONGLIFE COOLANT is flammable. Keep them away from heat and flames.
14-9
2. Air Bleeding of Cooling System
With the pressure cap removed and the coolant temperature at 90 C {195 F}, let the engine idle in order to bleed
air completely out of the cooling system.
After air bleeding is completed, refill the reservoir tank with coolant as needed.
3. Air/Gas Leakage Test

Presence of air or exhaust gas in coolant accelerates corrosion
of the cooling system components. To prevent this, carry out air/
gas leakage tests in accordance with the following procedure.
Remove the pressure cap.
WARNING
If the engine is hot, boiling coolant may spurt out from the
filler port when the pressure cap is loosened. To avoid a
scold, make sure to remove the pressure cap only when the
coolant is cold.
Run the engine until the coolant temperature rises to approxi-

mately 90 C {195 F}.
If air bubbles appear continuously through the filler port, there is
air or exhaust gas penetrating into the cooling system.
Presence of air in coolant can be an indication of loose cylinder
head bolts, loose water pump mounting bolts, loose hose con-
nections, and/or a damaged hose.
Presence of exhaust gas in coolant can be an indication of a
damaged cylinder head gasket and/or cracks in the cylinder
head.
14-10
14
M E M O
14-11
DISCONNECTION AND CONNECTION OF HOSES AND PIPES
14-12
14
14-13
DISCONNECTION AND CONNECTION OF HOSES AND PIPES
Removal sequence
1 Upper radiator hose 13 Water pipe 25 O-ring
2 Lower radiator hose 14 Water hose
3 Heater hose 15 Water pipe *a: Radiator
4 Heater pipe 16 Water hose
*b: Thermostat cover
5 Heater hose 17 Water hose
*c: Breather cover
6 Heater hose 18 Water hose *d: Exhaust gas recirculation valve
7 Heater pipe 19 Water hose
*e:f: Exhaust gas recirculation cooler
8 Heater hose 20 Water pipe
* Exhaust gas recirculation cooler
9 Eyebolt 21 Water-out hose bracket
10 Water pipe 22 Water-in hose : Non-reusable parts
11 Eyebolt 23 Connector
12 Water and vacuum pipe 24 Adapter
CAUTION
Install each hose clamp to the angle indicated in the illustration so that sufficient clearance is assured be-
tween the hose clamp and its surrounding parts.
Keep the O-ring free of engine oil. Engine oil will make the O-ring swell, which may cause leakage.

Bolt (connector mounting) 8 {5.9, 0.82}
Clamp 1.5 to 2.0 {1.1 to 1.5, 0.15 to 0.2} Wet
Clamp 3.0 to 4.5 {2.2 to 3.3, 0.3 to 0.5}
Eyebolt (water pipe mounting)
25.5 {19, 2.6}
Eyebolt (water and vacuum pipe mounting)
Bolt (water and vacuum pipe mounting)
Bolt (water pipe mounting) 23.2 {17, 2.4}
Bolt (adapter mounting)
Nut (water pipe mounting) 4.9 {3.6, 0.5}

Clamp screw threads Engine oil As required
O-ring Soapy water As required
14-14
14
Installation: Water hose
Install the water hose with the white mark on its end aligned with
the padding on the water pipe.
14-15
RADIATOR
Removal sequence
1 Air scoop 8 Baffle plate upper 15 O-ring
2 Upper shroud 9 Baffle plate RH 16 Support cushion
3 Lower shroud 10 Baffle plate LH 17 Radiator
4 Baffle plate RH 11 Support rod (See later section.)
5 Baffle plate RH 12 Support cushion
6 Baffle plate LH 13 Upper support : Non-reusable parts
7 Baffle plate LH 14 Radiator drain cock
14-16
14
Bolt (upper shroud mounting)
5 to 7 {3.7 to 5.2, 0.5 to 0.7}
Bolt (lower shroud mounting)
Bolt (support rod mounting)
Nut (support cushion mounting)
12 to 15 {8.9 to 11, 1.18 to 1.47}
Bolt (upper support mounting)
Nut (support cushion mounting)
Radiator drain cock 2.5 0.5 {1.8 0.4, 0.25 0.05}
14-17
RADIATOR
Radiator
1 Pipe
2 Bush
3 Side member
4 Upper tank
5 Packing
6 Lower tank
7 Packing
8 Core
CAUTION
Do not disassemble the radiator unless defects are evident.
Handle the upper tank and lower tank carefully, as they are made of plastic and may crack under impact.
Check the number of paint marks put near the upper tank and lower tank mounting tabs. The number of
paint marks corresponds to the number of times the tabs have been unbent and re-clinched. If the core
has already two paint marks, replace it with a new one.
Assembly sequence
Service standards
Air leakage from radiator
0 cm3 {0 mL} Repair or replace
(air pressure 147 kPa {21 psi, 1.47 kgf/cm2})

Bolt (side member mounting) 13 {9.6, 1.3}
14-18
14
Special tools
Overhaul handle MH062875
Installation and removal of upper tank

Claw MH062876
and lower tank
Punch assembly MH062877

Inspection: Radiator air leakage
Connect a hose and radiator cap tester to the upper tank.
Plug the lower tank and put the entire radiator into a tank filled
with water.
Use the radiator cap tester to apply an air pressure of 147 kPa
{21 psi, 1.47 kgf/cm2} and check for air leakage.
If air leakage is found, repair or replace the radiator.
Replace the following parts according to the area of leakage.

Area of leakage Cause
Tank body Cracks in tank
Upper tank Defective tabs
Lower tank Tank base Defective packing
Cracks in tank
Tube body, tube ends Cracks in tube
14-19
RADIATOR
NOTE
The core may have paint marks that indicate the number of
times the upper tank and lower tank mounting tabs have
been unbent and re-clinched. Replace the core if it has al-
ready two paint marks.
One paint mark is made every time the tabs are unbent and
re-clinched. Upper tank paint marks should be counted sep-
arately from lower tank paint marks.
Removal procedure
Removal: Upper tank and lower tank
Attach onto .
Using the stopper bolt on , adjust the jaw span of to
the dimension indicated in the illustration.
CAUTION
Make sure to adjust the stopper bolt before using the tools.
Failure to do so may cause damage to .
Using , undo the tabs that are holding the tank in place.
Once each tab is unbent, grip more tightly to straighten it
out completely.
Undo all the tabs on the entire periphery of the tank, then re-
move the tank using the inlet hose fitting as a grip.
14-20
14
If the tank does not come off easily, tap it lightly with a soft-face
hammer (rubber or plastic hammer) to loosen it.
CAUTION
Handle the tanks carefully, as they are made of plastic and
may crack easily under impact.
Inspection: Core fitting surfaces of tank
Inspect the core fitting surfaces of the tank for any dirt or dam-
age. If necessary, clean them thoroughly.
Replace the tank(s) if defective.
CAUTION
Carry out the inspection with your bare hands to avoid put-
ting foreign matter on the fitting surfaces.
Inspection: Tank fitting groove of core

Check the tank fitting groove of the core for any foreign matter or
cracks.
If foreign matter is found on the groove surfaces, lightly scrub it
off with a No.1000 sandpaper taking care not to damage the sur-
faces, or blow it off with compressed air.
If a crack is found on the groove surfaces, repair the crack or re-
place the core.
CAUTION
Installing a packing and tank on the core without removing
foreign matter from the groove surfaces can lead to coolant
leakage. Make sure to inspect the entire groove surfaces
extremely carefully. Even one strand of hair is enough to
cause leakage.
Repair of core
CAUTION
The following core repair procedure involves tungsten inert
gas arc welding (TIG arc welding). Only personnel compe-
tent for doing this type of welding should carry out the job.
Dry the core completely before performing welding. Weld-
ing wet parts could be extremely dangerous.
Scrub both ends A of a leaky tube as well as the surrounding ar-

eas B of each end with a stainless wire brush. Continue scrub-
bing until the aluminum layer becomes exposed.
14-21
RADIATOR
Drill a small hole in the tube to let the air out when both ends of
the tube are welded closed.
CAUTION
Failure to drill an air release hole in the tube may cause pin-
holes to form in the welds.
Connect one of the support edges of the core to ground with a

wire.
CAUTION
Inadequate connection of the ground wire can cause a
short circuit to a part of the core, which may cause the part
to melt.
Close both ends of the tube by TIG arc welding.

Welding conditions
Welding rod: A4043
(diameter approximately 2 mm { 0.079 in.})
Welding current: AC80A
After the welding is completed, check for the following defects. If
any of these defects are spotted, repair the defect or replace the
core.
Undercuts
Cracks in weld bead
Cracks in base metal
CAUTION
Make sure that welds are proper. Any defect in welding can
lead to recurrence of leakage.
Installation: Upper tank and lower tank
If there is a gap between the tank and core s tank holding plate
when the tank is placed in position, lightly tap the plate with a
rubber or plastic hammer to eliminate the gap.
CAUTION
When installing the tank and packing, use your bare hands
to avoid putting foreign matter on the parts.
14-22
14
Attach onto .
Using the stopper bolt on , adjust the jaw span of to
the dimension indicated in the illustration.
Bend and clinch the tabs of the core over the brim of the tank in
the sequence indicated in the illustration.
1 to 4: Clinch the two tabs at the center on each side of the tank.
5 to 8: Clinch the rest of the tabs in the order indicated by the ar-
rows.
CAUTION
The tabs on sides 1 and 2 cannot be clinched using .
Use a pair of pliers with the noses wrapped with vinyl tape
to clinch these tabs.
After clinching all the tabs, check for leakage.
Put a paint mark on a clearly visible area of the core to indicate

the number of times the tabs have been unbent and re-clinched.
CAUTION
One paint mark should be made for each of the upper and
lower tanks every time the tabs for it are unbent and re-
clinched.
14-23
COOLING FAN, V-BELT AND WATER PUMP
Removal sequence
1 Cooling fan 4 Water pump *a: Alternator
2 Automatic cooling fan coupling
3 V-belt
5 Gasket
6 Fan pulley
*b: Compressor
<with air conditioner>
Tension pulley
<without air conditioner>
CAUTION
The automatic cooling fan coupling and the water pump cannot be disassembled. It must be replaced if
defective.
Make sure that there is no oil or grease on the V-belts. V-belts soiled with oil or grease may easily slip, re-
sulting in deteriorated performance of the cooling system.

New 7.5 to 8.5 {0.30 to 0.33}
with air conditioner
Reused 9.5 to 10.5 {0.37 to 0.41}
3 V-belt tension Adjust
New 8 to 10 {0.31 to 0.39}
without air conditioner
Reused 10 to 12 {0.39 to 0.47}
14-24
14
Nut (fan pulley mounting) 196.1 {145, 20}
Special tools
Belt tension gauge MH062345 Measurement of tension of V-belt
Inspection and cleaning procedure

Inspection: Automatic cooling fan coupling
Make an inspection of the following points. Replace the automat-
ic cooling fan coupling if defective.
Check that:
the hydraulic oil sealed inside the coupling is not leaking;
the coupling does not make any abnormal noise or rotate un-
evenly due to defects in the inside bearing when rotated man-
ually; and
the automatic cooling fan coupling does not move too much
when pushed and pulled in the axial directions when the en-
gine is cold.
Cleaning: Automatic cooling fan coupling

When removing foreign matter from the bimetal, be careful not to
press too hard against the bimetal.
Inspection after installation

Inspection: Tension of V-belts
Press each V-belt at a central portion between pulleys with a
force of approximately 98 N {22 lbs, 10 kgf} as shown in the illus-
tration and measure the amount of deflection of the belt.
A: Alternator pulley
B: Air conditioner compressor pulley or tension pulley
C: Fan pulley
D: Water pump pulley
14-25
COOLING FAN, V-BELT AND WATER PUMP
Place the small O-ring on at the scale mark corresponding
to 98 N {22 lbs, 10 kgf} (press force).
Place the large O-ring on at the scale mark corresponding
to the maximum permissible deflection value specified for the
belt.
Place at a central portion between pulleys of the V-belt and

push the handle (indicated by the arrow in the illustration) until
the O-ring touches the flange.
Measure the amount of deflection of the V-belt.

If the measured value deviates from the standard value range,
adjust the tension of the belt as follows.
Adjustment of V-belt
(1) Vehicles with air conditioner
Loosen the alternator mounting nuts (2 locations) and adjust the
tension of the V-belt by tightening or loosening the adjustment
bolt.
After the adjustment is completed, retighten the mounting nuts
firmly.
CAUTION
Excessive tension in the V-belt may damage not only the
belt itself but also the bearings of the related components.
(2) Vehicles without air conditioner

Loosen the tension pulley mounting sleeve and turn in or out the
adjustment bolt to adjust the tension of the V-belt.
After the adjustment is completed, retighten the mounting sleeve
firmly.
CAUTION
Excessive tension in the V-belt may damage not only the
belt itself but also the bearings of the related components.
14-26
TENSION PULLEY 14
1 Sleeve
2 Bearing
3 Tension pulley
4 Spacer
5 Shaft
6 Tension pulley bracket
Assembly sequence
verse.

Sleeve 49 {36, 5.0}
14-27
THERMOSTAT
1 Thermostat cover
2 Thermostat
*a: Oil cooler
Assembly sequence
verse.

Valve opening temperature 82 2 C {180 3.6 F}
2 Thermostat 10 {0.39} or more / Replace
Valve lift / temperature
95 C {205 F}
Inspection: Thermostat
Stir the water using a stirring rod to maintain an even water tem-
perature in the container, then conduct the tests indicated below.
If the measured values deviate from the standard value ranges,
replace the thermostat.
(1) Valve opening temperature
Hold the thermostat with wire to keep it away from the heat
source.
Heat the water gradually to the valve opening temperature.
Maintain this temperature for five minutes and make sure that
the valve is completely open.
Make sure that the valve closes completely when the water tem-
perature drops below 65 C {150 F}.
(2) Valve lift
Heat the water to a temperature slightly higher than the valve
opening temperature. Maintain this temperature for five minutes
and measure the valve lift.
14-28
14
Installation: Thermostat
Mount the thermostat on the thermostat cover in the illustrated
direction.
14-29
PRESSURE CAP AND WATER OUTLET CASE
1 Pressure cap 6 Clip
*a: Vacuum hose
2 Clip 7 Water hose *b: Breather cover
3 Eyebolt 8 Water outlet case : Non-reusable parts
4 Water and vacuum pipe 9 Gasket
5 Water pipe
Assembly sequence
Service standards
110 15 kPa
1 Pressure cap valve opening pressure {16 2.2 psi, Replace
1.1 0.15 kgf/cm3}

Bolt (water and vacuum pipe mounting)
Bolt (water pipe mounting) 23.2 {17, 2.4}
Bolt (water outlet pipe mounting)
Eyebolt (water and vacuum pipe mounting) 25.5 {19, 2.6}
14-30
14
Inspection: Pressure cap
(1) Pressure valve opening pressure
Replace the pressure cap if the measured value deviates from
(2) Inspection of vent valve

Before starting the inspection, check the level of coolant in the
reservoir tank.
Run the engine at full speed. Stop the engine when the level of
coolant in the reservoir tank noticeably rises.
Wait until the coolant temperature drops to the ambient tempera-
ture. Then, check if the coolant in the reservoir tank has returned
to the same level as that confirmed before the engine was start-
ed.
If the coolant has failed to return to its original level, the vent
valve is defective. In this case, replace the pressure cap.
CAUTION
Be aware that removing the pressure cap before the coolant
cools down to the ambient temperature will result in loss of
vacuum in the radiator, which disables the coolant from be-
ing returned to the reservoir tank.
14-31
INDEX
SPECIFICATIONS ............................................................................... 15-2

1. Air Cleaner.............................................................................................15-2
2. Turbocharger.........................................................................................15-3
3. Muffler ....................................................................................................15-4
TROUBLESHOOTING......................................................................... 15-5

1. Measurement of Turbocharger Boost Pressure.................................15-6
AIR DUCT AND AIR CLEANER <EXCEPT CREW CAB> ................. 15-8
AIR DUCT AND AIR CLEANER <CREW CAB>............................... 15-12
TURBOCHARGER ............................................................................ 15-16
INTERCOOLER ................................................................................. 15-22
INTAKE MANIFOLD .......................................................................... 15-24
EXHAUST MANIFOLD ...................................................................... 15-25
EXHAUST PIPE................................................................................. 15-26
MUFFLER .......................................................................................... 15-28
15-1
SPECIFICATIONS/STRUCTURE AND OPERATION
SPECIFICATIONS
/
Item Specifications
Air cleaner element Filter paper type
Model TD04
Turbocharger
Manufacturer Mitsubishi Heavy Industries, Ltd.
Intercooler Tube and corrugated fin type air-to-air heat exchanger

1. Air Cleaner
The air cleaner is a single element
type.
When the engine slows down below
the predetermined speed, the level of
vacuum changes and causes the un-
loader valve to vibrate. Vibration of the
unloader valve allows the air cleaner
to automatically discharge any water
and dust that has accumulated in its
inside.
15-2
15
2. Turbocharger
2.1 Waste gate mechanism

The waste gate mechanism allows ex-
cess exhaust gas to escape from the
turbocharger by means of an actuator
in order to maintain the boost pressure
at an appropriate level. This prevents
overrunning of the turbocharger and
excessive pressure buildups in the in-
take manifold.
The boost pressure is led via a rubber
hose from the compressor cover to
chamber A in the actuator. When the
boost pressure in chamber A is less
than the predetermined value, the ac-
tuator does not function and the waste
gate valve remains closed. All exhaust
gas then flows toward the turbine
wheel.
15-3
When the boost pressure in chamber
A exceeds the predetermined value,
the waste gate valve opens, reducing
the amount of exhaust gas flowing to-
ward the turbine wheel. As a result,
the speed of the compressor wheel
and thus the boost pressure are re-
duced.
3. Muffler
Converter is built into muffler to de-
crease the amount of particulate mat-
ter (PM) in the exhaust gas.
15-4
TROUBLESHOOTING 15
Symptoms
Intake and exhaust system vibrates and/

Fuel consumption is too high
or makes abnormal noises

Reference Gr
Exhaust gas is white

Exhaust gas is black
Possible causes
Air cleaner Clogged air cleaner element O O O
Defective bearing O O O
Carbon deposits on turbine wheel O O
Interference between turbine wheel and turbine
O O O
back plate
Interference between turbine wheel and turbine
O O O
housing
Cartridge assembly
Bent shaft O O O
Damaged turbine wheel O O O
Interference between compressor wheel and com-
O O O
pressor cover
Turbocharger
Seizure of thrust sleeve and/or thrust bearing O O O
Damaged compressor wheel O O O
Oil leakage due to worn piston ring and/or insert O O O
Poorly installed piston ring O
Unsmooth sliding of inner parts due to clogged lubri-
O O
cating oil pipe and/or eye bolt
Damaged oil seals due to clogged oil return pipe O O
Poorly mounted compressor cover O O O O
Poorly mounted turbine housing O O
Intercooler O
Butterfly valve stuck in closed position O O O
Throttle actuator Gr13E
Poorly adjusted butterfly valve O O O
Deformed front pipe, muffler, and/or tail pipe O
Poorly installed front pipe, muffler, and/or tail pipe O
Inappropriate valve clearance O
Defective cylinder head gasket O
Worn valve and valve seat and/or carbon deposits O
Gr11
Weakened valve springs O
Worn and/or damaged piston rings O O
Worn and/or damaged piston ring grooves O O
Malfunctioning cooling system O Gr14
Excessive engine oil level O Gr12
Seizure of main moving parts O Gr11
Uneven or excessive fuel injection O Gr13E
15-5
1. Measurement of Turbocharger Boost Pressure

67.8 kPa
Boost pressure (temperature: 20 C {68 F}; {20 in. Hg,
Inspect or adjust
air pressure: 100 kPa {29.9 in. Hg, 760 mmHg}) 509 mmHg}
/3100 rpm
Special tools
Boost pressure gauge MH061366
Measurement of turbocharger boost

pressure
Boost pressure gauge

MH062047
adapter
Before measuring the turbocharger boost pressure, clean or re-

place the air cleaner element.
Disconnect the vacuum hose from the boost pressure sensor.
Connect the pipe between the vacuum hose connected to
the gas filter and .
Warm up the engine well, then measure the boost pressure at
no-load maximum speed. Also measure the engine speed and
atmospheric temperature.
15-6
15
Adjust the boost pressure to the standard value (boost pressure
changes according to the atmospheric temperature and the en-
gine speed).
[Atmospheric temperature correction of boost pressure]

Based on the current atmospheric temperature, determine the
appropriate boost pressure correction coefficient in the graph.
[Engine speed correction of boost pressure]

Subtract the median of the no-load maximum speed values from
the engine speed at the time of boost pressure measurement.
Use the difference to determine the necessary boost pressure
correction value (Pa) in the graph.
Median: 3200 rpm
[Calculation of corrected boost pressure]

With P as the measured boost pressure, determine the correct-
edboost pressure Pb using the following equation:
Pb = KtP + Pa
Pb: Corrected boost pressure
P: Measured boost pressure
Kt: Ambient temperature correction coefficient for boost pres-
sure
Pa: Boost pressure correction value
The turbocharger must be inspected and/or adjusted if Pb is be-
low the specified limit.
15-7
AIR DUCT AND AIR CLEANER <EXCEPT CREW CAB>
1
2
Air inlet duct
Connector
7
8
Connector
Air box
*a::
Turbocharger
Non-reusable parts
3 PCV hose 9 Rubber seal PCV: Positive Crankcase Ventilation
4 Air hose 10 Air cleaner cap
5 Insulator 11 Air cleaner element
6 Air duct 12 Air cleaner case
Assembly sequence

Clamp 3.0 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
15-8
15
Cleaning procedure
Cleaning: Filter element
Blow a jet of compressed air at a pressure not higher than 685
kPa {100 psi, 7 kgf/cm2} against the inside surfaces of the ele-
ment.
Move the compressed air jet up and down along all pleats of the
filter paper element.
CAUTION
Do not strike the element or hit it against another ob ect to
remove dust.
Do not blow compressed air against outside surfaces of the
element.
Inspection: Element
Shine some electric light inside the element.
Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.
Installation: Air cleaner cap
: Alignment mark
Installation: Rubber seal

Align slit of rubber seal with key of air cleaner case.
15-9
AIR DUCT AND AIR CLEANER <EXCEPT CREW CAB>
Installation: Air box
Align slit of air box with key of air cleaner case.
Installation: Air duct

Fit clamp over protrusions of connector.
Push air duct in until it hits air cleaner case.
15-10
15
M E M O
15-11
AIR DUCT AND AIR CLEANER <CREW CAB>
1 Air inlet duct 7 Air hose 13 Air cleaner element
2 Connector 8 Air pipe 14 Air cleaner case
3 PCV hose 9 Connector
4
5
Air hose
Insulator
10
11
Air box
Rubber seal
*a::
Turbocharger
Non-reusable parts
6 Air duct 12 Air cleaner cap PCV: Positive Crankcase Ventilation
Assembly sequence

Clamp 3.0 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
15-12
15
Cleaning procedure
Cleaning: Filter element
Blow a jet of compressed air at a pressure not higher than 685
kPa {100 psi, 7 kgf/cm2} against the inside surfaces of the ele-
ment.
Move the compressed air jet up and down along all pleats of the
filter paper element.
CAUTION
Do not strike the element or hit it against another ob ect to
remove dust.
Do not blow compressed air against outside surfaces of the
element.
Inspection: Element
Shine some electric light inside the element.
Replace the element if thin spots or broken parts are evident in
the filter paper, or if the packing at the top of the element is dam-
aged.
Also replace the element if the dust on the element is damp with
oily smoke or soot, regardless of the replacement schedule.
Installation: Air cleaner cap
: Alignment mark
Installation: Rubber seal

Align slit of rubber seal with key of air cleaner case.
15-13
AIR DUCT AND AIR CLEANER <CREW CAB>
Installation: Air box
Align slit of air box with key of air cleaner case.
Installation: Air duct

Fit clamp over protrusions of connector.
Push air duct in until it hits air cleaner case.
Installation of connector
Align paint mark on connector with protrusion on air pipe, and
push in the Air hose.
15-14
15
M E M O
15-15
TURBOCHARGER
Removal sequence
1 Air hose 9 Gasket 17 Oil pipe
2 Air inlet hose 10 Oil return pipe 18 Turbocharger
3 Turbocharger coupler 11 Gasket (See later section.)
4 O-ring 12 Eye bolt 19 Gasket
5 Front pipe 13 Water pipe
6 Gasket 14 Eye bolt *a: Exhaust manifold
7 Insulator 15 Water and vacuum pipe : Non-reusable parts
8 Exhaust coupler 16 Eye bolt
15-16
15
Clamp 3 to 3.4 {2.2 to 2.5, 0.3 to 0.35}
Clamp 3.9 to 4.9 {2.9 to 3.6, 0.4 to 0.5}
Bolt (Turbocharger coupler mounting)
Bolt (Insulator mounting) 23.2 {17, 2.4}
Bolt (Exhaust pipe stay mounting)
Bolt (Front pipe mounting)
25 to 30 {18 to 22, 2.5 to 3.1}
Nut (Front pipe mounting)
Nut (Exhaust coupler stay mounting)
Nut (Exhaust coupler mounting) 53 {39, 5.4}
Nut (Turbocharger mounting)
Eye bolt (water pipe mounting)
25.5 {19, 2.6}
Eye bolt (water and vacuum pipe mounting)
Eye bolt (Oil pipe mounting) 23.5 {17, 2.4}

O-ring
Turbocharger
Installation: Turbocharger
When installing the turbocharger, fill adequate amount of engine
oil through the oil hole for smooth operation.
Installation: Air inlet hose

Install the air inlet hose on the turbocharger coupler to the indi-
cated dimension.
15-17
TURBOCHARGER
Turbocharger
1 Hose
2 Actuator
3 Coupling
4 Turbine housing
5 Snap ring
6 Compressor cover
7 O-ring
8 Cartridge assembly
Assembly sequence
verse.
CAUTION
The cartridge assembly cannot be dis-
assembled. If the turbine wheel or the
compressor cover is damaged or does
not rotate smoothly, replace the entire
cartridge assembly.

0.03 to 0.10 0.11
Play in axial directions Replace
{0.0012 to 0.0039} {0.0043}
Cartridge 0.40 to 0.53
8 Turbine wheel end 0.58 {0.023} Replace
assembly Play in radial {0.016 to 0.021}
directions 0.55 to 0.66
Compressor wheel end 0.72 {0.028} Replace
{0.022 to 0.026}

Bolt (coupling fastening) 7.8 to 8.8 {5.8 to 6.5, 0.8 to 0.9} Wet

Bolt threads MoriCoat BR-2 Plus As required
Work before removal

Mating marks
Draw a line across the coupling, turbine housing, compressor
cover, and cartridge assembly. This line will serve as mating
marks in the installation procedure.
15-18
15
Removal procedure
Removal: Turbine housing
CAUTION
Tap all around the end of the turbine housing with a rubber
hammer or a similar tool, being careful not damage the tur-
bine housing.
Do not let the blades of the cartridge assembly hit the tur-
bine housing, as they are easily bent.
Removal: Compressor cover

CAUTION
Tap all around the end of the turbine housing with a rubber
hammer or a similar tool, being careful not damage the tur-
bine housing.
Do not let the blades of the cartridge assembly hit the tur-
bine housing, as they are easily bent.
Work after disassembly

Cleaning
Before cleaning the parts, carry out a visual inspection for any
marks of burns or wear that may become difficult to find after the
cleaning. If any defects are evident, replace the part(s).
Immerse the disassembled parts in an inflammable solvent (Da-
icleaner-T-30 by Daido Chemical Industry Co., Ltd.). Remove
the parts from the solvent, and dry them with compressed air.
If there is any solid matter remaining on the parts, remove them
with a plastic scraper or a bristle brush.
Reimmerse the parts in the solvent.
Dry each part with compressed air.
Inspection: Cartridge assembly
(1) Play in axial directions
If the measurement exceeds the specified limit, replace the car-
tridge assembly.
15-19
TURBOCHARGER
(2) Play in radial directions
If the measurement exceeds the specified limit, replace the car-
tridge assembly.
Installation: Snap ring
Fit the snap ring into the compressor cover with the tapered sur-
face on top.
CAUTION
Always keep one hand on the snap ring to prevent it from
flying off.
Work after installation

Inspection: Rotation of cartridge assembly
Turn both wheels of the cartridge assembly to check that they
rotate smoothly.
If anything abnormal is found, disassemble the cartridge assem-
bly and perform necessary service.
15-20
15
M E M O
15-21
INTERCOOLER
1 Air inlet hose 5 Air inlet pipe RH
*b:
a: Air inlet duct
2 Air inlet pipe LH 6 Air inlet hose
* Turbocharger coupler
3 Air inlet hose 7 Intake temperature sensor
4 Air inlet hose 8 Intercooler
CAUTION
Do not remove forcedly the air inlet hose using a screwdriver or other similar tool. Doing so could dam-
age the fluorine treatment layer on the inside surface of the hose, deteriorating the resistance to oil of the
hose.
Assembly sequence

Intercooler air leakage
8 (air pressure: 200 kPa {29 psi, 2.0 kgf/cm2} 0 cm3 {0 cu.in.} Replace
maintained for 30 seconds)

Clamp 3.9 to 4.9 {2.9 to 3.6, 0.4 to 0.5}
Intake temperature sensor 24.5 {18, 2.5}
15-22
15
Inspection: Intercooler
Plug one of the air ports on the intercooler and connect an air
source to the other port. Place the intercooler in a tank of water
and apply air pressure of the specified level (200 kPa {29 psi,
2.0 kgf/cm2}) to the intercooler and retain the pressure for 30
seconds.
Replace the intercooler if any air leakage is evident.
Installation: Air inlet hose

Connect the air inlet hose to the RH air inlet pipe with the white
paint on the hose aligned with the boss on the pipe.
Connect the air inlet hoses to the intercooler, RH air inlet pipe
and turbocharger coupler to the dimensions indicated in the il-
lustrations.
Connect the air inlet hose to the LH air inlet pipe with the white
paint on the hose aligned with the boss on the pipe.
Connect the air inlet hoses to the intercooler, LH air inlet pipe
and air inlet duct to the dimensions indicated in the illustrations.
15-23
INTAKE MANIFOLD
1 Air inlet duct 6 Vacuum hose 11 Gasket A
2 Gasket 7 Gas filter
3 Intake throttle 8 Intake manifold B : Non-reusable parts
4 Gasket 9 Gasket B
5 Boost pressure sensor 10 Intake manifold A
Assembly sequence

Bolt (Air inlet duct and throttle actuator mounting)
Bolt (Boost pressure sensor bracket mounting) 23.2 {17, 2.4}
Bolt (Intake manifold B mounting)
Bolt (Boost pressure sensor mounting) 12.7 {9.4, 1.3}
Gas filter 14.7 to 19.6 {11 to 14, 1.5 to 2.0}
15-24
EXHAUST MANIFOLD 15
1 Insulator
2 Under insulator
3 Exhaust gas recirculation pipe
4 Gasket
5 Distance piece
6 Exhaust manifold
7 Gasket
Assembly sequence
verse.

Bolt (insulator mounting) 11.8 {8.7, 1.2}
Nut (exhaust gas recirculation pipe mounting) 20.6 {15, 2.1}
Nut (exhaust manifold mounting) 41.2 {30, 4.2}
Installation: Gasket
Install the gasket on the cylinder head with their surfaces facing
in the illustrated directions.
15-25
EXHAUST PIPE
1 Brace bracket 4 Exhaust brake unit *a Exhaust manifold
2 Gasket 5 Front pipe : Non-reusable parts
3 Front pipe
CAUTION
Loosen the marked bolt first to prevent undue forces from being applied to the exhaust pipe.
Assembly sequence
CAUTION
Tighten the marked bolt last to prevent undue forces from being applied to the exhaust pipe.

Nut (front pipe mounting)
25 to 30 {18 to 22, 2.5 to 3.1}
Bolt (front pipe mounting)
Bolt (exhaust brake unit mounting) 27 {20 to 29, 2.75}
15-26
15
Installation: Front pipe
Install the front pipe so that the amounts of offset in both vertical
and horizontal directions between the pipes in front of and be-
hind the bellows are smaller than the dimension indicated in the
illustration.
CAUTION
The bellows on the front pipe have the purpose of reducing
the level of noise from the vehicle. It is not intended for
compensating for misalignment that may result from im-
proper installation of the front pipe. Install the front pipe
properly to avoid excessive tension or other stress on the
bellows.
15-27
MUFFLER
1 Tail pipe
2 Gasket
3 Gasket
4 Muffler
*a:: Front pipe

Non-reusable parts
Assembly sequence
verse.
WARNING
Do not touch any of the water that may have accumulated inside the muffler. If you accidentally get some
on your skin, wash it off immediately with water.
CAUTION
Do not kick or strike the muffler, as this can cause damage to the cataly er inside the muffler.

Nut (tail pipe mounting)
26 to 33 {19 to 24, 2.7 to 3.2}
Nut (muffler mounting)
15-28
INDEX

1. Exhaust Gas Recirculation System ............................................... 17-2
2. Crankcase Emission Control System ............................................ 17-7
EXHAUST GAS RECIRCULATION SYSTEM

1. Inspection Procedure .................................................................... 17-8
2. Cautions to Observe When Performing Inspections ...................... 17-9
3. Inspections Based on Diagnosis Codes ...................................... 17-10
4. Multi-Use Tester Service Data...................................................... 17-12
5. Actuator Tests Performed Using Multi-Use Tester ....................... 17-12
6. Inspections Performed at Electronic Control Unit Connectors .... 17-13
7. Inspection of Electrical Equipment.............................................. 17-14
8. Installed Locations of Parts ......................................................... 17-15
9. Electric Circuit Diagram .............................................................. 17-20
EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER... 17-24
CRANKCASE EMISSION CONTROL SYSTEM ............................... 17-26
17-1
1. Exhaust Gas Recirculation System
1.1 Overview
In the exhaust gas recirculation system, the engine electronic control unit and multiple electronic drive units con-
trol the exhaust gas recirculation valve and intake throttle in accordance with information from sensors on various
aspects of the engine (engine speed, coolant temperature, throttle opening, etc.).
Exhaust gas recirculation involves the introduction of inert gases in the post-combustion exhaust emissions into
the intake manifold. By reducing the combustion temperature, it reduces the amount of nitrogen oxides (NOx),
which are harmful, in the exhaust emissions. Further, an exhaust gas recirculation cooler cools the recirculated
exhaust emissions, thereby reducing the peak combustion temperature.
The intake air quantity is adjusted by means of intake throttle control such that the effectiveness of exhaust gas
recirculation is maximized.
17-2
17
1.2 Electronic control system
(1) System block diagram
Input signals Engine electronic control unit Output signals
Engine speed sensor Exhaust gas Engine warning lamp

recirculation valve
Water temperature sensor control function
Accelerator pedal position Exhaust brake 3-way

sensor Intake throttle magnetic valve
control function
Memory clear switch

Fault diagnosis
function Electronic drive unit relay
Diagnosis switch
CAN communication
Motor Motor drive signals Motor drive signals Motor
Position sensor Valve position data Valve position data Position sensor
Exhaust gas Fault data Fault data Intake throttle

recirculation valve
Exhaust gas recirculation Throttle electronic
electronic drive unit drive unit
CAN: Control Area Network

EGR: Exhaust gas recirculation
EDU: Electronic drive unit
17-3
(2) Exhaust gas recirculation valve control function
In accordance with data from sensors, the engine electronic control unit determines the exhaust gas recirculation
valve opening that suits the operating condition and sends a control signal (this indicates the target exhaust gas
recirculation valve opening) to the exhaust gas recirculation electronic drive unit.
When necessary to prevent black smoke emissions and engine speed instability (for example, when the engine is
heavily loaded, when the engine is lightly loaded, and when the exhaust brake is operating), the engine electronic
control unit stops exhaust gas recirculation valve control.
The exhaust gas recirculation electronic drive unit activates the exhaust gas recirculation valve motor. At the
same time, it monitors the extent of valve lift using a position sensor and sends this information (this indicates the
actual exhaust gas recirculation valve opening) to the engine electronic control unit.
This operation makes it possible for the target exhaust gas recirculation valve opening indicated by the engine
electronic control unit to be precisely maintained.
(2.1) Exhaust gas recirculation valve
A motor in the exhaust gas recirculation valve is driven by con-
trol signals from the exhaust gas recirculation electronic drive
unit. Via a rod, the motor's operation opens and closes the
valve.
(3) Intake throttle control function

When the engine electronic control unit determines from sensor data on the engine speed and engine loading that
the vacuum pressure in the intake manifold is low, it increases the amount of exhaust emissions introduced into
the intake manifold by determining an appropriate butterfly valve opening and by sending corresponding control
signals (these indicate the target throttle opening) to the throttle electronic drive unit.
The throttle electronic drive unit activates the valve motor. At the same time, it monitors the valve opening using a
position sensor and sends this information (this indicates the actual throttle opening) to the engine electronic con-
trol unit.
This operation makes it possible for the target throttle opening indicated by the engine electronic control unit to be
precisely maintained.
17-4
17
(3.1) Intake throttle
In accordance with signals from the throttle electronic drive unit,
the motor opens and closes the butterfly valve, thereby adjusting
the intake air amount such that the effectiveness of exhaust gas
recirculation is maximized.
(4) Fault diagnosis function

While the starter switch is in the ON position, the engine electronic control unit continuously monitors the electron-
ic drive units and sensors for faults. In the event that the engine electronic control unit finds a component faulty, it
causes an indication to be made in the meter cluster to alert the driver. At the same time, it memorizes the fault lo-
cation in the form of a diagnosis code and starts a control during fault.
While the engine is running, the exhaust gas recirculation electronic drive unit and throttle electronic drive unit
continuously monitor communication with the position sensor and motor of the exhaust gas recirculation valve,
communication with the position sensor and motor of the intake throttle, and communication with the engine elec-
tronic control unit. In the event that they identify a fault, they send fault data to the engine electronic control unit.
While control necessitated by a fault is taking place, the system's functionality is limited to ensure vehicle and driv-
er safety. It is possible to read the memorized diagnosis code using a Multi-Use Tester or from flashing of the
warning lamp.
NOTE
different.
17-5
1.3 Electronic control unit connection diagram
17-6
17
2. Crankcase Emission Control System
The crankcase emission control system returns blowby gases to an air duct to prevent them from being released
to the outside air.
The positive crankcase ventilation valve keeps constant the pressure inside the crankcase.
17-7
1. Inspection Procedure
System inspection can be performed most effectively using a Multi-Use Tester-III. Types of system inspection are
broadly classified in accordance with fault symptoms and diagnosis codes as follows:
Inspection based on diagnosis code memorized by electronic control unit
Inspection performed on assumption of intermittent fault
Vehicle enters workshop.
Diagnosis code(s) is read.
Error code Normal code Communication

output Normal code output with Multi-Use
output after Tester impossible
deletion of
error code
Ascertain cause of Take steps on

diagnosis code generation; assumption of
perform inspection. intermittent fault.
If communication between the Multi-Use Tester-III and all

other systems is impossible, a fault in the diagnosis circuitry
is highly probable. If communication between the Multi-Use
Perform test drive. Tester-III and only the exhaust gas recirculation system is
impossible, an open circuit in the exhaust gas recirculation
system s diagnosis output circuitry or power supply circuitry
(including the earth circuit) is conceivable.
If diagnosis code is generated during test drive, again ascertain cause of code generation and perform inspection.
If diagnosis code memorized by electronic control unit is not generated during test drive, perform inspection based
on diagnosis code and on assumption of intermittent fault.
Delete diagnosis code.
17-8
17
2. Cautions to Observe When Performing Inspections
CAUTION
The battery voltage must be the standard voltage.
Make sure no harness connector or component connector is loose. Before disconnecting any connector,
place the starter switch in the LOCK position and wait 20 seconds.
After effecting a repair, delete the diagnosis code using the Multi-Use Tester-III or memory clear switch.
As a general rule, inspection work should be performed with the starter switch in the LOCK position.
However, it may be necessary to perform certain tasks with the starter switch in the ON position. At these
times, be careful not to cause short circuits between connector terminals and between terminals and the
vehicle body.
Indicated component resistances may not fall within the standard ranges if they are unduly affected by
the temperature and/or by the accuracy of the tester. Standard values in the text are given on the assump-
tion of room temperature (10 to 35 C {50 to 95 F}).
After rectification of an abnormality, the system s ability or inability to automatically return to normal con-
trol from the special control that begins when a fault occurs depends upon the diagnosis code, i.e., the
fault location. When the system resumes normal control, the warning lamp goes off.
Even when an abnormality has been rectified and the system has automatically returned to normal con-
trol, the diagnosis code corresponding to the fault location remains in the memory of the electronic con-
trol unit.
Following a fault that does not permit an automatic return to normal control from the special control that
begins when a fault occurs, it is necessary to clear the diagnosis code from memory in order for the sys-
tem to recover.
17-9
3. Inspections Based on Diagnosis Codes
3.1 Diagnosis code list
NOTE
different.
Code Message Flashes
P0403 EGR 1 67
P0404 EGR System 02
P1121 Intake Throttle 1 28
P1625 EDU Relay 84
P1630 CAN (EGR) 95
P1635 CAN (Intake Throttle) 96
3.2 Diagnosis code generation conditions and inspection items
P0403: EGR 1 (warning lamp flashes: 67)

Any of the following items:
Exhaust gas recirculation motor is short-circuited to earth, short-circuited to
power supply line, or open-circuited.
Exhaust gas recirculation position sensor is open-circuited.
Abnormality (target position data outside range, data not received, etc.) oc-
curs in communication between electronic drive unit and exhaust gas recircu-
lation valve.
Power supply voltage is abnormal (excessively high or excessively low).
Motor or sensor abnormality: System recovers (power is re-supplied to elec-
tronic control unit) if signal becomes normal when starter switch is turned OFF
Recoverability ON.
Communication or power supply voltage abnormality: System recovers if sig-
nal becomes normal with starter switch in ON position.
Exhaust gas recirculation system error evaluation is stopped.
Service data 1F: EGR Position
Actuator test A1: EGR 1
#530: Exhaust gas recirculation valve
Inspection Electrical equipment Exhaust gas recirculation electronic drive unit
Engine electronic control unit
Engine electronic control unit, exhaust gas recirculation electronic drive unit, and
exhaust gas recirculation valve systems
P0404: EGR System (warning lamp flashes: 02)

Generation condition Motor abnormality (permanent)
System recovers (power is re-supplied to electronic control unit) if signal be-
Recoverability
comes normal when starter switch is turned OFF ON.
Service data 1F: EGR Position
#530: Exhaust gas recirculation valve
Inspection Electrical equipment Exhaust gas recirculation electronic drive unit
Exhaust gas recirculation electronic drive unit and exhaust gas recirculation
valve systems
17-10
17
P1121: Intake Throttle 1 (warning lamp flashes: 28)
Intake throttle abnormality (motor abnormality, position sensor abnormality, or
motor seizure)
Actuator test A7: Intake Throttle 1
#529: Intake throttle
Electrical equipment Throttle electronic drive unit
Inspection
Engine electronic control unit, throttle electronic drive unit, and intake throttle
systems
P1625: EDU Relay (warning lamp flashes: 84)

Generation condition Electronic drive unit relay is short-circuited, open-circuited, or overloaded.
Exhaust gas recirculation control and throttle control are stopped. (Exhaust emis-
sions worsen.)
Service data 90: EDU Power Relay
Actuator test B2: EDU Relay
Inspection Electronic control unit connector 01 : Electronic drive unit relay
Electrical equipment #201: Electronic drive unit relay
Electric circuit diagram Electronic drive unit relay system
P1630: CAN (EGR) (warning lamp flashes: 95)

Communication with exhaust gas recirculation electronic drive unit is impossible.
(CAN messages are not received for certain period, or CAN bus is off.)
sions worsen.)
Exhaust gas recirculation electronic drive unit
Inspection Engine electronic control unit
CAN communication circuitry to engine electronic control unit and exhaust gas
recirculation electronic drive unit
P1635: CAN (Intake Throttle) (warning lamp flashes: 96)

Communication with throttle electronic drive unit is impossible. (CAN messages
are not received for certain period, or CAN bus is off.)
sions worsen.)
Actuator test A7: Intake Throttle 1
Throttle electronic drive unit
Inspection Engine electronic control unit
CAN communication circuitry to engine electronic control unit and throttle elec-
tronic drive unit
17-11
4. Multi-Use Tester Service Data
NOTE
It is possible to see service data and actuator tests simultaneously.
1F EGR Position . % Idling 0%
20 Intake Throttle Position . % Idling 50 %

Starter switch ON ON
90 EDU Power Relay ON/OFF Starter switch OFF OFF
[Actuator test] B2: EDU relay
5. Actuator Tests Performed Using Multi-Use Tester

Maintain exhaust gas recirculation valve opening indicated [Service data]
A1 EGR 1
by Multi-Use Tester. 1F: EGR Position
Maintain intake throttle opening indicated by Multi-Use [Service data]
A7 Intake Throttle 1
Tester. 20: Intake Throttle position
Electronic drive unit relay drive signal Relay operating sound
(Errors related to exhaust gas recirculation and to the intake [Service data]
throttle can be detected when this actuator test is executed.) 90: EDU Power Relay
B2 EDU Relay
17-12
17
6. Inspections Performed at Electronic Control Unit Connectors
These inspections aid troubleshooting by enabling you to check whether electronic control unit signals are being
correctly transmitted via the vehicle harness and connectors.
The white-on-black number 01 corresponds to the similarly printed reference number in section 3. Inspec-
tions based on diagnosis codes .
6.1 Electronic control unit connector terminal layout
6.2 Inspection instructions

CAUTION
Some inspections are performed with the connectors removed. Others are performed with the connectors
fitted. Observe the following caution:
Do not touch any terminal except those specified for the inspection. Be particularly careful not to cause
short circuits between terminals using the tester probes.

01 [Conditions]
Starter switch ON
Voltage of electronic drive unit relay Vehicle-side harness connected (Perform inspection on back of connector.)
[Requirements]
Terminals ( )-( ): B39-B14
With relay operating: Corresponding to battery voltage
With relay not operating: 0V
17-13
7. Inspection of Electrical Equipment
#201 Inspection of relay (normally open, 5 pins)
Perform a continuity check and an operation check. If there is
any abnormality, replace the relay.
#529 Inspection of intake throttle

the throttle.
(1) Coil resistance of motor
Standard value 1.45 0.21
(2) Position sensor

lated parts.
normal, replace the intake throttle.
#530 Inspection of exhaust gas recirculation valve

the exhaust gas recirculation valve.
(1) Coil resistance of motor
Measure the resistance between terminals 8 and 7, the resis-
tance between terminals 8 and 6, and the resistance between
terminals 7 and 6.
Standard value 2.1 0.3
(2) Position sensor

lated parts.
normal, replace the exhaust gas recirculation valve.
17-14
17
8. Installed Locations of Parts
17-15
17-16
17
17-17
17-18
17
17-19
9. Electric Circuit Diagram
17-20
17
17-21
17-22
17
17-23
EXHAUST GAS RECIRCULATION VALVE, PIPE AND COOLER
Removal sequence
1 Exhaust gas recirculation 7 Exhaust gas recirculation 14 Exhaust gas recirculation
bracket cooler adapter A cooler
2 Exhaust gas recirculation 8 Exhaust gas recirculation 15 Connector
valve gasket 16 O-ring
3 Exhaust gas recirculation 9 Exhaust gas recirculation pipe 17 Exhaust gas recirculation
valve gasket B 10 Exhaust gas recirculation pipe cooler bracket A
4 Exhaust gas recirculation gasket 18 O-ring
valve gasket A 11 Exhaust gas recirculation
5 Exhaust gas recirculation
cooler adapter B
gasket
12 Exhaust gas recirculation
*a:: Water hose
Non-reusable parts
6 Exhaust gas recirculation cooler bracket B
gasket 13 Exhaust gas recirculation
gasket
NOTE
Even when all coolant in the crankcase has been drained out, approximately 1L {1.1qt.} of coolant re-
mains in the exhaust gas recirculation cooler. Before removing the exhaust gas recirculation cooler,
make ready a container to catch the coolant.
Perform installation by following the removal sequence in reverse.
17-24
17
Bolt (mounting of exhaust gas recirculation bracket)
Bolt (mounting of exhaust gas recirculation cooler adapter A)
Bolt (mounting of exhaust gas recirculation cooler adapter B)
23.2 {17, 2.4}
Nut (mounting of exhaust gas recirculation pipe)
M8 bolt (mounting of exhaust gas recirculation cooler bracket
A)
Bolt (mounting of exhaust gas recirculation valve)
Bolt (mounting of exhaust gas recirculation cooler)
M10 bolt (mounting of exhaust gas recirculation cooler bracket 44.5 {33, 4.5}
A)
Bolt (mounting of exhaust gas recirculation cooler bracket B)
Nut (mounting of exhaust gas recirculation pipe) 20.6 {15, 2.1}
Bolt (mounting of exhaust gas recirculation valve) 57.5 {42, 5.9}
Bolt (mounting of connector) 8 {5.9, 0.82}
Nut (mounting of exhaust gas recirculation valve) 57.5 {42, 5.9}
Lubricants and sealants

Mark Point of application Type Quantity
O-ring Soapy water As required
Inspection procedures
Inspection: Exhaust gas recirculation cooler
(1) Exhaust gas passage side
Fit a cover over the exhaust gas outlet of the exhaust gas recir-
culation cooler, and connect a hose to the exhaust gas inlet.
Then, submerge the exhaust gas recirculation cooler in a con-
tainer of water. Make sure the coolant passage is full of water.
Apply air pressure of 294 kPa {43 psi, 3 kgf/cm2} through the
hose. Check that air does not leak from any part of the exhaust
gas recirculation cooler.
If there is any abnormality, replace the exhaust gas recirculation
cooler.
(2) Coolant passage side

Fit covers over the exhaust gas recirculation cooler's exhaust
gas inlet, exhaust gas outlet, and coolant outlet, and connect a
hose to the coolant inlet. Then, submerge the exhaust gas recir-
culation cooler in a container of water.
Apply air pressure of 196 kPa {28 psi, 2 kgf/cm2} through the
hose. Check that air does not leak from any part of the exhaust
gas recirculation cooler.
If there is any abnormality, replace the exhaust gas recirculation
cooler.
17-25
CRANKCASE EMISSION CONTROL SYSTEM
Removal sequence
1 Spacer 4 Breather gasket *a: PCV pipe
2 Breather cover
(See later section.)
5
6
PCV hose
PCV valve
*b::Front case
Non-reusable parts
3 Gasket 7 O-ring PCV: Positive crankcase ventilation
Perform installation by following the removal sequence in reverse.

Bolt (mounting of breather cover)
23.2 {17, 2.4}
Bolt (mounting of PCV valve)
Bolt (mounting of breather cover) 9.8 {7.2, 1.0}
Lubricant and for sealant

O-ring Engine oil
17-26
17
Breather cover
Removal sequence
1 Breather cover A
2 Separator plate
3 Gasket
4 Element
5 Breather cover B
:Non-reusable parts

Screw (mounting of breather cover) 7.8 to 11.8 {5.8 to 8.7, 0.8 to 1.2}
17-27

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INDEX

EQUIPMENT TYPE CODES LIST ...................................................... 00-2

POWER TRAIN LIST ...................................... ................................. 00-3

HOW TO READ THIS MANUAL ........................................................ 00-4

CHASSIS NUMBER, ENGINE NUMBER,

VEHICLE IDENTIFICATION NUMBER ........................................... 00-11

PRECAUTIONS FOR MAINTENANCE OPERATION ..................... 00-12

JACKING UP THE VEHICLE .......................................................... 00-24

TABLE OF STANDARD TIGHTENING TORQUES.......................... 00-36

Variation (W: With directly-mounted transfer)

Load carrying capacity of truck class (tonnage)

Vehicle type (T: Truck)

Vehicle type (T: Truck)

Tooth profile (H: Hypoid gear)

On-vehicle Inspection and Adjustment

Suggestions or supplementary information for more efficient use of equipment or a

Terms and Units

Left and right

Example: 390 N m {290 ft.lbs, 40 kgf m}

Unit SI unit {imperial unit, metric unit} Conversion factor

Example: 30 mm {1.18 in.}

Unit SI unit {imperial unit} Conversion factor

P1463: Exhaust Brake M/V1 (Warning lamp flashes: 93)

Refer to Inspection of Electrical

Refer to Wiring Diagrams.

Power train label located in the position illustrated indicates the

(1) Country J: Japan

Perform service operations on a level surface. Before starting,

Take extreme care when removing/installing heavy items such

Do not allow anyone to pass or stay under a lifted item which

When disassembling parts, visually check them for wear, cracks,

To facilitate correct reassembly of parts, make alignment marks

Before working on the electrical system, disconnect the battery

When separating connectors, grasp the connectors themselves

Before washing the vehicle, cover electrical parts to keep them

1. Handling Precautions for Electric Circuits

1.1 Inspection of harnesses

(1.2) Non-waterproof connectors

(2.2) Inspections on male terminals

Be careful not to short-circuit pins together with the test

When using a multimeter to check continuity, do not allow the

1.2 Inspection of connectors

Check whether wires have been separated from their terminals

Check for defective connections caused by loose terminals, by

(2) Checking for loose terminals

1.3 Inspections when a fuse blows

The main causes of short circuits are as follows:

2. Service Precautions for Alternators

Never disconnect the battery terminals with the engine running.

Never perform inspections using a high-voltage multimeter.

Keep alternators dry.

Disconnect the battery terminals before quick-charging the bat-

Connectors and other parts to be checked are those included or

Current flows backward as shown below.

Disconnect the battery s ( ) terminal.

Cover all parts of the vehicle that may be damaged by welding

Connect the welder s ( ) cable to the vehicle as close as possi-

System compatible with Multi-Use Tester-III